摘要
高速旋风铣削淬硬丝杠(HRC60以上)是一种新兴的高效绿色加工方法,加工时工件一次铣削完成,不使用任何切削液,加工效率大约是磨削加工的5-8倍,在国外滚动部件加工行业得到了广泛应用。国内一些生产厂家也先后购买了旋风硬铣机床,但滚珠丝杠的加工精度与国外还存在很大差异,主要原因有以下几个方面：一是缺乏对旋风硬铣机理和实验研究；二是国内、外生产企业在工件材料存在差异,在控制工件热变形误差上没有可以参考的数据。上述原因限制了旋风硬铣削丝杠精度的提高。如何减小滚珠丝杠旋风硬铣削加工的热变形误差,进一步提高螺距加工精度,是当前功能部件企业亟待解决的一个问题。
滚珠丝杠旋风硬铣削加工过程中,刀具工件接触区产生大量的切削热,使工件温度升高产生了热变形。基于此,本文深入分析高速切削的切削热问题的研究现状,指出了当前关于切削的研究集中在连续切削领域,而对于成型刀具的高速断续切削的切削热问题研究仍存在不足。课题以控制旋风硬铣加工的热变形误差为目的,建立了参数化的切削热仿真模型和热变形仿真模型,通过温度分布实验验证了模型的正确性；建立了基于BP神经网络的热变形规律预测模型,研究了热变形误差补偿的实现方法,实现了基于预测模型的热变形误差补偿,提高了的大型滚珠精密丝杠加工的螺距精度。主要研究内容如下：
1、深入研究旋风硬铣削加工工艺参数、工件材料、刀具材料、工件的装夹方式、工件刀具运动方式,分析了影响旋风硬铣削加工精度的动态和静态因素,指出影响工件螺距累积误差的主要是工件待加工段的热变形。同时,深入研究工件螺距误差曲线变化规律及旋风硬铣滚珠丝杠的工艺过程,提出工件与液压悬浮支架的摩擦热而产生的热变形,加工区域液压悬浮支架的回落与上升而形成的工件弹性变形,也是影响螺距误差的两个重要因素。
2、分析了旋风硬铣削加工机理,在考虑工件型号、工艺参数对铣削热的影响的基础上,建立了参数化的旋风硬铣削仿真模型。该模型区别于以往的2D或3D正交切削仿真模型的等厚度切削仿真,考虑了成型刀具在切削过程中切削量由薄变厚又由厚变薄对切削温度及切削热的影响。应用该参数化模型计算了不同工件型号、工艺参数条件下,成型PCBN刀具高速旋风硬铣淬硬轴承钢工件时刀具、工件的温度以及切削热分配比例,优化了工艺参数,并为进一步的工件温度场和热伸长分析奠定了载荷基础。
3、建立了基于傅里叶定律的工件热传导方程,分析了移动热源作用下的工件温度分布动态变化规律,在此基础上进行工件的热变形规律研究。滚珠丝杠旋风硬铣加工过程中切削热源沿工件螺旋线移动,工件上的温度分布在时间上和空间上都是变化的。首先建立工件的热传导方程,确定了工件端面和表面的边界条件。然后建立参数化有限元仿真模型,研究了工件动态温度分布规律、待加工段温度分布变化规律,分析了工件参数对温度分布的影响规律。用T1400红外测温仪进行工件温度分布实验,提取工件轴向温度分布数据,验证了仿真结果的有效性。在ANSYS中进行热一结构耦合,得出了加工过程中工件的热伸长变化规律,重点研究了影响螺距累积误差的待加工段热伸长变化规律,指出待加工段的热伸长变化分为动态和准稳态两个阶段。
4、针对旋风硬铣滚珠丝杠热伸长规律的预测问题,提取了工件待加工段热伸长规律特征值,建立了基于BP神经网络算法的预测模型,并用已经深入研究过的工件热伸长数据训练网络。对于热误差的补偿问题,直接提取样本工件仿真实验数据,利用机床数控系统螺距补偿功能,采用插值补偿算法实现螺距误差补偿。对于未经过实验验证变形规律的工件,用BP神经网络算法预测工件热变形规律的曲线特征,以曲线特征为基础进行曲线拟合,拟合的结果作为热变形误差补偿的依据。
滚珠丝杠旋风硬铣削热变形误差补偿试验结果表明,应用基于BP神经网络预测的插值补偿控制方法,大型滚珠丝杠的旋风硬铣加工螺距精度显著提高。本课题所采用的工件热变形误差及控制的研究思路及成果可为其他杆类零件的热变形误差控制提供参考,对促进我国大型精密机械制造技术的发展具有重要的借鉴意义。
High speed and hard whirling ball screw (above HRC60) is a new high efficiency and precision machining technique. The work piece machining can be finished by only once milling without cutting fluid. The milling efficiency could be5to8times than grinding method, so it has been widely used in foreign rolling components processing industry. Some domestic manufacturers also have purchased the whirlwind hard milling machine. However, there is a great difference between domestic and foreign ball screw precision, mainly due to the following aspects:First, the lack of a whirlwind hard milling mechanism and experimental studies; Second, there are differences in the workpiece material between domestic and foreign manufacturers,and there are no reference data on the workpiece thermal deformation error controlling. These reasons largely restricted to improve the accuracy of screw whirlwind hard milling. It is an urgent problem to be solved in the current rolling features enterprise that how to control the thermal deformation error of the whirlwind hard milling and further improve the precision of large ball screws.
A lot of cutting heat is generated in the contact area of tool and the workpiece, which leads to the deformation of the workpiece. Based on this, this paper analyzes the research status of the high-speed cutting heat and points out that the current study focused on continuous cutting. However, there is still insufficient in the study of the forming tool's high-speed intermittent cutting. In order to control thermal deformation error of the whirlwind hard milling, establish a parameterized cutting heat simulation model and thermal deformation simulation model,and verify the correctness of the model through the temperature distribution experiment; establish a thermal deformation prediction model of BP neural network, study on the thermal deformation error compensation method, achieve the error compensation based on thermal deformation prediction model,improve the accuracy of the large pitch precision ball screw machining. The main contents are as follows:
1. Investigate the whirlwind hard milling technology, such as process parameters, workpiece material, tool material, workpiece clamping way, the motion mode of the workpiece and tool and so on. Analysis the dynamic and static factors that affecting whirlwind hard milling precision, point out that the mainly factor affecting the cumulative pitch error is thermal deformation of workpiece section to be machined. Simultaneously, the workpiece pitch error curve analysis shows that pitch error forming factors also include workpiece's thermal deformation causede by frictional heat of the workpiece and hydraulic suspension bracket and the elastic deformation caused by the fall and rise of hydraulic suspension bracket.
2. Analysis the principle of the whirlwind hard milling, establish a parameterized whirlwind hard milling simulation model in consideration of the workpiece and the process parameters effecting on the milling heat. This model is different from the previous2D or3D orthogonal cutting simulation models, considering the formed cutter and the changes of cutting thickness in the processing. Calculate the temperature of the tool, workpiece and cutting heat distribution ratio under different parts models and different process parameters when PCBN tools whirlwind milling hardened bearing steel, optimize process parameters and lay the load foundation for further analysis of temperature field and thermal deformation.
3. Establish workpiece heat conduction equation based on Fourier's law, analyze the dynamic changes of the workpiece temperature distribution under the effect of moving heat source, on this basis, analyze thermal structure coupling to obtain the thermal deformation of the workpiece. Deformation of the workpiece is caused by cutting heat which moves along the workpiece helix and enables the workpiece temperature to rise. Temperature distribution of the workpiece is changing in time and space during processing, establish workpiece heat conduction equation firstly, establish a parameterized finite element simulation model, determine the boundary conditions, study on the dynamic temperature distribution of the workpiece, especially of segment to be processed; analyze the impact of parameters on the temperature distribution of the workpiece.Measure the axial distribution of the workpiece temperature by TI400infrared thermometer to verify the simulation results. Obtain thermal elongation variation of the workpiece segment to be processed by thermal structure coupling in ANSYS. Point out to divide thermal elongation into dynamic stage and quasi-steady stage.
4. For prediction of whirlwind hard milling ball screw thermal elongation law, extract thermal elongation law eigenvalues of the segment to be machined, establish the prediction model based on BP neural network algorithm, and train network by studied thermal elongation data. For thermal elongation error compensation problem, compensate error by pitch compensation function of CNC system for the sample workpiece. For workpiece of new parameters, predict characteristic value of the thermal deformation curves with BP neural network algorithm, fit deformation curves based on characteristic value, and compensate the thermal deformation according to fitting curve.
Whirlwind hard milling thermal deformation error compensation results show that the compensation control method makes the ball screw pitch accuracy improved significantly.Research methods and results of this study can be generalized to other types of process control, which provide theoretical and methodological reference for machining error control during the process of precision machining and have an important reference to promote the further development of precision machinery manufacturing technology.
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