目的 预测薄壁筒工件车削振动状态下加工表面形貌。方法 综合考虑刀具与工件几何参数、切削用量以及切削振动参数的影响,建立一种机理与数据相融合的薄壁筒切削表面形貌及粗糙度预测模型。首先,基于切削原理推导切削刀刃上点在加工过程中相对于工件表面的运动轨迹方程以及坐标变换矩阵,建立薄壁筒切削表面形貌运动学模型,随后利用时频分析提取切削过程中工件振动位移信号的特征,最后,将构建的振动特征方程代入运动学机理模型中仿真计算表面形貌。结果 探明了加工表面形貌特征与切削振动信号频率特性之间的映射关系,数值仿真获得不同加工参数下薄壁筒的表面形貌及粗糙度,工件A在稳定切削区的仿真表面粗糙度与实测表面粗糙度的相对误差为4.27%,在颤振区的平均相对误差为6.03%;工件B在稳定区的仿真表面粗糙度与实测表面粗糙度的相对误差为3.61%,在颤振区域的相对误差为2.42%。结论 预测表面与实测表面结果具有一致性,研究成果可为薄壁筒类零件切削表面质量的在线监测与控制提供理论依据。
Abstract
Thin-walled cylinder parts which are widely used in automotive and aerospace industry are prone to vibration during machining operations as a result of their high compliance, leading to special textures left on the surface. The aim of this paper is to predict the surface morphology of thin-walled cylinder workpieces in the presence of turning vibrations by digital-model linkage modeling. A novel prediction model of the cutting surface topography and roughness of thin-walled cylinders based on the combination of the mechanism and online data is established by taking into account the effects of the geometrical parameters of cutting tools and workpieces, machining parameters, and cutting vibration parameters comprehensively. At first, based on the principle of machining, the motion trajectory equation and the coordinate transformation matrix of the points on the cutting edge relative to the workpiece surface in the machining process are derived. Through subtracting the coordinates of the tool and the workpiece at their contact point, the kinematics model of the machined surface of the thin-walled cylinder can be established. After that, machining experiments are conducted on an industrial lathe, in which two thin-walled cylinder workpieces with different dimensions are presented for comparison. In machining operations, one side of the machined cylinder is clamped with the chuck and the other is free without the tailstock center support. Two orthogonal eddy current sensors are used to acquire the displacement of the thin-walled cylinders. In addition, a MarSurf PS10 roughness measuring instrument is utilized to attain the surface roughness distribution along the axis of the workpiece after each cutting pass. It shows that the dynamic response as well as the machined surface topography of the thin-walled cylinder can exhibit strong variability along the cutting path. Finally, the time-frequency analysis is used to extract the characteristics of workpiece vibration signals for constructing the characteristic equations in different cutting process states. The mapping relationship between the characteristics of surface topography and the frequency features of vibration signals is identified. The constructed characteristic vibration equation is then substituted into the kinematic mechanism model to simulate and calculate the surface topography, and the surface topography and roughness of the thin-walled cylinder under different machining parameters are obtained using numerical simulation. It can be seen that the predicted surface shows consistency with the measured surface. And the relative error between the simulated surface roughness and the measured surface roughness of workpiece A in the stable cutting zone is 4.27%, and the average relative error in the chattering zone is 6.03%. The relative error between the simulated surface roughness and the measured surface roughness of workpiece B in the stable region is 3.61%, and the relative error in the chattering region is 2.42%. The results of this research can provide a theoretical basis for on-line monitoring and control of the cutting surface quality of thin-walled cylinder parts in intelligent machining scenarios. In addition, the formulated mapping relation between the vibration characteristics and the surface topography provides an overall insight into vibration behaviors of thin-walled cylinder workpieces during machining processes.
关键词
薄壁筒 /
切削 /
振动 /
表面形貌 /
数模联动 /
粗糙度
Key words
thin-walled cylinder /
cutting /
vibration /
surface topography /
digital-model linkage /
roughness
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基金
国家自然科学基金面上项目（52175108）
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