轴颈外圆磨削成圆过程的双转子耦合模型及仿真算法

主轴轴颈外圆的圆度对机床主轴部件的回转精度具有直接而重要的影响。磨削加工是实现轴颈外圆高精度加工的最重要的手段。虽然磨削技术在主轴外圆加工上已长期应用，但是利用现有的研究成果，还难以对一个既定的磨削系统的磨削成圆过渡过程进行完整有效的定量仿真，也难以对磨削工件的最终圆度进行科学合理的预测。在吸收国内外磨削转子系统模型成果的基础上，进一步考虑外圆磨削过程中砂轮和工件之间的相互耦合作用、材料去除、转子振动及变形协调规律，建立了外圆磨削系统的双转子耦合振动模型，提出了模拟轴颈材料去除和圆度变化的"磨削力-瞬时磨削深度"迭代算法。利用所建立的双转子模型和迭代算法，对不同磨削策略下轴颈外圆成圆的过渡过程进行了定量仿真，再现了轴颈材料去除和外圆轮廓变化的全过程；比较研究了不同磨削策略对磨削效率和最终加工圆度的影响规律。进行了相应的磨削试验和对比验证，试验结果证实了所提出的轴颈外圆磨削的双转子模型和迭代算法的有效性和合理性。

Dual-rotor Coupling Model and Simulation Algorithm for Round Journal Grinding Process

Shaft journal roundness directly effects machine tool spindle rotational accuracy. Since grinding has been applied in journal machining for a long time, it is an important method to achieve high precision journal machining. However, based on existing research results, it is difficult to perform effective complete quantitative simulations for the journal profile grinding process of a given grinding system, and it is also hard to make scientific and reasonable prediction for the finishing roundness. Based on the conventional grinding rotor system model, the grinding wheel-workpiece coupling effect, material removal, rotor vibration and compatibility functions, a new dual-rotor vibration grinding system model is established. A novel "transient grinding force-depth" iterative algorithm is proposed to simulate the material removal and the roundness variation. Using the model and the algorithm, the journal rounding process under different grinding strategies are quantitively simulated. The material removal processes and profile changing procedure are reproduced in the calculation. The grinding strategy effects on grinding efficiency and finishing roundness are studied. Comparative experiments are performed, and the proposed method is validated by the test results.