CN102658499A - Spindle thermal distortion compensation method for precision horizontal machining center - Google Patents
Spindle thermal distortion compensation method for precision horizontal machining center Download PDFInfo
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Abstract
A spindle thermal distortion compensation method for a precision horizontal machining center comprises the steps as follows: a spindle model of a machine tool is simplified structurally; an ANSYS (finite element analysis software)-Workbench is utilized to perform mesh generation on a spindle entity model that is simplified, so as to obtain a spindle finite element model; and boundary conditions are calculated by combining with the practical spindle rotational speed, the environmental temperature, the coolant velocity, the flow rate, the inlet and outlet oil temperature and the like, and configuration is performed. Thermodynamics analysis and statics analysis are carried out in the ANSYS-Workbench to obtain more accurate spindle temperature field distribution and thermal deformation. Based on a finite element emulation result, the spindle temperatures in different positions and the spindle thermal deformations are analyzed at different rotational speeds by utilizing the Spearman rank correlation analysis, and spindle thermal key points are found out, so that references are provided to spindle thermal error tests and thermal error compensation. Finally, a thermal error compensation model is built up by utilizing a least squares method according to the key point temperature of the spindle and the thermal errors in the practical tests. Based on the thermal error compensation model, the spindle thermal error compensation is carried out by combining with thermal error compensation strategies of a numerical control system of the machine tool.
Description
Technical field
The invention belongs to accurate horizontal Machining centers process; Specially refer to accurate horizontal Machining centers main shaft thermal error compensation method; Comprise axis system temperature field and thermal deformation finite element simulation computational methods, warm key point system of selection, hot error testing and modeling method, and the heat error compensation implementation method.
Background technology
Main shaft is as the critical component of lathe, and the quality of its performance directly influences machine finish, stability and range of application.In recent years, high-speed main spindle becomes a development trend of main shaft, yet the main shaft internal bearings can produce big calorimetric under the rotation at a high speed, thereby causes main shaft to deform, and influences machining accuracy.At present, the method that reduces hot error both at home and abroad mainly is divided three classes: 1, reduce thermal source caloric value and the transmission of control heat, as strengthening coolant rate, improve environment temperature control system; 2, machine tool structure optimal design is as adopting the thermal tracking structure and rationally selecting the little material of coefficient of thermal expansion for use; 3, heat error compensation.Compare with preceding two kinds of methods, heat error compensation can improve machine tool accuracy on the basis that does not change lathe mechanism, and spends less, implements conveniently.
In the machine tool chief axis heat error compensation, set up the precision height, heat error compensation model that robustness is good is a difficult point, and the quantity of optimized choice temperature point and position are the bases of hot error modeling.Find through the CJFD retrieval, have a lot of documents to use methods such as gray system theory, stepwise regression analysis, information theory principle and carry out the temperature point selection, but major part all is based on test data of experiment.In order to obtain lathe temperature data enough under the multi-state, need arrange a large amount of temperature sensors during experiment and different operating mode lower main axis temperature field is repeatedly tested, not only increased the complexity and researcher's workload of experiment, and the consumption plenty of time.
Implement for heat error compensation; Pan Shuwei proposes to utilize a kind of software systems based on the PMAC multi-axis motion control card, Yang Jianguo in patent 200410093428.1, to disclose a kind of Digit Control Machine Tool real time error compensator based on the biasing of lathe exterior coordinate system in " based on the spindle of numerical control lathe heat error compensation system research of PAMC " that 2007 " mechanical engineering " delivered.More than two kinds of methods all can realize heat error compensation, reduce hot error greatly, but need increase the compensation hardware unit in that system is outside, and need the professional to carry out software programming, both increased the complexity of system, increased cost again.
Summary of the invention
The object of the invention proposes a kind of accurate horizontal Machining centers main shaft thermal error compensation method in order to overcome the deficiency of above-mentioned existing method.
For achieving the above object, the technical scheme that the present invention adopts is:
1) accurate horizontal Machining centers main shaft to be compensated is simplified, and the model after will simplifying imports among the ANSYS/Workbench; The speed of mainshaft, environment temperature, cooling liquid speed, flow and turnover oil temperature in conjunction with actual measurement are calculated boundary condition; And carry out thermodynamics and the analysis of statics finite element simulation with the boundary condition substitution ANSYS/Workbench that calculates and then to the main shaft of simplifying, obtain more accurate main shaft temperature field distribution and thermal deformation;
2) based on the finite element simulation analysis result; Extracting the temperature and the main shaft thermal deformation of arbitrary node analyzes; Promptly utilize the Spearman rank correlation coefficient; Rank correlation analysis is carried out in temperature rise and main shaft thermal deformation to different operating mode lower main axis system diverse location, selects the axis system warm key point according to coefficient correlation that calculates and lathe concrete structure, the coefficient correlation computing formula:
Wherein d represent corresponding two variable X, Y value the difference of corresponding order, n is paired data (X, number Y);
3) at axis system warm key point and front-end of spindle magnet-type temperature sensor and Reinshaw laser feeler are installed respectively; Realize main shaft warm key point temperature survey and the hot error measure of main shaft; The output of temperature sensor directly inserts digital control system during measurement, and utilization PLC calculates the temperature collect and the difference of environment temperature; Utilize the hot error of this numerical value and main shaft, set up hot error model; Simultaneously with the triggering amount of this numerical value as heat error compensation; Directly realize heat error compensation in conjunction with machine tool numerical control system heat error compensation strategy; Compensation method has two kinds: directly hot error model is embedded and realize the main shaft heat error compensation in the digital control system; Or, finally utilize the heat error compensation table that the hot error of main shaft is compensated according to the heat error compensation model generation heat error compensation table of setting up.
The present invention is the basis with the heat error compensation model, in conjunction with machine tool numerical control system heat error compensation strategy, implements the main shaft heat error compensation, has reduced the problem of the hot error of accurate horizontal Machining centers main shaft effectively.
Description of drawings
Fig. 1 is accurate horizontal Machining centers main shaft thermal error compensation method flow chart;
Fig. 2 is the accurate horizontal Machining centers axis system of certain a model cross-sectional schematic;
Fig. 3, Fig. 4 are the accurate horizontal Machining centers axis system of Fig. 2 temperature point position sketch map; Wherein: the expression finite element simulation extracts the node location of temperature data, and T1-T11 is a node serial number;
Fig. 5-Fig. 7 is respectively main shaft when being rotating speed 2000r/min, 3000r/min, 4000r/min, hot error testing curve map before and after the axial hot error model curve of main shaft and the compensation.
The specific embodiment
Below in conjunction with accompanying drawing the present invention is done further explain.
Referring to Fig. 1,1, the finite element simulation of accurate horizontal Machining centers axis system temperature field and thermal deformation
1) applying of the foundation of FEM model and boundary condition: at first based on the machine-tool spindle system design feature; Through Pro/E software accurate horizontal Machining centers axis system is simplified, the physical model of simplifying is imported carry out the grid division in the ANSYS/Workbench analysis software; Select different division methods based on the design feature of the different parts of axis system when grid is divided, select to scan division, select tetrahedron to divide or freely divide baroque parts like cylinder, square to tactical rule.In conjunction with actual conditions, in the ANSYS/Workbench analysis software to the different component settings material different of axis system parameter.Combine the speed of mainshaft, environment temperature, cooling liquid speed, flow and the turnover oil temperature of actual measurement to calculate boundary condition in addition, and in the ANSYS/Workbench analysis software, be provided with;
2) accurate horizontal Machining centers axis system temperature field and thermal deformation emulation: after being provided with more than the completion; Utilize ANSYS/Workbench software to carry out thermodynamics and statics finite element simulation analysis (ignoring the influence of thermal contact resistance during analysis); Thereby obtain different rotating speeds lower main axis system temperature field and main shaft thermal deformation; Measured result calculates because the boundary condition that is provided with is based on, so finite element simulation calculates more near actual conditions and has higher precision;
2, select based on the main shaft warm key point of finite element simulation
The result that the finite element simulation of axis system temperature field and main shaft thermal deformation is analyzed during from different rotating speed; Extract main shaft diverse location node temperature and main shaft thermal deformation, calculate the Spearman rank correlation coefficient between main shaft diverse location node temperature and main shaft thermal deformation.The Spearman rank correlation coefficient is a kind of nonlinear interaction coefficient, is used to describe the intensity of contact between two stochastic variables (X, Y), and computing formula is:
Wherein d represent corresponding two variable X, Y value the difference of corresponding order, n is paired data (X, number Y).
According to coefficient correlation result of calculation, in conjunction with the lathe concrete structure, the position of selecting to try one's best near thermal source and convenient layout temperature sensor is the main shaft warm key point.
3, axis system warm key point temperature, hot error testing and hot error modeling
At axis system warm key point and front-end of spindle magnet-type temperature sensor and Reinshaw laser feeler are installed respectively; Convenient fixing and dismounting when the magnet-type temperature sensor uses; The sensor output directly inserts digital control system, and system handles and record signal of sensor automatically; The Reinshaw laser feeler is fixed on the main shaft both sides; Automatically to main shaft at no thermal source with there is the axis system coordinate position under two kinds of situation of thermal source to carry out record; Twice coordinate subtracts each other and is the hot error of main shaft, avoided because the random error that manual operation, reading carelessness bring.According to the main shaft warm key point temperature and the hot error of main shaft of actual measurement, utilize least square method to set up the hot error model of main shaft.Least square method is simple in structure, be widely used, have certain precision and realize through the simple program of computer easily, is the most simple and effective hot error modeling method.
4, main shaft heat error compensation
Different machine tool numerical control systems has different heat error compensation strategies; The system that for example has only allows to utilize the heat error compensation table to the hot error of main shaft is compensated; The system that has can directly embed hot error model and realize the main shaft heat error compensation in the digital control system, but hot error model should not be too complicated.The present invention combines accurate horizontal Machining centers digital control system to be studied, and selects rational heat error compensation strategy to carry out the main shaft heat error compensation.During compensation, utilize the magnet-type temperature sensor that the main shaft key temperatures is tested, in the test gained data input digital control system, and utilize PLC to calculate the difference of axis system key point temperature and environment temperature.Utilize this numerical value as the triggering amount,, finally realize the main shaft heat error compensation in conjunction with the heat error compensation model of embedding digital control system or the heat error compensation table that generates according to model.
Below be one embodiment of the present of invention, referring to Fig. 2-4, present embodiment is an instance with the accurate horizontal Machining centers of certain model, in conjunction with accompanying drawing the specific embodiment is elaborated:
1. model simplification
Grid is divided quality, is practiced thrift finite element simulation computing time when improving finite element modeling, need in Pro/E software, simplify accurate horizontal Machining centers axis system archetype, simplifies content and comprises:
1) parts such as deletion motor and coupled shaft coupling, belt pulley;
2) deletion screw, mounting screw hole, oil pipe, oil filler point tiny characteristics;
3) deletion rounding and chamfering;
4) utilize the simple structure physical model to replace the labyrinth parts,, replace main shaft and afterbody encoder with multidiameter as replacing bearing, coolant jacket with simple annulus;
5) for guaranteeing grid division quality, the boss of deletion＜10mm or notch feature;
6) guaranteeing to revise each moulded dimension of adjustment under the constant situation of overall structure, guarantee the accurate assembling of each parts.
2. the foundation of FEM model
Before utilizing ANSYS/Workbench software that accurate horizontal Machining centers axis system is carried out the finite element simulation analysis; Need set up its FEM model, concrete steps are following: the physical model after 1) will simplifying imports in the Workbench workbench through the interface menu of Pro/E-Workbench.2) physical model is carried out grid and divide, during division, need to select different division methods according to the design feature of the different parts of axis system.For example, division methods is scanned in employing for simple entity such as bearing, coolant jackets; Adopt tetrahedron to divide or freely divides for complex component such as main shaft, main spindle boxes, the grid cell size is through manual setting, to the parts of primary study, adopt like main shaft and to carry out mesh refinement, and the bigger parts grid of physical dimension can be suitably more sparse.3) in the present embodiment, ignore the influence of contact thermal resistance between each parts, faying face is set to Bonded (bonding).4) combine reality, in the material depot of ANSYS/Workbench software, select each parts respective material of main shaft, and then different spindle units is provided with material different.
3 boundary conditions apply and FEM calculation
For improving the accuracy that finite element simulation calculates, boundary condition accurately need be set.In the present case; When respectively rotating speed being 2000r/min, 3000r/min, 4000r/min; Main spindle box wall surface temperature, coolant rate and flow velocity and the axis system turnover oil temperature of accurate horizontal Machining centers main shaft under the idle running situation etc. carried out actual measurement and statistics; According to measured data boundary condition is calculated again, thereby obtain boundary condition accurately.
4. main shaft temperature field, thermal deformation finite element simulation
Utilize ANSYS/Workbench software that different rotating speeds lower main axis system is carried out thermodynamics and the calculating of statics finite element simulation, obtain the temperature field and the thermal deformation of accurate horizontal Machining centers axis system under the different rotating speeds.
5. select based on the main shaft warm key point of finite element simulation
Owing to before and after the axis system two bearings are arranged respectively in the present case, be main thermal source, therefore combine main axle structure to choose some nodes in front and back and analyze, node serial number is T1-T11,, T12 is an environment temperature, like Fig. 3-shown in Figure 4.Based on temperature field and thermal deformation finite element simulation result, extract above node temperature and spindle end over glaze thermotropism deformation values, calculate the Spearman rank correlation coefficient between main shaft diverse location temperature and main shaft thermal deformation.The Spearman rank correlation coefficient is a kind of nonlinear interaction coefficient, is used to describe the intensity of getting in touch between two stochastic variables, and computing formula is:
Wherein d represent temperature variable X and the axial heat distortion amount Y of main shaft the difference of corresponding order, n is paired data (X, number Y).
According to coefficient correlation result of calculation,, select to arrange conveniently that near thermal source, the obvious order of temperature rise the position of temperature sensor is the main shaft warm key point in conjunction with the lathe concrete structure as far as possible.
6. axis system warm key point temperature test, hot error testing and hot error modeling
Utilize the magnet-type temperature sensor that the temperature of axis system key point is tested, this temperature sensor can directly be adsorbed on the point that needs test, is easy for installation and removal; The temperature sensor output directly inserts digital control system, realizes real time record and observation to main shaft diverse location temperature.Utilize the Reinshaw laser feeler that spindle end over glaze thermotropism error is tested; During test; The Reinshaw laser feeler is fixed on the main shaft both sides; Automatically to the different rotating speeds lower main axis at no thermal source with there is the axis system coordinate position under two kinds of situation of thermal source to carry out record, twice coordinate subtracts each other and is the axial hot error of main shaft.According to measured data, utilize least square method to set up the hot error model of axis system, its expression formula is: f (x)=C
1x
2+ C
2X+C
3, x is the difference of warm key point and environment temperature in the formula, ℃; F (x) is the heat error compensation value, μ m, C
1, C
2, C
3Be constant.
7. main shaft heat error compensation
Be that example is carried out heat error compensation explanation with the heat error compensation table in the present case: based on the corresponding heat error compensation amount of the different temperature rises of heat error compensation Model Calculation, thereby set up the heat error compensation table, and the heat error compensation table is directly to be embedded in the digital control system.According to the requirement of digital control system, the temperature rise value in the heat error compensation table of embedding digital control system is since 0 ℃, and the compensation rate of 0 ℃ of correspondence is made as 0 μ m, and temperature rise is spaced apart 0.5 ℃.After lathe started, temperature sensor was gathered the temperature of lathe diverse location, and digital control system PLC goes out the difference of axis system warm key point and environment temperature according to test result calculations.This temperature gap is the triggering amount of heat error compensation, and digital control system can be searched in the heat error compensation table corresponding heat error compensation value automatically, and through the control main shaft along Z to the position realize the axial hot compensation of error of main shaft.After based on this thermal error compensation method the axial hot error of accurate horizontal Machining centers main shaft in this example being compensated, referring to Fig. 5.When the speed of mainshaft was 2000r/min, hot error reduced 85%; Referring to Fig. 6, during rotating speed 3000r/min, hot error reduces 89%; Referring to Fig. 7, during rotating speed 4000r/min, hot error reduces more than 91%.
Therefore, thermal error compensation method disclosed by the invention can effectively reduce the hot error of accurate horizontal Machining centers main shaft, has improved machining accuracy.
Claims (1)
1. accurate horizontal Machining centers main shaft thermal error compensation method is characterized in that:
1) accurate horizontal Machining centers main shaft to be compensated is simplified, and the model after will simplifying imports among the ANSYS/Workbench; The speed of mainshaft, environment temperature, cooling liquid speed, flow and turnover oil temperature in conjunction with actual measurement are calculated boundary condition; And carry out thermodynamics and the analysis of statics finite element simulation with the boundary condition substitution ANSYS/Workbench that calculates and then to the main shaft of simplifying, obtain more accurate main shaft temperature field distribution and thermal deformation;
2) based on the finite element simulation analysis result; Extracting the temperature and the main shaft thermal deformation of arbitrary node analyzes; Promptly utilize the Spearman rank correlation coefficient; Rank correlation analysis is carried out in temperature rise and main shaft thermal deformation to different operating mode lower main axis system diverse location, selects the axis system warm key point according to coefficient correlation that calculates and lathe concrete structure, the coefficient correlation computing formula:
Wherein d represent corresponding two variable X, Y value the difference of corresponding order, n is paired data (X, number Y);
3) at axis system warm key point and front-end of spindle magnet-type temperature sensor and Reinshaw laser feeler are installed respectively; Realize main shaft warm key point temperature survey and the hot error measure of main shaft; The output of temperature sensor directly inserts digital control system during measurement, and utilization PLC calculates the temperature collect and the difference of environment temperature; Utilize the hot error of this numerical value and main shaft, set up hot error model; Simultaneously with the triggering amount of this numerical value as heat error compensation; Directly realize heat error compensation in conjunction with machine tool numerical control system heat error compensation strategy; Compensation method has two kinds: directly hot error model is embedded and realize the main shaft heat error compensation in the digital control system; Or, finally utilize the heat error compensation table that the hot error of main shaft is compensated according to the heat error compensation model generation heat error compensation table of setting up.
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