CN108628249B - Milling machining chatter control method and system based on auxiliary superimposed vibration - Google Patents
Milling machining chatter control method and system based on auxiliary superimposed vibration Download PDFInfo
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Abstract
The invention provides a milling chatter control method and system based on auxiliary superimposed vibration. The system comprises an actuating device arranged at the front end of a main shaft of the milling machine tool, and a controller which is connected with a CNC system of the machine tool and used for reading the rotating speed and the feeding speed of the main shaft and the tooth number of a milling cutter tool, wherein the controller is used for obtaining the maximum amplitude and the frequency of actuating force according to the maximum amplitude of auxiliary superimposed vibration and the periodic frequency of the auxiliary superimposed vibration and outputting a corresponding control voltage signal to control the actuating device. In the milling process, the actual working rotating speed condition and the cutting feed amount are considered, and the milling chatter stable domain boundary is changed by applying an auxiliary superposition vibration method in the feed direction, so that the chatter is controlled.
Description
Technical Field
The invention belongs to the field of high-speed milling, mainly relates to a chatter control technology in a milling process, and particularly relates to a milling chatter control method and system based on auxiliary superimposed vibration.
Background
In the high-speed milling process, in consideration of economic benefits, the stability of the milling process needs to be ensured, and the unstable flutter phenomenon is avoided as much as possible, so that the cutting efficiency is ensured. The occurrence of chatter during the milling process can cause a series of problems, such as deterioration of the surface quality of the machined workpiece, rapid wear of the tool, breakage of the tool, reduction of the service life of machine tool components (such as a spindle system), and the like, and can also seriously affect the actual cutting efficiency. Therefore, how to avoid the chattering in the milling process by a certain means is significant, and the method attracts attention of many people. At present, there are many methods for controlling chatter of milling, and from the implementation strategy, the method roughly includes three main categories: the first is cutting by using a milling cutter with a non-constant spindle speed or non-uniform cutter teeth, and destroying the induction condition of chatter within a certain range; secondly, various damping units or damping devices are designed, are arranged on a main shaft system or a clamp and the like, absorb energy generated by self-excited vibration and can improve the boundary of a milling flutter stable region to a certain extent; and in the third category, through designing actuating devices in different forms, an active control acting force is applied to the front end of a workpiece or a main shaft system according to a feedback signal of a sensor in the cutting process, and the mechanical characteristics of the whole dynamic milling process are changed through the input of the actuating force, so that the flutter active control is realized. The first method and the second method are relatively simple, but have certain limitations, for example, the first method is not suitable for the working condition with higher rotating speed, has higher requirement on the strength of the cutter, and the like, while the damping unit or the device in the second method is difficult to actively adjust according to the actual cutting working condition, and the capability of improving the stability domain boundary of milling chatter is limited. In the third method, an active actuating force is applied to the milling system by an actuating device based on a designed active control algorithm according to a feedback signal reflecting the processing state, and the suppression effect on chatter vibration is obvious.
Disclosure of Invention
Aiming at the problems in the prior art, the invention provides a milling chatter control method and system based on auxiliary superimposed vibration.
The invention is realized by the following technical scheme:
a milling chatter control method based on auxiliary superimposed vibration is characterized in that the milling chatter is controlled by generating the auxiliary superimposed vibration in the cutting feed direction of a main shaft and a cutter in the milling process.
Preferably, the auxiliary superimposed vibration is generated in the spindle-tool cutting feed direction by the following method;
an actuating device is arranged at the front end of a main shaft of the milling machine tool, is arranged on the x direction and the y direction of a machine tool coordinate system and is used for respectively exerting action on the radial x direction and the radial y direction of the main shaft under the working condition of main shaft rotationThe power is used for realizing the synthesis of the power in the random cutting feed direction of the cutter; when the actuating device applies sine periodic actuating force to the spindle system, corresponding vibration displacement response X is generated at the tool nose point of the toolsAs an auxiliary superposition vibration.
Further, the vibration displacement response X of the tool nose point of the main shaft tool is established through experimentssThe amplitude a of the vibration control device is in the following relationship with the actuating force generated by the actuating device, and the vibration displacement at the tool point of the tool is quantitatively controlled;
a＝kF
f is the amplitude of the actuating force applied to the front end of the main shaft by the actuating device, and k is the relation coefficient of the vibration displacement response amplitude at the tool nose point and the amplitude of the actuating force.
And further, when a function relation between the vibration displacement response of the tool nose point of the main shaft tool and the actuating force is established, measuring the vibration displacement response of the tool nose point of the main shaft tool by using the non-contact displacement sensor, and recording the displacement response amplitude of the tool nose point of the main shaft tool under different amplitude periodical actuating forces, so that the amplitude relation coefficient k between the vibration displacement response amplitude of the tool nose point and the actuating force is obtained.
Further, aiming at different working conditions, a controller connected with the actuating device reads the rotating speed and the feeding speed of the main shaft from a CNC system of the machine tool, then integrates the number of teeth of the milling cutter tool to obtain the periodic frequency and the maximum amplitude of the auxiliary superposition vibration applied along the cutting feeding direction of the main shaft and the tool,
according to the maximum amplitude a of the auxiliary superimposed vibration required to be applied at the tool nose pointmaxAnd the relation between the vibration displacement response of the tool point of the main shaft tool and the actuating force generated by the actuating device is used for obtaining the maximum amplitude of the actuating force, and the consistent actuating force frequency is obtained by the cycle frequency of the auxiliary superposition vibration, so that a control voltage signal is output to the actuating device arranged at the front end of the main shaft, the required actuating force is generated in the cutting feeding direction of the main shaft-tool, and the required auxiliary superposition vibration is generated at the tool point of the tool.
Still further, the supplementary superimposed vibration XsIs determined by the following equation:
wherein f is the frequency of the auxiliary superposition vibration in Hz; omega is the rotating speed of the main shaft, and the unit is rpm; and N is the number of cutter teeth of the milling cutter used in milling.
Further, the maximum amplitude of the supplementary superimposed vibration is determined by:
amax＝ρ·X0
wherein, amaxThe unit is mm for assisting the maximum amplitude of the superposition vibration; x0The unit of the feeding speed of milling machining is mm/tooth, rho is selectable proportionality coefficient, and 0 < rho < 1.
A milling chatter control system based on auxiliary superimposed vibration comprises an actuating device arranged at the front end of a main shaft of a milling machine tool, and a controller connected with a CNC system of the machine tool and used for reading the rotating speed and the feeding speed of the main shaft and the tooth number of a milling cutter tool, wherein the controller is used for obtaining the maximum amplitude and the frequency of actuating force according to the maximum amplitude of the auxiliary superimposed vibration and the periodic frequency of the auxiliary superimposed vibration and outputting a corresponding control voltage signal to control the actuating device.
Preferably, the controller connected with the actuating device reads the rotating speed and the feeding speed of the main shaft from a CNC system of the machine tool according to different working conditions, and then integrates the number of teeth of the milling cutter tool to obtain the periodic frequency and the maximum amplitude of the auxiliary superimposed vibration applied along the cutting feeding direction of the main shaft and the milling cutter tool.
Preferably, the actuating device is installed in x and y directions of a machine tool coordinate system and used for applying actuating forces to the radial x and y directions of the spindle respectively under the rotation working condition of the spindle to synthesize the actuating forces of the tool in any cutting feed direction.
Compared with the prior art, the invention has the following beneficial technical effects:
the invention improves the stable region boundary of the milling process by applying the auxiliary superposition vibration method in the cutting feed direction of the main shaft-cutter in the milling process; the method is based on the milling chatter generation mechanism, and applies certain form of auxiliary superimposed vibration in the cutting feed direction of the main shaft and the cutter in the milling process to change the dynamic cutting depth, introduces new periodic excitation for the whole dynamic milling process, changes the time lag of the system, and finally has the beneficial effects of improving the milling stable domain boundary of the whole system and realizing chatter control. Meanwhile, the auxiliary superimposed vibration applied in the cutting feeding direction of the main shaft and the cutter does not influence the quality of the cut surface, and on the contrary, the existence of the superimposed vibration can reduce the tiny convex peaks left on the cut surface by the cutter teeth in the periodic cutting process, thereby further improving the quality of the cut surface.
Furthermore, the method of the invention can adaptively adjust the applied auxiliary superimposed vibration according to different working conditions such as rotating speed, cutting feed speed of the main shaft and the cutter, the number of the cutter teeth and the like, and has the advantages of simple method, easy realization and good applicability.
Drawings
Fig. 1 is a schematic diagram of the working principle of the system of the present invention.
In the figure: 1 is a machine tool main shaft, 2 is an actuating device arranged at the front end of the main shaft, 3 is a cutter, and 4 is a workpiece to be processed.
Detailed Description
The present invention will now be described in further detail with reference to specific examples, which are intended to be illustrative, but not limiting, of the invention.
The invention relates to a milling processing chatter control method and system based on auxiliary superimposed vibration.
As shown in figure 1, the method of the invention is realized on a flutter control system of a machine tool spindle shown in figure 1, an actuating device 2 is arranged at the front end of the spindle 1, and the actuating device 2 is arranged under a machine tool coordinate systemCan respectively exert actuating forces on the radial x direction and the radial y direction of the main shaft under the working condition of the rotation of the main shaft. Further, the combination of the power in any cutting feed direction of the cutter can be realized. When an actuating device 2 arranged at the front end of a main shaft 1 applies sinusoidal periodic actuating force to a main shaft system, a corresponding vibration displacement response X can be generated at the front end 3 of the main shaft-cutter system, namely the cutter point of a cuttersReferred to herein as supplementary superimposed vibration.
In order to realize the method, firstly, an actuating device arranged at the front end of a main shaft is utilized to apply sinusoidal periodic actuating force to a main shaft system, meanwhile, a non-contact displacement sensor is utilized to measure the vibration displacement response of the front end of the main shaft, and the displacement response amplitude of the front end of the main shaft under the periodic actuating force with different amplitudes is recorded. The following main shaft front end vibration displacement response X is establishedsThe amplitude a of (a) is related to the actuating force generated by the actuating device 2:
a＝kF；
f is the amplitude of the actuating force applied to the front end of the main shaft by the actuating device, and k is the relation coefficient of the vibration displacement response amplitude at the tool nose point and the amplitude of the actuating force.
When the functional relation between the vibration displacement response of the tool nose point of the main shaft tool and the actuating force is established, the non-contact displacement sensor is utilized to measure the vibration displacement response of the tool nose point of the main shaft tool, and the displacement response amplitude of the tool nose point of the main shaft tool under different amplitude values of periodic actuating force is recorded, so that the relation coefficient k between the vibration displacement response amplitude of the tool nose point and the actuating force is obtained.
And then, auxiliary superimposed vibration with a certain frequency is applied in the cutting feeding direction of the main shaft and the cutter in the milling process, so that the dynamic cutting depth is changed, new periodic excitation is introduced in the whole dynamic milling process, the time lag of the system is changed, and finally the milling stable domain boundary of the whole system is improved, thereby realizing the control of flutter.
Specifically, the periodic frequency of the auxiliary superimposed vibration applied in the spindle-tool cutting feed direction is determined by the following equation:
wherein f is1The frequency of the auxiliary superimposed vibration is in Hz and is consistent with the frequency of the actuating force; omega is the rotating speed of the main shaft, and the unit is rpm; and N is the number of cutter teeth of the milling cutter used in milling.
The maximum amplitude of the applied auxiliary superimposed vibration is set in consideration of the feed speed at the time of milling. In order to avoid the phenomenon of tooth jumping in the milling process caused by overlarge vibration amplitude, the following relation is considered:
amax＝ρ·X0
wherein, amaxThe unit is mm for assisting the maximum amplitude of the superposition vibration; x0The feeding speed of the milling process is in mm/tooth, rho is an optional proportionality coefficient and is more than 0 and less than 1.
Further, aiming at different working conditions, a controller connected with an actuating device at the front end of the main shaft reads the rotation speed and the feeding speed information of the main shaft from a CNC system of the machine tool, then integrates the number of the milling cutter teeth in the milling cutter information to obtain the periodic frequency and the maximum amplitude of the auxiliary superposed vibration applied along the cutting feeding direction of the main shaft and the cutter, and according to the maximum amplitude a of the auxiliary superposed vibration required to be applied at the tool nose point of the cuttermaxAnd the relation between the vibration displacement response of the tool point of the main shaft tool and the actuating force generated by the actuating device 2, obtaining the maximum amplitude of the actuating force, obtaining the consistent actuating force frequency by the cycle frequency of the auxiliary superposition vibration, and outputting a control voltage signal to the actuating device arranged at the front end of the main shaft, so that the required actuating force is generated in the cutting feeding direction of the main shaft-tool, and the corresponding actuating force is applied to the front end of the main shaft, thereby generating the required auxiliary superposition vibration in the cutting feeding direction of the main shaft-tool, namely generating the required auxiliary superposition vibration at the tool point of the tool.
Claims (8)
1. A milling chatter control method based on auxiliary superimposed vibration is characterized in that in the milling process, the milling chatter is controlled by generating the auxiliary superimposed vibration in the cutting feed direction of a main shaft and a cutter;
generating auxiliary superimposed vibration in the spindle-tool cutting feed direction by the following method;
the front end of a main shaft (1) of a milling machine tool is provided with an actuating device (2), the actuating device (2) is arranged in the x direction and the y direction under a machine tool coordinate system and is used for applying actuating forces to the main shaft in the radial x direction and the radial y direction respectively under the working condition of main shaft rotation so as to realize the synthesis of the actuating forces in the random cutting feeding direction of a cutter; when the actuating device (2) applies sine periodic actuating force to the main shaft system, corresponding vibration displacement response X is generated at the tool nose point of the toolsAs an auxiliary superposition vibration;
establishing vibration displacement response X at tool nose point of main shaft tool through experimentsThe amplitude a of the vibration control device is in the following relation with the actuating force generated by the actuating device (2), and the vibration displacement at the tool point of the tool is quantitatively controlled;
a＝kF
f is the amplitude of the actuating force applied to the front end of the main shaft by the actuating device, and k is the relation coefficient of the vibration displacement response amplitude at the tool nose point and the amplitude of the actuating force.
2. The milling machining chatter control method based on the auxiliary superimposed vibration as claimed in claim 1, wherein when a functional relationship between a vibration displacement response at a tool nose point of a main shaft tool and an actuating force is established, a non-contact type displacement sensor is used for measuring the vibration displacement response at the tool nose point of the main shaft tool, and the displacement response amplitude at the tool nose point of the main shaft tool under different amplitude periodical actuating forces is recorded, so that an amplitude relationship coefficient k between the vibration displacement response amplitude at the tool nose point and the actuating force is obtained.
3. The milling machining chatter control method based on the auxiliary superimposed vibration as claimed in claim 1, wherein for different working conditions, the controller connected with the actuating device reads the spindle rotation speed and the feed speed from the CNC system of the machine tool, and then synthesizes the number of the milling cutter teeth to obtain the cycle frequency and the maximum amplitude of the auxiliary superimposed vibration applied along the cutting feed direction of the spindle-cutter,
according to the maximum amplitude a of the auxiliary superimposed vibration required to be applied at the tool nose pointmaxAnd the relation between the vibration displacement response of the tool point of the main shaft tool and the actuating force generated by the actuating device (2) obtains the maximum amplitude of the actuating force, and the consistent actuating force frequency is obtained by the cycle frequency of the auxiliary superposed vibration, so that a control voltage signal is output to the actuating device arranged at the front end of the main shaft, the required actuating force is generated in the cutting feeding direction of the main shaft-tool, and the required auxiliary superposed vibration is generated at the tool point of the tool.
4. The milling machining chatter control method based on auxiliary superimposed vibration as claimed in claim 3, wherein the auxiliary superimposed vibration X issIs determined by the following equation:
wherein f is the frequency of the auxiliary superposition vibration in Hz; omega is the rotating speed of the main shaft, and the unit is rpm; and N is the number of cutter teeth of the milling cutter used in milling.
5. The milling machining chatter control method based on the auxiliary superimposed vibration as claimed in claim 4, wherein the maximum amplitude of the auxiliary superimposed vibration is determined by the following formula:
amax＝ρ·X0
wherein, amaxThe unit is mm for assisting the maximum amplitude of the superposition vibration; x0The feed rate for milling is in mm/tooth, p is a selectable proportionality coefficient, and 0<ρ<1。
6. A milling chatter control system based on auxiliary superimposed vibration, characterized in that, the control method according to any one of claims 1-5 is adopted, comprising an actuating device (2) arranged at the front end of a main shaft (1) of a milling machine tool, a controller connected with a CNC system of the machine tool for reading the main shaft rotating speed and the feeding speed, and the number of teeth of a milling cutter tool, wherein the controller is used for obtaining the maximum amplitude and the frequency of the actuating force according to the maximum amplitude of the auxiliary superimposed vibration and the periodic frequency of the auxiliary superimposed vibration, and outputting a corresponding control voltage signal to control the actuating device (2).
7. A milling vibration control system based on auxiliary superimposed vibration as claimed in claim 6, characterized in that, for different working conditions, the controller connected with the actuating device reads the spindle rotation speed and the feed speed from the CNC system of the machine tool, and then synthesizes the number of the milling cutter teeth to obtain the cycle frequency and the maximum amplitude of the auxiliary superimposed vibration applied along the cutting feed direction of the spindle-cutter.
8. The milling machining chatter control system based on the auxiliary superimposed vibration is characterized in that the actuating device (2) is installed in the x direction and the y direction of a machine tool coordinate system and used for applying actuating forces to the radial x direction and the radial y direction of the spindle under the rotation working condition of the spindle respectively to synthesize the actuating forces of the tool in any cutting feed direction.
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| CN110587377B (en) * | 2019-09-03 | 2020-07-17 | 重庆大学 | Method for monitoring defects of milling cutter on line |
| JP7218701B2 (en) * | 2019-09-30 | 2023-02-07 | ブラザー工業株式会社 | Machine tool, feedback control method and computer program |
| CN111043389A (en) * | 2019-12-31 | 2020-04-21 | 潍柴动力股份有限公司 | Control method and control device of electromagnetic valve and vehicle |
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