应用电流变材料改变镗杆动态特性的研究

为保证镗削加工切削稳定性,基于电流变材料设计一种智能型镗杆。该镗杆可通过调节施加于电流变材料上的电场强度来改变整个镗杆的动态特性,并借以抑制切削颤振。采用 端部激振方法研究镗杆在不同激振频率和不同电场强度下的动态特性。实验结果表明,在不同的电场强度和振动频率下,电流变材料表现出来的振动特性差异明显,使镗杆的支撑刚度和结构阻尼特性发生显著的变化。     

电流变材料抑振机构动态性能测试与分析

电流变材料在振动控制中表现出优良的阻尼抗振性能,但由于电流变材料在振动结构中随振动幅度、振动频率和施加电场强度的变化,其动态性能表现出明显的差异,使控制模型难于准确制定。通过对含有电流变材料的抑振机构进行动态性能测试试验,获取在不同电场强度和不同激振频率下的迟滞曲线,并结合所建立的迟滞曲线数学模型将电流变材料在结构振动控制中所表现出来的动态性能分为牛顿粘性液体、屈服前弹性体、屈服前粘弹体、非线性体和屈服后粘性体,同时,分析了电流变材料不同动态特性出现的条件及其对整个结构动态性能的影响。这种试验分析方法为有效制定电流变抑振机构的控制策略提供了科学依据。     

专利

一种机床切削颤振在线智能控制方法及其系统。用于精密柔性制造加工领域。系统包括利用电流变材料设计一种动态特性可以在线快速调整的智能型镗杆,向电流变材料施加高压电场的电斥变换器、计算机、电荷放大器及输入加速度信号的加速度传感器,加工系统动态特性在线调整主要依靠含有电流变材料的机械结构进新行。控制方法包括系统初始化、颤振识别和颤振控制三部分。该方法中采用CDM方法在线     

切削系统可变刚度结构及其颤振控制方法的研究

就电流变材料在切削颤振在线控制中的应用进行了研究,提出了几种用于控制镗削颤振的智能型颤振抑制装置.根据电流变材料的非线性振动特性和再生型颤振控制理论提出了切削颤振的变刚度控制方法.给出的仿真试验结果验证了该方法的有效性.     

电流变减振器仿真分析

电流变减振器是根据电流变材料具有电流变效应的特性,通过电场来控制电流变流体的流动特性,以实现阻尼力控制。从应用研究的角度出发,将电流变液减振器应用于汽车半主动悬架的减振,通过Matlab/Simulink仿真软件研究模糊控制用于变阻尼汽车半主动悬架控制的可行性。     

深孔加工镗杆的结构模态对切削颤振的影响

本文通过对普通镗杆和减振镗杆的动态特性及结构模态的研究,分析了镗杆对深孔加工中产生的切削振动的影响。     

自供能电流变弹性体减振器的设计与特性分析

新型智能材料电流变弹性体是电流变材料的衍生体,兼有电流变液和弹性体的优点,在主被动的振动控制领域中有着极大的应用前景。基于电流变弹性体的刚度和阻尼可电控调节的特性以及压电陶瓷的正压电效应,研制一种基于D33挤压模式的压电自供能电流变弹性体减振器,并对其在不同激励和场强下的振动响应特性进行实验分析。试验数据表明相比无场强条件下,在压电供电和1 000 V恒压的条件下能有效增大电流变弹性体结构阻尼,改变减振器振动响应谱峰值的频率和幅值,提高系统的隔振效果。     

基于电流变材料的智能结构研究进展与应用

电流变材料是功能是全面的智能材料之一,可由计算机进行控制,根据外部条件的变化快速地改变它的材料特性。文章综合评述了国内外对电流变材料性能及其电流变效应理论的研究,以及电流变材料在动力传动、阀控液压伺服驱动系统、机器人技术、振动控制和机械制造加工系统中应用的进展。     

悬架不确定性的滑模半主动控制分析

在电流变液特性试验的基础上,提出基于电流变阻尼悬架的滑模半主动控制。依据滑模控制理论,采用极点配置法确定滑模切换面参数,应用比例切换的控制方法和等速趋近率确定控制律并改善滑模运动的动态品质,同时采用RBF神经网络算法优化滑模控制效果。针对悬架质量参数和车速不确定性,运用MATLAB/SIMULINK进行了悬架半主动控制的建模和仿真分析。仿真结果显示,与被动悬架相比基于RBF神经网络的滑模半主动控制能有效改善悬架性能,对于悬架的不确定性有较好的自适应性。     

多刃均布式镗杆系统振动耦合问题研究

深孔镗削过程中,由于镗杆的悬伸量较大,刚度差,强度低,在镗削过程中易产生振动。自激振动是金属切削过程中产生的振动类型之一,同时其振动机理的揭示以及对它的控制相对于受迫振动的研究而言较为困难。本文针对多刃均布式镗杆系统,在建立其力学模型的基础上,计算镗刀所受的动态切削力,并对镗杆振动系统耦合微分方程进行推导计算,对该耦合系统的稳定性进行分析,最后得出引起该系统产生自激振动的条件。     

基于电流变材料的切削颤振在线监控技术研究

提出可以利用电流变材料的电控流变特性,通过在线调控切削系统动态特性以提高切削稳定性。并针对镗削系统,开发出一套可根据实时采集的切削振动信号自适应地快速调整系统动态特性以避免颤振发生的颤振智能监控系统。     

Parameter optimization of time-varying stiffness method for chatter suppression based on magnetorheological fluid-controlled boring bar

An innovative chatter suppression method based on a magnetorheological (MR) fluid-controlled boring bar for chatter suppression is developed. The MR fluid, which can change stiffness consecutively by varying the strength of the applied magnetic field, was applied to adjust the stiffness of the boring bar and suppress chatter. The cutting dynamic stability under different natural frequencies of the structure was analyzed by an energy method, which shows that cutting dynamic stability depends on both the natural frequency of the structure and the spindle speed. The chatter suppression mechanism with varying natural frequency is analyzed for further parameter optimization. Furthermore, both theoretical analyses and numerical simulations indicate that a square wave exciting current with a large amplitude and a moderate frequency has a better effect on regenerative chatter suppression. Experiments utilizing a MR fluid-controlled boring bar under an exciting current with different waveforms and frequencies were conducted. The experimental results show that the chatter can be significantly suppressed using MR fluid-controlled boring bar under a square wave exciting current with a frequency of 4–6 Hz and an amplitude of 0–2 A.     

Development of a novel boring tool with anisotropic dynamic stiffness to avoid chatter vibration in cutting: Part 1: Design of anisotropic structure to attain infinite dynamic stiffness

This paper presents a novel design method of the anisotropic structure to attain infinite dynamic stiffness to avoid chatter vibration in boring operations. Because a long and slender tool is used for boring operations, the stiffness of the tool holder is likely to decrease, resulting in low chatter stability. Although it is difficult to improve the stiffness of the boring holder itself, the nominal dynamic stiffness for the cutting process can be improved by designing an appropriate anisotropy in the dynamic stiffness of the boring tool. In this study, we formulate a theoretical relationship between the mechanical structural dynamics and chatter stability in boring operation and present the basic concept of tool design with anisotropic structure. In the actual tool design, ideal anisotropy may not be realized because of the influence of design error. Therefore, an analytical study was conducted to clarify the influence of the design error on the vibration suppression effect. Analytical investigations verified that the similarity of the frequency response functions in the modal coordinate system and the design of the compliance ratio according to the machining conditions are important. Furthermore, we designed a boring tool with an anisotropic structure which can achieve the proposed anisotropic dynamics. The frequency response function was evaluated utilizing FEM analysis. The estimated anisotropic dynamics of the proposed structure could significantly improve the nominal dynamics for boring operations.     

Improvement of chatter stability in boring operations with passive vibration absorbers

This paper is focused on the behavior of boring bars with a passive dynamic vibration absorber (DVA) for chatter suppression. The boring bar was modeled as a cantilever Euler-Bernoulli beam and only its first mode of vibration was considered. The stability of the two-degree-of-freedom model was analyzed constructing the stability diagram, dependent on the bar characteristics and on the absorber parameters (mass, stiffness, damping, and position). Two analytical approaches for tuning the absorber parameters were compared. The selection criterion consisted on the maximization of the minimum values of the stability-lobes diagram. Subsequent analysis performed in this work, allowed formulating of new analytical expressions for the tuning frequency improving the behavior of the system against chatter.     

镗削颤振快速预报技术研究

切削颤振切导致产品质量、生产效率、刀具和机床使用寿命的降低 ,同时造成噪声污染 ,影响操作者身心健康。随着工厂自动化发展 ,操作者日益远离加工现场 ,对切削颤振进行在线监视预报和控制变得越来越重要。但由于其发生发展的过程极其短暂 ,使颤振的在线预报十分困难。本文在讨论了镗削颤振发展机理的基础上 ,提出了一种基于神经网络进行颤振预报的新方法。用 L O- RBF模型进行传感信号预处理 ,结果输入 Fuzzy ARTMap模型进行颤振识别 ,大大缩短了信号处理时间 ,提高了识别的准确性 ,取得了满意的结果。     

AFFECTION OF ER FLUID ON STIFFNESS OF VIBRATION SYSTEM

On the application of an electric field, the mechanical properties of ER(Electro-rheological) fluid are very complex. The damping force of ER fluid is linear without electric field and is nonlinear when an electric field is applied. By increasing the strength of the electric field, the behavior of ER fluid changes from linear viscous to nonlinear viscoelastic-plastic. External electric fluid changes natural behavior of system with ER fluid besides the mechanical properties of ER fluid. The affect of ER fluid on the stiffness of nonlinear vibration system with ER dampers is analyzed by iterative perturbation method. The results show that the stiffness of structure would be increased with growing of the strength of the electric field.     

电流变液减振器在抑制深孔切削颤振上的研究

针对深孔机床切削中的颤振问题,设计了一套基于流动模式的电流变液减振器,分析了电流变液减振器的阻尼力并得出其表达式;又通过对切削颤振产生原因的分析,推导出瞬时动态钻削力的表达式;并在研究了深孔机床切削过程的基础上,建立了切削系统动力学模型,得出安装电流变液减振器后的动力学方程。在给定动力学方程中的参数值后,通过计算机仿真,对比安装和未安装电流变液减振器后的振动时域图,时域图表明电流变液减振器能有效地抑制深孔机床的切削颤振。     

基于变结构刚度的精密孔镗削颤振抑制新方法

精密孔镗削过程中容易出现颤振现象,它会导致加工精度低和表面质量差等问题。为了解决此问题,首先针对镗削过程中最为常见的再生型颤振建立了动力学模型,并在此基础上,分别讨论了主轴变速方法和变结构刚度方法对切削颤振的抑制机理,对比两种方法发现：它们的抑振机理异曲同工,但是,变结构刚度方法能够避免主轴变速法对刚性较低的切削系统不适用的缺点。其次,为了能对精密孔镗削过程施加变结构刚度法来抑制颤振,本文设计制作了一种基于磁流变液的智能镗杆,通过调节外加磁场强度的大小实现刚度和阻尼特性参数的无级变化,改变机械系统的动态特性,从而达到抑制颤振的目的。最后在车床CA6140上搭建了磁流变智能镗杆的颤振抑制实验系统,通过一系列的实验发现：该方法能够快速高效的抑制镗削过程中产生的颤振,并且使加工表面的粗糙度从Ra 10μm降至Ra 1.5μm,大幅度提高了加工表面质量。     

Stabilization of high frequency chatter vibration in fine boring by friction damper

Friction damper has been found successful to prevent high frequency chatter occurring at more than 10,000Hz, and causing problem of reduced tool life in fine boring operation. The new damper is characterized by simple structure that consists of an additional mass attached to the main vibrating structure with small piece of permanent magnet. The principle is straightforward in which Coulomb and viscous frictions dissipate vibration energy at the interface between the damper and main vibrating structure. The damper needs no tuning, and is effective at high frequency. The paper first introduces a typical design of the friction damper with experimental proof by cutting tests of its effectiveness in eliminating the high frequency chatter in fine boring, and assuring normal tool life of the cutting edge. Theoretical and experimental analyses are introduced for understanding the fundamental principle and characteristics of the new damper. The new damper is effective for boring tools, which vibrate at frequency more than 5,000Hz.