摘要
在现代装备制造业中,关键的核心技术是数控技术,它决定着一个国家装备制造业的水平,而数控技术的关键技术之一是插补,其中特别是插补算法中的曲线曲面插补的弦高误差算法在其中扮演着核心技术的角色,本文就此理论和应用问题进行了研究。
在零件数控精加工过程中,插补算法的弦高误差与零件精加工表面粗糙度是成正比的。由于弦高误差计算的复杂性,提出复杂参数曲线加工中的弦高误差控制算法,它是利用插补点处弧长误差、坐标值及一阶导数信息间接对弦高误差进行控制。其中插补点处的弧长误差由辛普生公式求出,插补点处的坐标值及一阶导数信息由插补算法得到,因而计算量的增加并不显著。对算法的误差情况进行讨论,并利用Nurbs曲线的仿真实例证实此算法单步插补运算时间不大于300μs的前提下,达到的弦高误差加工精度为2.587 83×10-6mm。
弦高误差是影响零件加工的表面质量的关键因素。利用引入误差补偿值的参数曲面的高精度刀具轨迹规划算法与本文的弦高误差控制算法相结合能够在满足实时性的前提下将弦高误差控制在预定范围内,使零件加工达到预定精度,其本质是通过实时改变零件加工的进给速度来达到提高零件加工质量。在弦高误差的计算过程中,许多必要的计算数据(主要是曲面插补点处的坐标值信息及一阶导数信息)已在引入误差补偿值的参数曲面的高精度刀具轨迹规划算法求出,不必重复计算,只须通过简单的计算公式就可以计算出插补点间的弧长误差并计算出弦高误差,由于避免在直接求取弦高误差时对二阶导数的计算,因而计算量增加不大。同时此算法适用于在插补点处具有一阶连续导数且有二阶导数的各类参数曲线插补及弦高误差控制,适应性较广。
螺旋齿轮通常是采用专用螺旋锥齿轮数控机床来进行加工,但是由于采用专用设备价格昂贵,利用率低,显然不适合加工单件、小批量生产螺旋锥齿轮。基于以上原因,研究了采用通用五轴数控机床进行螺旋锥齿轮,开发了基于天津大学自主开放式数控系统TDNC-H8开通用五轴数控螺旋锥齿轮数控加工系统。该系统具有在线切削仿真功能,该功能采用了“层片分割”算法,相比以前螺旋锥齿轮仿真算法来说,具有计算速度快、精度高的优点。
基于采集信号类型、采集方式、信号分析、状态辨识以及监测诊断的实现各点,研究了旋转部件非稳态信号的采集分析和实现方法,提出了基于阶比分析的信号故障提取技术和AR模型的状态辨识方法,并在linux环境下进行了算法实现。最后基于上述算法和监测诊断应用于天津大学自主开放式数控系统TDNC-H8通用五轴数控螺旋锥齿轮数控加工系统,对于曲面、曲线加工能得到很大技术提升。
In the modern equipment manufacturing, the key technique is numeric control, which determines the machine manufacturing level of a country. One of the key techniques in numeric control is interpolation, and the chord deviation of curve and surface in interpolation displays the core technology. This dissertation intends to work on the theory and application on this problem.
In the process of component finishing in numeric control, the chord deviation in interpolation is scale with surface roughness of the component finishing. Due to the complexity of chord deviation calculation, we propose the chord deviation control algorithm in complex parameter curve manufacturing. It indirectly controls the chord deviation in the way of employing arc-length error, coordinate values and first order derivative in the interpolation points. The arc-length error in the interpolation points is calculated by the Simpson Formula, and the coordinate values and first-order derivative in the points are achieved by interpolation algorithm, as a result the calculation does not increase too much. This paper discusses the error of the algorithm, and uses simulation results of Nurs curve to testify that this algorithm can achieve accuracy of the chord deviation as 2.587 83×10-6mm under the assumption that the calculation of single interpolation is no bigger than 300μs.
The chord derivation is the key factor in the surface quality of component finishing. Combination of the algorithm proposed in this paper and the parameter surface high accuracy cutting tool trajectory algorithm with the error compensation can control the chord deviation in a certain range with the satisfaction of real-time. It reaches the predetermined accuracy in the component finishing, and the nature of it is to improve the component quality by changing the feed speed in real-time. In the process of calculating the chord derivation, many necessary data are already there in applying the parameter surface high accuracy cutting tool trajectory algorithm with error compensation, and do not need to compute again. It just requires simple calculation for the arc-length error in the interpolation points and gets the chord deviation. No increase of computation appears since it does not need to directly calculate second order derivation for the chord deviation. Meanwhile, this algorithm is suitable for the various parameter curve interpolation and chord deviation control in the interpolation points with continuous first order derivation and existing second order deviation.
Screw gear is used to producing with screw gear NC machine. Due to the high price and low utilization ratio when employing special equipment, it’s not suitable for single screw gear or small batch. Based on this, we focus on producing the screw gear with five-axis NC machine, and develop NC processing system based on the TDNC-H8 which is an open NC system. This new system has the function of cutting simulation in real-time, and this function employs the algorithm of Slice method. It computes faster and has higher accuracy compared with former screw gear simulation algorithm.
Based on the signal sampled type, sampling method, signal analysis, state identification, monitoring and diagnosis, this paper studies on the sampling analysis and implementation of the unstable signal of rotating parts. We also propose a fault extraction technique based on order analysis and a state identification method of AR model, and implement experiments under Linux. This paper applies the above algorithm and monitoring & analysis on TDNC-H8, which is a five-axis NC Spiral bevel gear manufacturing system developed by Tianjin University. The results show that the proposed methods can greatly promote the manufacturing technology on curves and surfaces.
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