CN102706497B - Rapid milling force measurement, identification and simulation calculation system - Google Patents

Abstract

The invention relates to a rapid milling force measurement, identification and simulation calculation system, which comprises hardware and software, wherein the hardware comprises a bearing platform, a three-way force sensor, a bearing base, an aviation interface plug, a signal amplifier, an aviation power supply and a data acquisition card, and the software comprises a milling force collection module, a milling force identification module and a milling force simulation module; the upper end surface of the three-way force sensor is connected with the bearing platform, the bottom of the three-way force sensor is connected with the bearing base, a data connecting wire of the bearing base is connected with the three-way force sensor through one end of the aviation interface plug, and the other end of the aviation interface plug is connected with the signal amplifier; and a signal output end of the signal amplifier is connected with an input of the data acquisition card and an output of the aviation power supply, an output USB (universal serial bus) interface of the data acquisition card is connected with the milling force collection model, the data of the milling force collection module provide milling force data for the milling force identification module, milling force coefficients are calculated by the milling force identification module, and the milling force simulation module can realize the rapid forecasting of the size of the milling force through the relation between the milling force coefficients and parameters.

Description

The measurement of a kind of Rapid milling power, identification and simulation computing system

(1) technical field

The present invention relates to the measurement of a kind of Rapid milling power, identification and simulation computing system, by the Milling Force of the workpiece under the different Milling Parameters of this systematic survey, carry out identification and calculate Milling Force coefficient, realize the Accurate Prediction of the Milling Force under arbitrary parameter.Application based on this system, can obtain under any Milling Parameters, and sextuple Milling Force coefficient and three-dimensional emulation Milling Force value, the invention belongs to high-accuracy working research and detection technique field.

(2) background technology

Milling Parameters is as affecting one of key factor of machined surface quality, change to have directly with Milling Force and contact, the size of Milling Force is all influential to a great extent to the wearing and tearing of the stability of process, workpiece surface quality and cutter and breakage, and Milling Parameters selection is unreasonable, can make Milling Force excessive, the distortion of generation cutter relieving, or cause the vibration of cutter, make Surface Creation chatter mark, not only seriously affected surperficial crudy, and need to polish for the second time, reduced widely the efficiency of processing.For a long time, although people are accumulating comparatively rich experience data aspect the Milling Parameters of Choice and process, but the condition of the combination of lathe-cutter-workpiece changes, many empirical parameters are not just applicable, especially in Now Domestic manufacturing enterprise, introduced a large amount of advanced persons' numerical control device, but due to the effective ways and the instrument that lack Milling Parameters and choose, the data that can only rely on external lathe and cutter manufacturer to provide are carried out reference, can not give full play to the due usefulness of sophisticated equipment, restrict largely manufacturing development.So, invent and a kind ofly can in actual production process, by simple measurement, can obtain Milling Force coefficient accurately, then realize the system of carrying out Accurate Prediction of the Rapid milling power under any Milling Parameters is just seemed to particularly necessary.

(3) summary of the invention

1, object: object of the present invention is exactly for the measurement of a kind of Rapid milling power, identification and simulation computing system are provided, it has overcome the deficiencies in the prior art, identification and the cutting force simulation integrated function of having realized milling force measurement, Milling Force coefficient, can also fast, accurately go out the important parameter in the process such as cutter distortion, tool displacement, stress.

2, technical scheme: the measurement of a kind of Rapid milling power of the present invention, identification and simulation computing system, it consists of hardware and software two parts, hardware components is comprised of load platform, three-dimensional force transducer, load base, aviation interface plug, signal amplifier, space flight power supply, data collecting card, and software section is comprised of Milling Force collection, Milling Force identification and cutting force simulation module.

Position annexation between them is: the upper surface of three-dimensional force transducer is connected with load platform; Three-dimensional force transducer bottom is connected with load base, and the data bus connection of three-dimensional force transducer, is connected with three-dimensional force transducer by aviation interface plug one end, and the other end is connected with signal amplifier; The signal output part of signal amplifier is connected with data collecting card input, by space flight power supply, for signal amplifier provides galvanic current, is pressed; The output USB interface of data collecting card is connected with the Milling Force acquisition module in computer.The data of Milling Force acquisition module provide 9 groups of Milling Force data for Milling Force recognition module, and Milling Force recognition module is calculated Milling Force coefficient, and cutting force simulation module, by the relation between Milling Force coefficient and Milling Parameters, realizes Milling Force size fast prediction.Specifically can be with reference to figure 1.

Described load platform is square-shaped metal plate, and platform upper surface is many group threaded holes, and major function will be fixed on load platform by milling workpiece, be connected with three-dimensional force transducer, play the transfer function of power.Its major function in order to three-dimensional force transducer after holding any three received strength and changing, have the Voltage-output of corresponding linear scaling.

The square betal can that described load base is interior sky; major function: play on the one hand protection three-dimensional force transducer; prevent that liquid coolant and smear metal are splashed to quality and precision that on three-dimensional force transducer, impact is measured; as connecting the three-dimensional force transducer member that is connected with workbench (platform of machine tool) arbitrarily, play load effect on the other hand.

Described data collecting card is rectangle, and length is respectively 145mm*120mm*20mm, and major function is in order to carry out acquisition process to the voltage signal obtaining.

Described signal amplifier is rectangle, and length is respectively 110mm*75mm*50mm, and voltage signal is amplified to V level from mV level, convenient accurately processing.

Described space flight power supply is rectangle, and length is respectively 100mm*60mm*45mm, is the DC voltage of signal amplifier raising 0-10V.

Described three-dimensional force transducer is commercial that selects as required.

Described aviation interface plug is standard six core plugs, for connecting the interface between the data line of each equipment.

Software section is the exploitation of VB program language, and major function is used for the data of Milling Force to gather, the copying of Milling Force parameter identification and Milling Force size.

Wherein, the physical dimension of load platform is: long is 150mm, and wide is 150mm, thick 15mm;

Wherein, the physical dimension of load base is: long is 165mm, and wide is 165mm, thick 8mm;

Wherein, the quantity of aviation interface plug is 16, and model is HZ-8500;

Wherein, the model of three-dimensional force transducer is 8219A;

Wherein, the model of this signal amplifier is DFL-3;

Wherein, the model of this data collecting card is INV306U-5160.

The principle of work of whole invention: workpiece is subject to the effect of Milling Force in Milling Processes, workpiece will bear Milling Force and be passed to three-dimensional force transducer, the flexible member of three-dimensional force transducer produces distortion, the variation that foil gauge on flexible member has produced voltage signal due to its distortion, by to the collection of signal, calculating and analyzing and processing, just can realize Milling Force measurement, the identification of milling coefficient and the emulation of Milling Force.Concrete hardware collection and software Computing Principle are as follows:

1. the principle of three-dimensional Milling Force sensor hardware

Three-dimensional force transducer is mainly comprised of two parts: outer jointing jacket and flexible member, outer jointing jacket mainly plays a part to support, protect flexible member and sealing, posts foil gauge on flexible member, plays response and experience milling process to produce power.

(1) cloth sheet mode

Measure Milling Force and side force part: eight of cloth symmetrically in two orthogonal directions, the foil gauge direction direction that all parallels to the axis.As the A in Fig. 2, A ', B, B ', E, E ', F, F ' (symmetry direction)

Measure axial force part: cloth is four on same circumference, wherein two parallel and axis symmetric positions, another two perpendicular to axis direction symmetric position, as the C in Fig. 2, C ', D, D '

(2) group bridge mode

Below paste altogether 12 foil gauges, form three full-bridges, measure respectively X, Y, Z.Z-direction power is measured bridge See Figure 3

(a), X, Y-direction power are measured bridge See Figure 3 (b)

Adopt full-bridge mode can realize temperature compensation and increase electric bridge output signal.The axial force measuration bridge of Z direction has been eliminated the impact of moment of flexure, for eccentric axial force, also can accurately measure.Directions X Milling Force and Y-direction Milling Force are measured the impact that bridge has been eliminated axial force, and the output signal of an electric bridge directions X Milling Force is relevant with Y-direction Milling Force size, and irrelevant with arm of force length, both this bridge had constant calibration coefficient.

(3) three-dimensional force transducer is realized three-dimensional power measuring principle

See Fig. 4, on three-dimensional force transducer, have directions X Fx Milling Force, Y-direction Milling Force Fy, Z direction Milling Force Fz, the eccentric moment M producing, and the temperature stress T(regulation causing due to temperature variation: tension is for just, and compressive stress is for bearing).By the mechanics of materials, known, each power is respectively in the strain of respectively answering sheet to produce:

F _z：ε _Az=ε _A′z=ε _Bz=ε _Bz=-ε _z

F _y:ε _Ay=-ε _A′y=F _yL _a/(E-W ₁)

ε _By=-ε _B′y=F _yL _b/(E-W ₁)

Fx:ε _Ax=-ε _A′x=ε _Bx=ε _B′x=0

M：ε _AM=-ε _A′M=ε _BM=-ε _B′M=ε _M

T：ε _AT=ε _A′T=ε _BT=ε _B′T=ε _T

Superposition principle by power can obtain the strain on each foil gauge:

ε _A=ε _Ax+ε _Ay+ε _AM+ε _AT+ε _Az

Above various substitution is obtained:

ε _A=F _yL _a/(E-W ₁)-ε _M+ε _x+ε _T

In like manner:

ε _A′=F _yL _a/(E-W ₁)-ε _M–ε _x+ε _T

ε _B=F _yL _b/(E-W ₁)-ε _M+ε _x+ε _T

ε _B′=-F _yL _b/(E-W ₁)-ε _M–ε _x+ε _T

Foil gauge A, A ', B, B ' form a full-bridge

By electric bridge with poor characteristic must this bridge output strain be:

ε=ε _A+ε _B-ε _A′-ε _B′

Above various substitution is obtained:

ε=2（L _b-L _a）F _y/(E-W ₁)

(L in formula _b-L _a) be the distance between foil gauge A, B, be constant, E, W ₁the elastic modulus and the module of anti-bending section that are respectively material, both are constant.

So the output of this bridge only and Y-direction power be directly proportional, and have nothing to do with directions X, Z direction, moment of flexure, temperature and length.

Other direction force measurement principle is identical therewith.

2. the identification of Milling Force coefficient and calculate principle of simulation

Milling Force is one of key factor of research Milling Process mechanism, and in Milling Processes, Milling Force Model is set up according to blade shapes and parameter conventionally, and the present invention mainly adopts cylindrical screw face cutter model to calculate.The basis of Milling Force identification is under different Milling Parameters conditions, to obtain the size of Milling Force respectively, by the identification calculating formula of 6 parameters, obtain 6 prescription journeys and solve, obtain Milling Force coefficient, obtain the parameters such as characteristic that Milling Force coefficient can comprehensive representation goes out cutter.Specifically be calculated as follows:

According to Fig. 5, milling cutter in axial direction being got is highly the infinitesimal of dz, so the tangential force dF on spiral infinitesimal _t, radial force dF _r, and axial force dF _acan be represented by formula (1),

$\left.\begin{array}{c}{\mathrm{dF}}_{t,j}(\mathrm{\φ},z)=[K_{\mathrm{tc}}{h}_j\left({\mathrm{\φ}}_j\left(z\right)\right)+K_{\mathrm{te}}]\mathrm{dz}\\ {\mathrm{dF}}_{r,j}(\mathrm{\φ},z)=[K_{\mathrm{rc}}{h}_j\left({\mathrm{\φ}}_j\left(z\right)\right)+K_{\mathrm{re}}]\mathrm{dz}\\ {\mathrm{dF}}_{a,j}(\mathrm{\φ},z)=[K_{\mathrm{ac}}{h}_j\left({\mathrm{\φ}}_j\left(z\right)\right)+K_{\mathrm{ae}}]\mathrm{dz}\end{array}\right\}---\left(1\right)$

After carrying out changes in coordinates, Instantaneous Milling Force is carried out to Integration Solving, obtain following formula,

By digging angle φ ₁=0, cut out angle φ ₂after=90 substitution above formulas, obtain formula (3)

$\left.\begin{array}{c}{\stackrel{\‾}{F}}_x=-\frac{\mathrm{Nac}}{4}{K}_{\mathrm{rc}}-\frac{\mathrm{Na}}{\mathrm{\π}}{K}_{\mathrm{re}}\\ {\stackrel{\‾}{F}}_y=+\frac{\mathrm{Nac}}{4}{K}_{\mathrm{tc}}+\frac{\mathrm{Na}}{\mathrm{\π}}{K}_{\mathrm{te}}\\ {\stackrel{\‾}{F}}_z=+\frac{\mathrm{Nac}}{\mathrm{\π}}{K}_{\mathrm{ac}}+\frac{\mathrm{Na}}{2}{K}_{\mathrm{ae}}\end{array}\right\}---\left(3\right)$

By (3) formula, when the size of known every group of Milling Force just can instead be released Milling Force COEFFICIENT K _tc, K _rcequivalent.

Can obtain the Milling Force coefficient of different milling conditions.

The emulation of Milling Force size, brings the Milling Force coefficient of acquisition in (1) formula into, for the parameter of any given milling condition milling cutter, cut wide, cutting-in, can obtain the value of any Milling Force.

3, advantage and effect

The present invention is the measurement of a kind of Rapid milling power, identification and simulation computing system, can realize the Milling Force size of the different Milling Parameters of prediction.Its advantage is can emulation 0-1500Hz(0-20000r/min) the three-dimensional Milling Force of arbitrary size in interior frequency and 0-15000N, by the method for Milling Force identification, realizes determining of Milling Force coefficient fast.By the milling coefficient after identification, can simulation and prediction go out the size of the Milling Force under any Milling Parameters.The size of Milling Force verifies the rationality of machined parameters, thereby realizes the optimization of Milling Parameters.

(4) accompanying drawing explanation

Fig. 1 is the one-piece construction schematic diagram of the measurement of a kind of Rapid milling power of the present invention, identification and simulation computing system

Fig. 2 is the patch location figure of flexible member foil gauge of the present invention

Fig. 3 (a) is the schematic diagram that Z direction foil gauge is arranged

Fig. 3 (b) is X, the schematic diagram that Y-direction foil gauge is arranged

Fig. 4 is the stressed schematic diagram of flexible member of the present invention

Fig. 5 (a) bears the schematic diagram of three-dimensional force for milling cutter

Fig. 5 (b) is the schematic diagram of the holding capacity of unit, milling cutter cross section

The login interface of Fig. 6 (a) software;

Fig. 6 (b) Milling Force signals collecting interface;

Fig. 6 (c) Milling Force parameter identification interface;

Fig. 6 (d) cutting force simulation interface.

Symbol description in Fig. 1 is as follows:

1 load platform; 2 three-dimensional force transducers; 3 load bases; 4 aviation interface plugs; 5 signal amplifiers; 6 space flight power supplys; 7 data collecting cards; 8 Milling Force collections, identification and emulation module;

Symbol description in Fig. 2 is as follows:

A, B, C, A ', B ', C ', D, E, F represent the foil gauge on three-dimensional force transducer

Symbol description in Fig. 3 is as follows:

A, B, C, A ', B ', C ', D represent the foil gauge on three-dimensional force transducer; U represents supply voltage.

Symbol description in Fig. 4 is as follows:

Fy represents the power of Y-direction, and Fx represents the Milling Force of directions X, and Fz represents the Milling Force of Z direction; A, B represent the foil gauge on three-dimensional force transducer; L _a, L _brepresent that foil gauge A and B are to the distance at the top of flexible member.

Symbol description in Fig. 5 is as follows:

X, Y, Z represents three directions; Dz represents the differentiation element along tool orientation; DFr, dFa, dFt represents on unit radially Milling Force, axially Milling Force and tangential Milling Force; Fx (φ), Fy (φ) represents unit, cross section X and Y-direction Milling Force;

Fr Ft represents radially Milling Force and the tangential Milling Force on cross section; Ae represents cutting-in; N represents rotating speed

(5) embodiment

Below in conjunction with accompanying drawing, describe embodiment of the present invention in detail.

See Fig. 1, the measurement of a kind of Rapid milling power of the present invention, identification and simulation computing system, it consists of hardware and software two parts, hardware is by load platform 1, three-dimensional force transducer 2, load base 3, signal amplifier 5, space flight power supply 6, data collecting card 7 and aviation interface plug 4 form.See Fig. 6 (a)-Fig. 6 (d), software section consists of Milling Force collection, identification and emulation module 8.Position annexation between them is: the upper surface of three-dimensional force transducer 2 is connected with load platform 1; Three-dimensional force transducer 2 bottoms are connected with load base 3, and data bus connection one end of three-dimensional force transducer 2 is connected with the aviation interface plug 4 of three-dimensional force transducer 2, and the other end is connected with signal amplifier 5; The signal output part of signal amplifier 5 is connected with data collecting card 7 inputs, by space flight power supply 6, for signal amplifier 5 provides galvanic current, is pressed; The output USB interface of data collecting card 7 is connected with the Milling Force collection in computer, identification and emulation module 8.Software section consists of the collection of software Milling Force, identification and emulation module 8, enter after software systems, first utilize the Milling Force function of software that milling milling experimentation is surveyed and gathered, after collection, obtain 6 groups of Milling Force data, discriminating function by software calculates Milling Force coefficient, finally utilize milling copying to obtain the relation between Milling Force coefficient and Milling Parameters, realize Milling Force size high-speed simulation and prediction.Fig. 2 is the patch location figure of flexible member foil gauge of the present invention; Fig. 3 (a) is the schematic diagram that Z direction foil gauge is arranged, Fig. 3 (b) is X, the schematic diagram that Y-direction foil gauge is arranged; Fig. 4 is the stressed schematic diagram of flexible member of the present invention; Fig. 5 (a) bears the schematic diagram of three-dimensional force for milling cutter, and Fig. 5 (b) is the schematic diagram of the holding capacity of unit, milling cutter cross section.

Described load platform 1 is square-shaped metal plate, and long is 150mm, and wide is 150mm, thick 15mm, and platform upper surface is many group threaded holes, major function will be fixed on load platform 1 by milling workpiece, be connected with three-dimensional force transducer 2, play the transfer function of power.

The pressure signal digital display meter of described three-dimensional force transducer 2 is to be cylindrical shape, diameter is 70, length is 120, three data output ends are exported respectively the voltage signal of directions X, Y-direction, Z direction, supply voltage is 10V, major function in order to three-dimensional force transducer after holding any three received strength and changing, have the Voltage-output of corresponding linear scaling.

The square betal can that described load base 3 is interior sky; long is 165mm; wide is 165mm; thick 8mm; major function: play on the one hand protection three-dimensional force transducer 2; prevent that liquid coolant and smear metal are splashed on three-dimensional force transducer 2 quality and precision that impact is measured, as connecting three-dimensional force transducer 2 member that is connected with load platform 1, play load effect on the other hand.

Described data collecting card 7 is rectangle, and length is respectively 145mm*120mm*20mm, and major function is in order to carry out acquisition process to the voltage signal obtaining.

Described signal amplifier 5 is rectangle, and length is respectively 110mm*75mm*50mm, and voltage signal is amplified to V level from mV level, convenient accurately processing.

Described space flight power supply 6 is rectangle, and length is respectively 100mm*60mm*45mm, is the DC voltage of signal amplifier raising 0-10V.

Described aviation interface plug 4 is standard six core plugs, for connecting the interface between the data line of each equipment.

Software systems are Milling Force collection, identification and emulation module 8, and it is the exploitation of VB program language, and major function is used for the data of Milling Force to gather, the copying of Milling Force parameter identification and Milling Force size.

Wherein, the quantity of aviation interface plug 4 is 16, and model is HZ-8500;

Wherein, the model of three-dimensional force transducer 2 is 8219A;

Wherein, the model of this signal amplifier 5 is DFL-3;

Wherein, the model of this data collecting card 7 is INV306U-5160.

Claims (7)

1. Rapid milling power measurement, identification and simulation computing system, it is characterized in that: it consists of hardware and software two parts, hardware components is comprised of load platform, three-dimensional force transducer, load base, aviation interface plug, signal amplifier, space flight power supply and data collecting card, and software section is comprised of Milling Force collection, Milling Force identification and cutting force simulation module; The upper surface of three-dimensional force transducer is connected with load platform; Three-dimensional force transducer bottom is connected with load base, and the data bus connection of three-dimensional force transducer, is connected with three-dimensional force transducer by aviation interface plug one end, and the other end is connected with signal amplifier; The signal output part of signal amplifier is connected with data collecting card input, by space flight power supply, for signal amplifier provides galvanic current, is pressed; The output USB interface of data collecting card is connected with the Milling Force acquisition module in computer; The data of Milling Force acquisition module provide 9 groups of Milling Force data for Milling Force recognition module, and Milling Force recognition module is calculated Milling Force coefficient, and cutting force simulation module, by the relation between Milling Force coefficient and Milling Parameters, realizes Milling Force size fast prediction;

Described load platform is square-shaped metal plate, and platform upper surface, for many group threaded holes will be for being fixed on load platform by milling workpiece, is connected with three-dimensional force transducer, plays the transfer function of power; Its function is being born after any three-dimensional power changes for three-dimensional force transducer, has the Voltage-output of corresponding linear scaling;

The square betal can that described load base is interior sky, play on the one hand protection three-dimensional force transducer, prevent that liquid coolant and smear metal are splashed to quality and precision that on three-dimensional force transducer, impact is measured, as connecting the three-dimensional force transducer member that is connected with workbench arbitrarily, play load effect on the other hand;

Described data collecting card is rectangle, and length is respectively 145mm*120mm*20mm, and its function is for carrying out acquisition process to the voltage signal obtaining;

Described signal amplifier is rectangle, and length is respectively 110mm*75mm*50mm, and voltage signal is amplified to V level from mV level, convenient accurately processing;

Described space flight power supply is rectangle, and length is respectively 100mm*60mm*45mm, is the DC voltage of signal amplifier raising 0-10V;

Described three-dimensional force transducer is commercial that selects as required;

Described aviation interface plug is standard six core plugs, for connecting the interface between the data line of each equipment;

Software section is Milling Force collection, Milling Force identification and cutting force simulation module, and it is the exploitation of VB program language, and its function is used for the data of Milling Force to gather, the copying of Milling Force parameter identification and Milling Force size.

2. a kind of Rapid milling power according to claim 1 measurement, identification and simulation computing system, is characterized in that: the physical dimension of this load platform is: long is 150mm, and wide is 150mm, thick 15mm.

3. a kind of Rapid milling power according to claim 1 measurement, identification and simulation computing system, is characterized in that: the physical dimension of this load base is: long is 165mm, and wide is 165mm, thick 8mm.

4. a kind of Rapid milling power according to claim 1 measurement, identification and simulation computing system, is characterized in that: the quantity of this aviation interface plug is 16, and model is HZ-8500.

5. a kind of Rapid milling power according to claim 1 measurement, identification and simulation computing system, is characterized in that: the model of this three-dimensional force transducer is 8219A.

6. a kind of Rapid milling power according to claim 1 measurement, identification and simulation computing system, is characterized in that: the model of this signal amplifier is DFL-3.

7. a kind of Rapid milling power according to claim 1 measurement, identification and simulation computing system, is characterized in that: the model of this data collecting card is INV306U-5160.

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