微铣削中考虑时变切削力系数的颤振稳定性预测

颤振问题严重制约了微铣床的加工效率和加工质量。加工过程中刀具的磨损使得系统的颤振稳定性预测精度逐渐降低。为解决上述问题,引入时变可靠性理论,并用Gamma过程描述刀刃半径随切削时间的变化关系。建立了系统的时变切削力、时变稳定性和时变可靠性模型,分析了给定条件下系统的颤振稳定性和颤振可靠度随加工时间的变化关系。给出了微铣削在高速铣削过程中在给定切深和主轴转速下系统的颤振时变稳定性和颤振时变可靠性的算例研究。研究表明:随着加工时间的增加系统的颤振稳定性逐渐降低,该方法能够更准确的预测出不同加工时间内系统的颤振稳定性。     

错齿BTA深孔振动钻削刀具系统径向减振特性研究

BTA深孔钻削刀具系统刚性差,加工过程极易发生多个方向的颤振,而刀具颤振对孔的加工精度和刀具的使用寿命具有重要影响。根据错齿BTA内排屑深孔钻刀具系统的特点,构建了深孔钻削过程刀具系统径向动力学模型,通过其特征方程研究了径向动力学特性。为了获得普通钻削与振动钻削条件下刀具系统径向振动的行为特征,将切削加工过程离散为满足状态方程连续条件的多个微小切削单元,并采用差分方程求解方法给出了普通钻削与振动钻削过程刀具径向振动位移的数值解。仿真和实验结果表明,所建立径向动力学模型的求解结果与实验结果相吻合,振动钻削对刀具系统径向振动具有较强的抑制效果,与普通钻削相比,孔加工圆度和表面粗糙度都有了明显改善。     

分离型超声波振动切削动力学模型及其稳定性分析

本文在理论研究和实验验证的基础上,给出了分离型超声波振动切削的动力学模型及其传递函数表达式,并对其切削稳定性进行了详尽的分析。本文从理论上论证了分离型超声波振动切削可以抑制切削颤振,其抑振效果由切削系数Ψ_u 唯一确定,这一结论与实验结果相吻合。     

切削过程混沌颤振的控制方法仿真研究

以Grabec提出的混沌颤振模型为基础,探讨了切削过程混沌颤振的控制方法.首先建立了混沌颤振仿真分析的SIMULINK模型,以此为基础进行了混沌颤振动力学分析,得到混沌颤振动力学响应的时间序列;其次,分别建立了混沌颤振控制的随机噪声控制模型、周期摄动以及延迟反馈控制模型;然后进行控制仿真,通过控制仿真得到的结果与混沌颤振动力学响应仿真结果的对比分析表明:在x,y方向同时施加延迟控制能够达到消除混沌颤振的目的,是一种比较好的控制方法.     

细长轴切削颤振的稳定性分析和实验研究

为了对细长轴的加工颤振进行稳定性研究,在对细长轴切削颤振机理的研究基础上,建立了刀具和细长轴耦合振动的两自由度系统的再生型颤振分析模型。利用解析法对时滞的动力学方程进行稳定性分析,得出了关于切削宽度和转速的稳定性切削极限图。从结果中可以得出两自由度系统的极限切削宽度比单自由度系统减小了28.6%。该成果可以为柔性零件的高效稳定加工提供理论切削参数。在车铣复合中心上进行了细长轴的切削颤振实验,通过与稳定性极限图的对比,发现实验结果与理论研究相吻合,并且总结出颤振发生前后刀具和细长轴的振动特性变化规律。这种振动特征的变化过程是对加工颤振进行监测和预警的重要识别指标     

电流变技术在抑制深孔切削颤振中的应用

针对深孔加工中出现的切削颤振问题,利用电流变液的电流变效应,设计一套基于流动和剪切混合工作模式的电流变减振器。通过对深孔切削系统的动力学模型的建立和分析,得到系统的运动微分方程。利用MATLAB/Sinmulink对动力学模型进行仿真分析并进行实验验证,结果表明电流变减振器能够减小颤振的振幅,且在不同电场强度下具有不同的减振效果。因此通过控制电流变减振器的电场强度可以有效地抑制深孔机床中切削颤振的发生。     

旋转镗杆切削颤振稳定性预测

研究考虑主轴旋转和内、外阻的镗杆颤振稳定性。将镗杆简化为二自由度模型,引入旋转陀螺和离心力以及内、外阻,结合再生时滞镗削力模型,建立旋转镗杆的颤振的动力学分析模型。采用频域法导出旋转镗杆切削系统的稳定性极限的求解公式。与时域数值积分结果的一致性验证了镗削稳定性叶瓣图计算结果的正确性。结果表明,旋转陀螺效应降低了镗削过程的临界切削深度。内、外阻之和越大,切削临界切削深度越大,在内、外阻之和给定时,内阻越大切削过程越稳定。同时提高镗杆的刚度和系统切削刚度将会分别导致临界切削深度的增加和减小。     

铣削过程颤振稳定性分析的研究进展

综述铣削过程颤振稳定性分析的研究概况和进展。颤振建模和稳定性分析是该方法两个关键环节。依据颤振形成的物理条件,将其分为摩擦型颤振、振型耦合型颤振和再生型颤振。从切削过程的非线性和切削系统的非线性两方面,重点介绍再生型颤振的非线性建模的研究成果。稳定性分析方法根据对颤振模型的求解方法,分为频域法、离散法及数值法,概括了各个方法的特点、效果及适用工况。最后介绍了近来兴起的微细铣削研究领域中颤振稳定性分析的研究成果。由于其尺度效应,微细铣削加工具有独特的加工机理和特点,颤振建模中需考虑的因素与传统铣削多有不同,但稳定性分析方法仍大多沿用传统铣削中的方法。     

机器人加工系统及其切削颤振问题研究进展

采用工业机器人加工系统来实现航空、航天等领域的装配现场加工,是非常有效的技术途径。由于机器人加工系统的整体刚度过低,在实际加工过程中较易自激产生颤振现象,造成加工失效甚至断刀现象,是当前机器人加工系统应用研究需要解决的技术难题。通过对国内外先进机器人加工系统的研究综述,重点分析机器人加工系统的主要特点及切削颤振问题,以机器人加工系统的刚度模型和动力学模型为理论基础,以期进一步揭示机器人加工系统切削颤振机理。为提高机器人加工系统的加工精度和动静态性能而设计出更适合的切削颤振主动抑制技术,并对有待进一步解决的问题以及未来的研究方向进行了讨论与展望。     

薄板件铣削颤振稳定性的非线性判据实验研究

铣削过程中非线性动力学行为一直伴随整个切削过程,为准确地判定和预测加工过程的颤振稳定性,基于实验方法,研究了两端固定薄板件铣削颤振稳定性的非线性判据。实验中以薄板件振动信号为研究对象,基于相平面法、庞加莱法和频谱分析了不同加工参数时的振动信号,绘制并讨论了最大Lyapunov指数与主轴转速和铣削深度的变化关系。最后以最大Lyapunov指数作为判据,通过等高线法确定铣削颤振稳定域,并和基于全离散法得出的铣削颤振稳定域进行比较分析,实验得出了航空铝合金7075-T6薄板件颤振稳定域的非线性判据。     

切削过程传递函数辨识的新方法

本文提出一种切削过程传递函数辨识的新方法,即用输入脉冲响应位移使切削过程传递函数从切削系统中解耦来测量内调制动态切削力系数.讨论了提高测量信噪比的可行方法,用指数窗函数压缩切削力测量中的噪声,其带来的误差是可以忽略的.最后示出了不同切削参数下动态切削力系数的测量值,并进行了简要的讨论.     

工艺系统刚度主轴方位对切削过程稳定性影响的研究

本文系统地讨论了工艺系统刚度主轴方位对切削过程稳定性影响的规律.理论分析和试验结果证明,工艺系统刚度主轴方位对系统稳定性的影响与切削过程动态切削力的构成有关.动态切削力的构成不同,工艺系统刚度主轴的最佳方位也不同.     

Prediction of cutting force based on machining parameters on AL7075-T6 aluminum alloy by response surface methodology in end milling

Cutting forces modeling is the basic to understand the cutting process, which should be kept in minimum to reduce tool deflection, vibration, tool wear and optimize the process parameters in order to obtain a high quality product within minimum machining time. In this paper a statistical model has been developed to predict cutting force in terms of geometrical parameters such as rake angle, nose radius of cutting tool and machining parameters such as cutting speed, cutting feed and axial depth of cut. Response surface methodology experimental design was employed for conducting experiments. The work piece material is Aluminum (Al 7075-T6) and the tool used is high speed steel end mill cutter with different tool geometry. The cutting forces are measured using three axis milling tool dynamometer. The second order mathematical model in terms of machining parameters is developed for predicting cutting forces. The adequacy of the model is checked by employing ANOVA. The direct effect of the process parameter with cutting forces are analyzed, which helps to select process parameter in order to keep cutting forces minimum, which ensures the stability of end milling process. The study observed that feed rate has the highest statistical and physical influence on cutting force.     

考虑被加工材料动态特性的切削动力学理论

本文考虑了率敏感材料动力特性对切削振动的影响.指出刀尖周围高应变率变形金属是典型的粘塑性介质,因而是影响切削振动的重要阻尼源.运用材料的粘塑性本构方程建立了新的切削动力学模型及其传递函数,并给出了材料粘性系数表达式.     

Two-level fracture criterion for materials

A phenomenological model of dynamic fracture of solids and a two-level fracture criterion, which takes into account increase in the degree of damage of materials on loading, are proposed. Within the framework of a model of elastoplastic solid, solutions of a three-dimensional problem of the dynamic fracture of rock on its interaction with the cutting tool have been obtained by a numerical method. The effect of the criterion on the development of the fracture process and the dependence of cutting force on time are considered.     

Identification of plasticity constants from orthogonal cutting and inverse analysis

The aim of this work is that from experimental determined cutting process parameters be able to predict the plasticity input constants to Finite Element Method (FEM) models. In the present study the Johnson–Cook constitutive model constants are determined on the basis of cutting process parameters in orthogonal cutting and by use of inverse analysis. Previously established links between Johnson–Cook constitutive model constants and cutting process parameters in the cutting process such as primary cutting force and chip compression ratio is used serve as a starting point in the inverse analysis. As a reference material AISI 4140 has been chosen in this study, which is a tempered steel. The Johnson–Cook constitutive model constants in the reference material are being changed within an interval of ±30%. The inverse analysis is performed using a Kalman filter. The material model for the reference material is validated on the basis of the experimental results in previous work. The model showed to predict the cutting process parameters with a high level of accuracy. The predicted Johnson–Cook constitutive model constants in the present study achieve an error between simulated- and experimental cutting process parameters of maximum 2%. The method described in this study is not limited to identify Johnson–Cook constitutive model constants, but the method can also be used for other constitutive models. The same applies to the process itself and the selected cutting process parameters, but orthogonal cutting has been used to illustrate and validate this method.     

Chatter instability analysis of spinning micro-end mill with process damping effect via semi-discretization approach

In this paper, the stability of delay differential equations (DDEs), describing self-excited vibrations in a micro-milling process, is investigated based on semi-discretization (SD) method. Due to the stubby geometry of micro-tools, the shear deformation and rotary inertia effects are considered for modeling the structure. The extended Hamilton’s principle is used to derive a detailed dynamical model of the spinning micro-tool with the support of misalignment in which the gyroscopic effects cause coupling of equations. Considering the actual geometry of the micro-end mill, exact dynamic stiffness (DS) formulations are developed to investigate the tool’s free vibration characteristics. The extracted mode shapes obtained from DS method are utilized as base functions in a Galerkin approach. Having considered regenerative cutting force, imposing the Galerkin method reduces the governing PDEs of the system to a set of DDEs. The resulting equations are discretized by means of SD procedure. Finally, numerical Floquet theory is utilized to investigate the stability of the system. Also, the effects of process damping on the stability diagrams are explored. The results show the efficiency of the proposed model and delineate the considerable influence of process damping on the stability borders of the system especially at low spindle speed.