深圳大学学报理工版

为探究工件中心刀具干涉的形成机理,实现刀高误差的在线辨识,围绕刀高误差存在情况下,刀具干涉的产生及加工过程参数的影响等方面展开研究.通过分别建立车削行程中工件中心圆台及刀具后刀面的三维形貌方程,基于两者间的位置关系推导刀具干涉区域半径的数学模型,探讨加工过程参数对刀具干涉区域三维形貌的影响.根据所推导的数学模型,利用刀具与工件挤压面积的投影来表征切削力的变化,建立刀高误差的预测模型.理论与试验研究结果表明,刀高误差、切削深度、刀尖半径及刀具后角直接影响刀具干涉区域的范围与形貌,工件刀高误差可通过监测切削行程中的切削力进行在线辨识.

In order to explore formation mechanism of the tool interference at the workpiece center and realize the online identification of tool height error, tool interference generation and the influence of the processing parameters were investigated under the condition of the tool height error. By establishing the equations of the three-dimensional(3D)topography of round platform and the tool clearance face respectively during the turning process, a mathematical model for calculating the radius of tool interference zone was derived based on the relationship between the two positions. Meanwhile, the influence of processing parameters on the 3D topography of the tool interference zone was discussed. According to the derived mathematical model, the cutting force was characterized by the projection of the extrusion area between tool and workpiece, whereby a prediction model for the tool height error was established. The theoretical and experimental results show that the tool height error, cutting depth, tool nose radius and tool clearance angle directly affect the range and shape of the tool interference zone. The tool height error can be identified online by monitoring cutting force during the turning process.

引言
1 刀具干涉模型
2 试验验证与结果对比
3 基于切削力的刀高误差表征
4 结语

图1 刀高误差下刀具切削示意图<br/>Fig.1 Schematic of tool cutting under tool height error

图1 刀高误差下刀具切削示意图
Fig.1 Schematic of tool cutting under tool height error

图2 金刚石刀具几何示意图<br/>Fig.2 Geometric schematic of diamond tool

图2 金刚石刀具几何示意图
Fig.2 Geometric schematic of diamond tool

图3 刀具与上层车削残留中心圆锥示意图<br/>Fig.3 Schematic of the relation between tool and residual center cone generated from upper layer turning

图3 刀具与上层车削残留中心圆锥示意图
Fig.3 Schematic of the relation between tool and residual center cone generated from upper layer turning

图4 中心圆台不同截面处刀具与工件干涉位置<br/>Fig.4 Interference location diagram of tool and workpiece at different sections of center circular table

图4 中心圆台不同截面处刀具与工件干涉位置
Fig.4 Interference location diagram of tool and workpiece at different sections of center circular table

图5 试验搭建图
Fig.5 Experimental setup

表1 黄铜工件试验切削参数<br/>Table 1 Cutting conditions used in experiment

表1 黄铜工件试验切削参数
Table 1 Cutting conditions used in experiment

图6 中心圆柱与中心圆锥形成示意图及三维形貌<br/>Fig.6 Schematic diagrams and 3D topography of center cylinder and cone

图6 中心圆柱与中心圆锥形成示意图及三维形貌
Fig.6 Schematic diagrams and 3D topography of center cylinder and cone

图7 不同加工过程参数下刀具干涉区域图<br/>Fig.7 Tool interference area diagrams under different processing parameters

图7 不同加工过程参数下刀具干涉区域图
Fig.7 Tool interference area diagrams under different processing parameters

表2 试验切削参数<br/>Table 2 Experimental cutting parameters

表2 试验切削参数
Table 2 Experimental cutting parameters

图8 刀具干涉区域半径理论值与试验值对比图<br/>Fig.8 Comparison of theoretical and experimental values of tool interference area radius

图8 刀具干涉区域半径理论值与试验值对比图
Fig.8 Comparison of theoretical and experimental values of tool interference area radius

图9 不同刀高误差下的切削力<br/>Fig.9 Cutting force under different tool height errors

图9 不同刀高误差下的切削力
Fig.9 Cutting force under different tool height errors

表3 不同刀高误差下的干涉作用力幅值<br/>Table 3 The amplitude of interference force under different tool height errors

表3 不同刀高误差下的干涉作用力幅值
Table 3 The amplitude of interference force under different tool height errors

图10 不同刀高误差下干涉作用力形态<br/>Fig.10 Interference force shapes under different tool height errors

图10 不同刀高误差下干涉作用力形态
Fig.10 Interference force shapes under different tool height errors

图11 刀具干涉区域投影图<br/>Fig.11 Projection of tool interference area

图11 刀具干涉区域投影图
Fig.11 Projection of tool interference area

图12 干涉作用力分量Fx的模拟值与试验值对比图<br/>Fig.12 Comparison of simulated and experimental values of interference force Fx

图12 干涉作用力分量Fx的模拟值与试验值对比图
Fig.12 Comparison of simulated and experimental values of interference force Fx

图13 不同刀高误差下切削力分量Fx幅值<br/>Fig.13 The amplitude of the cutting force Fx under different tool height errors

图13 不同刀高误差下切削力分量Fx幅值
Fig.13 The amplitude of the cutting force Fx under different tool height errors

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备注

引言

1 刀具干涉模型

2 试验验证与结果对比

3 基于切削力的刀高误差表征

4 结语

期刊信息

备注

引言

1 刀具干涉模型

2 试验验证与结果对比

3 基于切削力的刀高误差表征

4 结 语

期刊信息

4 结语