CN108970954B - Real-time compensation system and method for comprehensive errors of ultrasonic vibration auxiliary machining gear - Google Patents
Real-time compensation system and method for comprehensive errors of ultrasonic vibration auxiliary machining gear Download PDFInfo
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- CN108970954B CN108970954B CN201810941343.6A CN201810941343A CN108970954B CN 108970954 B CN108970954 B CN 108970954B CN 201810941343 A CN201810941343 A CN 201810941343A CN 108970954 B CN108970954 B CN 108970954B
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- 239000003365 glass fiber Substances 0.000 description 4
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- 229910000617 Mangalloy Inorganic materials 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B06—GENERATING OR TRANSMITTING MECHANICAL VIBRATIONS IN GENERAL
- B06B—METHODS OR APPARATUS FOR GENERATING OR TRANSMITTING MECHANICAL VIBRATIONS OF INFRASONIC, SONIC, OR ULTRASONIC FREQUENCY, e.g. FOR PERFORMING MECHANICAL WORK IN GENERAL
- B06B1/00—Methods or apparatus for generating mechanical vibrations of infrasonic, sonic, or ultrasonic frequency
- B06B1/02—Methods or apparatus for generating mechanical vibrations of infrasonic, sonic, or ultrasonic frequency making use of electrical energy
- B06B1/06—Methods or apparatus for generating mechanical vibrations of infrasonic, sonic, or ultrasonic frequency making use of electrical energy operating with piezoelectric effect or with electrostriction
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Abstract
The invention discloses an ultrasonic vibration assisted machining gear comprehensive error real-time compensation system which comprises a first connecting piece, a vibration amplitude transformer, a second connecting piece, a workpiece fixing shaft and a control system, wherein the first connecting piece is connected with the vibration amplitude transformer; the vibration amplitude transformer is provided with a piezoelectric actuator, the piezoelectric actuators are connected with an ultrasonic generator, and a first piezoelectric sensor is arranged at the tail end of the vibration amplitude transformer, which is in contact with the cutter gear; three groups of piezoelectric laminated actuators are embedded in the second connecting piece; four second piezoelectric sensors are mounted on the workpiece fixing shaft; the control system is connected with the ultrasonic generator, the first piezoelectric sensor, the second piezoelectric sensor and the piezoelectric stack actuator so as to control the whole system to work. The system and the method using the system can actively compensate errors caused by various reasons, obtain an expected processing track, keep the set values of vibration amplitude and phase angle difference in several directions, lock the vibration frequency near the natural frequency and improve the surface quality and the shape precision of a workpiece.
Description
Technical Field
The invention relates to the field of gear machining, in particular to a real-time compensation system and method for comprehensive errors of an ultrasonic vibration auxiliary machining gear.
Background
In the ultrasonic vibration-assisted machining, the machining accuracy is determined by the stability of the machining path of the tool, but when the ultrasonic vibration generating device excites vibration in one direction, and then generates predetermined vibration in another direction, for example, when a pair of piezoelectric actuators of the ultrasonic vibration generator excites a vibration horn to generate vibration in the X direction, vibration in the Y direction is generated, which is caused by the fact that the vibration pattern of the horn in the X and Y directions has some phase angle difference and generates resonance. The deformation of the cutter and the workpiece after being stressed and contacted in the machining process, the transmission matching of all parts of the machine tool, the dryness of vibration in different directions in the ultrasonic vibration process and other factors cause the deviation of the machining path from the preset path. This has a serious influence on the shape accuracy and surface quality of the workpiece after the ultrasonic vibration-assisted machining.
Disclosure of Invention
The present invention aims to solve the above technical problem at least to some extent. Therefore, the invention provides an ultrasonic vibration assisted gear machining comprehensive error real-time compensation system capable of improving the surface quality and the shape precision of a workpiece.
The technical scheme adopted by the invention for solving the technical problems is as follows: a real-time compensation system for comprehensive errors of an ultrasonic vibration auxiliary machining gear comprises a first connecting piece, a vibration amplitude transformer, a second connecting piece, a workpiece fixing shaft and a control system; the first connecting piece is provided with an inner cavity with a polygonal section and is fixedly connected with the second connecting piece; the vibration amplitude transformer is inserted into the inner cavity and can transmit torque to the first connecting piece, the tail end, far away from the inner cavity, of the vibration amplitude transformer is used for mounting a cutter gear, the vibration amplitude transformer is provided with a plurality of piezoelectric actuators, the vibration amplitude transformer can amplify vibration displacement and speed generated by the piezoelectric actuators, ultrasonic energy is gathered on the cutter gear and can generate axial-bending-torsion coupling vibration, the piezoelectric actuators are connected with an ultrasonic generator, and four first piezoelectric sensors which are arranged in a cross mode are mounted at the tail end, in contact with the cutter gear, of the vibration amplitude transformer; three groups of piezoelectric laminated actuators which are vertically arranged are embedded in the second connecting piece; the workpiece fixing shaft is opposite to the vibration amplitude transformer and used for mounting a workpiece gear, and four second piezoelectric sensors corresponding to the first piezoelectric sensors are mounted on the workpiece fixing shaft; the control system is connected with the ultrasonic generator, the first piezoelectric sensor, the second piezoelectric sensor and the piezoelectric stack actuator so as to control the whole system to work.
Further, the vibration amplitude transformer comprises a matching positioning section, a first actuator mounting section, a third connecting piece mounting section, a second actuator mounting section, a fourth connecting piece mounting section and a cutter gear mounting section which are sequentially arranged; the piezoelectric actuator comprises a first piezoelectric actuator and a second piezoelectric actuator; the matching positioning section and the cutter gear mounting section are positioned at two ends of the vibration amplitude transformer, the matching positioning section is connected with the bottom of the inner cavity in a matching way, the cutter gear mounting section is used for mounting a cutter gear, and the first piezoelectric sensor is mounted on the cutter gear mounting section; the first actuator mounting section is provided with a pair of first piezoelectric actuators which are opposite in position, a third connecting piece is mounted between the third connecting piece mounting section and the inner wall of the inner cavity, the outer ring of the section of the third connecting piece is a polygon matched with the inner cavity, the inner ring of the section of the third connecting piece and the section of the third connecting piece mounting section are polygons matched with each other, and the third connecting piece is fixedly connected with the first connecting piece; the second actuator mounting section is provided with a pair of second piezoelectric actuators, and the two first piezoelectric actuators and the two second piezoelectric actuators are arranged in a crossed manner; the fourth connecting piece installation section is provided with a first groove, a fourth connecting piece is installed between the first groove and the outer wall of the inner cavity, the fourth connecting piece is fixedly connected with the first connecting piece, the outer ring of the cross section of the fourth connecting piece is a polygon matched with the inner cavity, the inner ring of the cross section of the fourth connecting piece is circular, and the fourth connecting piece installation section is provided with groove holes which are uniformly distributed around the axis and obliquely arranged.
Further, the inner chamber cross-section is regular hexagon, third connecting piece cross-section inner circle and third connecting piece erection section cross-section are regular octagon, the third connecting piece is provided with corresponding bolt hole with first connecting piece in order to fix and pretension through bolted connection, install the first packing ring of adaptation between third connecting piece and the third connecting piece erection section, the third connecting piece is provided with disconnection department, the second gasket is installed to disconnection department, second gasket one end and first packing ring contact, the other end and first connecting piece contact.
Further, the recess hole is provided with two sets ofly, and every group recess hole is provided with four and encloses axis evenly distributed, first recess and fourth connecting piece correspond and are provided with two and set up along the axis interval.
Further, the vibration mode node of the vibration amplitude transformer is superposed with the positions of the third connecting piece and the two fourth connecting pieces.
Furthermore, an extension section and an intermediate shaft section are sequentially arranged between the second actuator mounting section and the fourth connector mounting section, the diameter of the intermediate shaft section in the whole vibration amplitude transformer is the largest, a connection section is arranged between the fourth connector mounting section and the cutter gear mounting section, and the extension curve of the outer ring of the connection section is a Gaussian curve and the diameter of the connection section gradually decreases from the fourth connector mounting section to the cutter gear mounting section.
The invention also provides a real-time compensation method for the comprehensive error of the ultrasonic vibration auxiliary machining gear, which comprises the following steps:
step one, a cutter gear and a workpiece gear are arranged on a machine tool, the machine tool comprises the ultrasonic vibration assisted machining gear comprehensive error real-time compensation system according to any one of the preceding claims, namely the cutter gear is arranged at the tail end of a vibration amplitude transformer to enable the cutter gear to vibrate together with the vibration amplitude transformer, and the workpiece gear is arranged on a workpiece fixing shaft to be machined;
controlling the tool workbench to move and simultaneously starting the ultrasonic generator to drive the corresponding piezoelectric actuator to work, so that the vibration amplitude transformer performs corresponding vibration, and the vibration amplitude transformer amplifies the vibration and transmits the amplified vibration to the tool gear, so that the tool gear and the workpiece realize a cycle period of part-time processing and part-time non-processing in one vibration period;
thirdly, the control system calculates the voltage required by the corresponding tangential piezoelectric laminated actuator to compensate the vibration displacement according to the real-time tangential vibration displacement of the vibration amplitude transformer acquired by the first piezoelectric sensor; meanwhile, calculating voltages required by the piezoelectric laminated actuators in three directions to compensate the displacement deviation according to the real-time displacement deviation of the workpiece gear acquired by the second piezoelectric sensor;
adding the voltage generated for compensating the real-time tangential vibration displacement of the vibration amplitude transformer, the voltage generated for compensating the real-time displacement deviation of the workpiece gear and the voltage for avoiding the movement of the piezoelectric laminated actuator in the third step according to the corresponding directions to obtain the voltages of the piezoelectric laminated actuator in the three directions;
and step five, the control system applies real-time pressure to the piezoelectric laminated actuators in the corresponding directions according to the voltages of the piezoelectric laminated actuators in the three directions obtained in the step four, so that the second connecting piece moves, and error real-time compensation is completed.
The invention has the beneficial effects that: the interference among different vibration modes in bending, torsion and axial coupling ultrasonic vibration auxiliary processing is avoided, the shape error caused by the deformation of a cutter after the cutter is stressed and contacted with a workpiece in the processing process, the transmission fit of parts of a machine tool, the interference of vibration in different directions in the ultrasonic vibration process and other factors can be actively compensated, an expected track is obtained, the vibration amplitude and the phase angle difference in a plurality of directions keep set values, the vibration frequency is locked near the natural frequency, the surface quality and the shape precision of the workpiece are improved, and the method can be used for processing various gears.
Drawings
The invention is further illustrated with reference to the following figures and examples.
FIG. 1 is a schematic view of the mounting structure of the present invention;
FIG. 2 is a schematic view of the construction of a vibrating horn;
FIG. 3 is a schematic view of the connection of the first connecting member, the third connecting member and the vibrational horn;
FIG. 4 is a schematic diagram of the torsional non-resonant vibration generation principle of a vibrating horn.
Detailed Description
The present invention will be described in detail below with reference to the accompanying drawings and examples.
Referring to fig. 1 to 4, the ultrasonic vibration assisted gear machining comprehensive error real-time compensation system comprises a first connecting piece 1, a vibration amplitude transformer 2, a second connecting piece 3, a workpiece fixing shaft 9 and a control system.
The first connecting piece 1 is provided with an inner cavity 11 with a polygonal section, and the first connecting piece 1 is fixedly connected with the second connecting piece 3; the first connecting piece 1 is made of high manganese steel, the outer ring of the first connecting piece is a regular hexahedron or a cylinder, the first connecting piece 1 is fixedly connected with the second connecting piece 3, the second connecting piece 3 is fixedly connected with a machine tool cutter workbench through a bolt, the machine tool cutter workbench is connected with a screw rod, and feeding and moving of the machine tool cutter workbench drive a cutter gear 261 on a vibration amplitude transformer 2 to process a workpiece. The first connecting part 1 is provided with an inner cavity 11, and the inner cavity 11 extends along the axis of the outer ring thereof. The vibration amplitude transformer 2 is inserted in the inner cavity 11, and the axis of the vibration amplitude transformer coincides with the axis of the outer ring of the first connecting piece 1 or the inner cavity 11. The cross-section of the inner cavity 11 is polygonal for transmitting and receiving a torsion moment, and preferably, the cross-section of the inner cavity 11 is regular hexagonal, so that the rigidity thereof can be maintained to the maximum when an external condition is determined.
The vibration amplitude transformer 2 is made of titanium alloy, so that the material loss in working frequency is low, the fatigue resistance is high, the acoustic impedance is low, and the vibration amplitude transformer can bear larger vibration speed and displacement amplitude. The step-shaped vibration amplitude transformer 2 has great stress concentration at the abrupt change position of the section, and the problem of fracture due to fatigue is easy to occur at the position close to the abrupt change position, so that a Gaussian curve, an arc and a cone line are adopted for transition at the abrupt change position, the stress concentration value can be reduced, and meanwhile, the actual resonance frequency of the vibration amplitude transformer 2 is close to the theoretical value.
The vibration amplitude transformer 2 is inserted in the inner cavity 11 and can transmit torque to the first connecting piece 1, the tail end of the vibration amplitude transformer 2, which is far away from the inner cavity 11, is used for mounting the cutter gear 261, and the vibration amplitude transformer 2 is provided with a plurality of piezoelectric actuators, wherein the piezoelectric actuators comprise a first piezoelectric actuator 4 and a second piezoelectric actuator 6. The vibration amplitude transformer 2 can amplify the vibration displacement and speed generated by the piezoelectric actuator, focus ultrasonic energy on the cutter gear 261 and generate axial-bending-torsion coupling vibration, the piezoelectric actuator is an ultrasonic transducer and can convert ultrasonic frequency electric energy generated by an ultrasonic generator into mechanical energy of ultrasonic vibration, and the ultrasonic generator is a device for providing ultrasonic frequency electric energy for the ultrasonic transducer.
The piezoelectric actuators are all connected with an ultrasonic generator, and four first piezoelectric sensors which are arranged in a cross manner are mounted at the tail end of the vibration amplitude transformer 2, which is in contact with the cutter gear 261, and are used for acquiring displacement data of the vibration amplitude transformer 2; two first piezoelectric sensors set up in Y upwards promptly, and two other first piezoelectric sensors set up in X upwards, and first piezoelectric sensor passes through the electric wire and is connected with control system, and control system receives the information that first piezoelectric sensor gathered, through signal processor, obtains the amplitude of vibration amplitude transformer 2 two directions, phase angle difference.
Three groups of piezoelectric laminated actuators which are arranged vertically are embedded in the second connecting piece 3; the second connecting piece 3 is an elastic body, and the piezoelectric laminated actuator is contacted with the second connecting piece 3 through a steel ball. The wafers in a piezo-stack actuator are connected in series, parallel to wires. When the piezoelectric laminated actuators are connected with a power supply through electric wires, voltage changes, displacement of the piezoelectric laminated actuators changes, the second connecting piece 3 moves, and the three groups of piezoelectric laminated actuators respectively correspond to the X direction, the Y direction and the Z direction, so that error compensation in three directions can be completed.
The workpiece fixing shaft 9 is opposite to the vibration amplitude transformer 2 in position and the axes of the workpiece fixing shaft and the vibration amplitude transformer are parallel and staggered, the workpiece fixing shaft 9 is used for mounting a workpiece gear 91, four second piezoelectric sensors corresponding to the first piezoelectric sensors are mounted on the workpiece fixing shaft 9, and the workpiece fixing shaft 9 is arranged at four positions of the workpiece fixing shaft 9 and used for obtaining displacement deviation of the workpiece fixing shaft; the second sensors are connected with a control system through electric wires, collected signals are processed through a signal processor, and the amplitude and phase angle difference of the workpiece fixing shaft in processing are obtained. The signal processor comprises a phase meter, an oscilloscope and a capacitance micrometer.
The control system is connected with the ultrasonic generator, the first piezoelectric sensor, the second piezoelectric sensor and the piezoelectric stack actuator so as to control the whole system to work.
The structure of the vibration horn 2 will be described in detail below.
The vibration amplitude transformer 2 comprises a matching positioning section 21, a first actuator mounting section 22, a third connector mounting section 23, a second actuator mounting section 24, a fourth connector mounting section 25 and a cutter gear mounting section 26 which are sequentially arranged. The first actuator mounting section 22, the second actuator mounting section 24, the fourth connector mounting section 25 and the cutter gear mounting section 26 are all cylindrical. The matching positioning section 21 and the cutter gear mounting section 26 are located at two ends of the vibration amplitude transformer 2, the cutter gear mounting section 26 is used for mounting the cutter gear 261, the cutter gear 261 is mounted at the tail end of the cutter gear mounting section 26, the mounting position of the cutter gear 261 is the maximum amplitude position of the vibration amplitude transformer, and the first piezoelectric sensor is mounted at the cutter gear mounting section 26. The matching positioning section 21 is connected with the bottom of the inner cavity 11 in a matching mode, preferably, a circular groove is formed in the bottom of the inner cavity 11, a third gasket 12 is installed at the circular groove, a conical groove is formed in the outer end of the third gasket 12, the matching positioning section 21 is a cone and matched with the conical groove, the taper of the cone is 1:12, the matching positioning section 21 is inserted into the conical groove and installed in the conical groove, the matching positioning section 21 and the third gasket 12 are used for transmitting and bearing axial loads, the third gasket is formed by compounding glass fibers and PET according to a sandwich layer structure, the middle of the third gasket is PET, and the inner portion and the outer portion of the third gasket are glass fibers.
The first actuator mounting section 22 is specifically a cylinder, the first actuator mounting section 22 is provided with a pair of first piezoelectric actuators 4 which are opposite in position, the two first piezoelectric actuators 4 are arranged at the end part close to the third connector mounting section 23 and are arranged at intervals in the Y direction, the first piezoelectric actuators 4 are connected to the first actuator mounting section 22 through bolts, and the first piezoelectric actuators 4 are used for realizing resonance bending vibration of the vibration amplitude transformer.
A third connecting piece 5 is arranged between the third connecting piece mounting section 23 and the inner wall of the inner cavity 11, the outer ring of the section of the third connecting piece 5 is a polygon matched with the inner cavity 11, the inner ring of the section of the third connecting piece 5 and the section of the third connecting piece mounting section 23 are polygons matched with each other, the sections are non-circular, and torque can be transmitted. The third connecting piece 5 is fixedly connected with the first connecting piece 1, preferably, the section inner ring of the third connecting piece 5 and the section of the third connecting piece mounting section 23 are regular octagons, and the section outer ring of the third connecting piece 5 is a regular hexagon. Further, the connection mode of the third connecting piece and the first connecting piece 1 is preferably, the third connecting piece 5 and the first connecting piece 1 are provided with corresponding bolt holes so as to be fixedly connected and pre-tightened through bolts, the number of the bolts is specifically three, the bolt holes of the third connecting piece 5 are blind holes, and a first gasket 8 in adaptation is arranged between the third connecting piece 5 and the third connecting piece mounting section 23. The section of the first gasket 8 is regular octagon, which is formed by compounding glass fiber and PET according to a sandwich layer structure, the middle part is PET, the inner part and the outer part are glass fiber, the high elastic modulus is provided, and the first gasket has a certain lubricating effect, and is not easy to generate fatigue damage in the process of repeatedly twisting the vibration amplitude transformer.
The third connecting piece 5 is provided with a break-off part, the break-off part is provided with a second gasket 51, one end of the second gasket 51 is in contact with the first gasket 8, the other end of the second gasket 51 is in contact with the first connecting piece 1, specifically, as shown in fig. 3, the cross section of the second gasket 51 is formed by splicing two right-angle folding blocks in opposite directions, and the splicing part has a certain arc and an inclination angle. This maintains a tight connection between the components while the bolt provides a compressive force toward the center. And the second gasket 51 has damping properties, and is capable of isolating vibrations of the vibrating horn from the machine tool table, and likewise, preventing vibrations of the machine tool moving table from interfering with vibrations of the vibrating horn.
The second actuator mounting section 24 mounts a pair of second piezoelectric actuators 6, the second piezoelectric actuators 6 are arranged at intervals in the X direction, the second piezoelectric actuators 6 are used for realizing the vibration of the axial resonance of the vibration horn, and the two first piezoelectric actuators 4 are arranged crosswise to the two second piezoelectric actuators 6, and the intersection points are on the axis. Preferably, the third connector mounting section 23 and the second actuator mounting section 24 form a stepped shaft, the diameters of the first actuator mounting section 22 and the second actuator mounting section 24 are sequentially reduced, the second actuator mounting section 24 is provided with a pair of mounting grooves at intervals in the X direction for mounting and matching the second piezoelectric actuator 6, after the second piezoelectric actuator 6 is mounted in the mounting grooves, the outer ring of the clamp spring 61 is clamped and fixed, the periphery of the clamp spring 61 close to the third connecting piece mounting section 23 is provided with a step, the step surface is a regular hexahedron and forms a second groove which can be matched with the third connecting piece mounting section 23 for mounting the third connecting piece 5, thus, a part of the third connecting piece 5 is arranged on the step of the clamp spring 61, which is equivalent to clamping and fixing the clamp spring 61, so that the second piezoelectric actuator 6 is fixed more stably, and the step of the circlip 61 has a limiting effect on the third connecting piece 5.
The fourth connecting piece mounting section 25 is provided with a first groove 251, a fourth connecting piece 7 is mounted between the first groove 251 and the outer wall of the inner cavity 11, the fourth connecting piece 7 is fixedly connected with the first connecting piece 1, the outer ring of the cross section of the fourth connecting piece 7 is a polygon matched with the inner cavity 11, namely a regular hexagon, and a circular gasket is arranged between the fourth connecting piece 7 and the first groove 251. The third connecting member 5, the fourth connecting member 7, the first washer 8, the second washer 51, the circular washer, and the snap spring 61 are made of a material having a high elastic modulus, and are snap-fitted into the vibration horn 2 by deformation.
The cross section of the fourth connecting piece 7 is circular, and preferably, two first grooves 251 and two fourth connecting pieces 7 are correspondingly arranged and are arranged at intervals along the axis. The fourth connecting member mounting section 25 is provided with groove holes 252 which are uniformly distributed around the axis and obliquely arranged, two groups of the groove holes 252 are provided, and four groove holes 252 are provided and uniformly distributed around the axis. The length of the groove hole 252 is the same as that of the fourth connector mounting section 25, and the included angle between the groove hole 252 and the axis is 30 degrees.
Wherein the vibration mode node of the vibration amplitude transformer 2 is superposed with the positions of the third connecting piece 5 and the two fourth connecting pieces 7, and the cutter gear 261 is installed at the position with the maximum bending vibration amplitude at the tail end of the vibration amplitude transformer. During installation, the third connecting piece 5 and one of the fourth connecting pieces 7 are rotated by 180 degrees, the angle difference between the two fourth connecting pieces 7 is 180 degrees, and the dynamic unbalance mass caused by the installation of the connecting pieces is mainly reduced as much as possible.
In this embodiment, the joints of different segments all adopt the optimal circular arc transition, and the radius of the circular arc transition is determined by the size and the vibration amplification coefficient of the cross sections of two adjacent segments at the joints. In order to achieve good vibration effect at the cutter gear and ensure transmission of axial vibration as much as possible, an extension section 27 and an intermediate shaft section 28 are sequentially arranged between the second actuator mounting section 24 and the fourth connector mounting section 25, the diameter of the intermediate shaft section 28 is the largest in the whole vibration amplitude transformer, and the lengths of the extension section 27 and the intermediate shaft section 28 are adjusted according to actual requirements. When subjected to alternating forces, a portion of the forces will drive the vibration horn 2 in a torsional motion, and due to the configuration of the recessed bore 252, the torsional stiffness of the fourth connector mounting section 25 is reduced to less than 1/8 of the torsional stiffness of the extension section 27, facilitating the generation of torsional vibrations, while the axial stiffness is also reduced for the generation of axial vibrations.
A connecting section 29 is arranged between the fourth connecting piece mounting section 25 and the cutter gear mounting section 26, and the outer ring extension curve of the connecting section 29 is a Gaussian curve and the diameter of the connecting section 29 gradually decreases from the fourth connecting piece mounting section 25 to the cutter gear mounting section 26. The axial vibration and bending vibration reach high vibration speed, the high vibration speed requirement during efficient rough machining and finish machining of various cylindrical gears is met, the vibration speed is higher in a certain vibration period, and the surface quality of a workpiece is improved and comprises surface roughness, residual stress and the like.
The first piezoelectric actuator 4 and the second piezoelectric actuator 6 are respectively connected with the ultrasonic generator through electric wires, the transmission of vibration frequency signals is transmitted through the wireless transmitter and the wireless receiver and is coded and decoded by the coding mechanism, and the piezoelectric actuators are specifically ultrasonic transducers which convert ultrasonic frequency electric energy generated by the ultrasonic generator into mechanical energy of ultrasonic vibration. The invention can select three vibration types for auxiliary processing according to different processing requirements, and the vibration types are specifically divided into ultrasonic axial-torsional coupling vibration, ultrasonic bending-torsional coupling vibration and ultrasonic axial-bending-torsional coupling vibration. The ultrasonic axial-bending-torsional coupling vibration is used for assisting in processing a cylindrical gear with a hyperbolic tooth form and a spiral tooth form; the ultrasonic axial-torsional coupling vibration is used for assisting in processing a cylindrical gear with a straight tooth shape or a helical tooth shape; the ultrasonic bending-torsion coupling vibration is used for assisting in machining to carry out cylindrical gear shape modification machining; the relative motion trajectory between the cutter gear 261 and the workpiece determines the tooth profile of the machined cylindrical gear.
The X direction herein is the up-down direction of the view of fig. 1, i.e., the cutting depth direction; the Z direction is the axial direction of the vibration amplitude transformer 2, namely the cutting speed direction; the Y direction is tangential, and the X direction, the Y direction and the Z direction are mutually vertical.
The vibration amplitude transformer generates axial vibration under the action of the pair of second piezoelectric actuators 6 in the x direction, the axial amplitude value is amplified through the fourth connecting piece mounting section 25, the vibration speed is amplified through the connecting section 29, the speed and the amplitude of the axial vibration are increased, the direction and the cutting speed are on the same horizontal line, the generated ultrasonic cavitation effect is more obvious, the cutting fluid can deeply permeate into the contact part of the cutting fluid, the temperature of the contact area of the workpiece and the cutter is further reduced, the surface quality of the workpiece is improved, and the service life of the cutter is prolonged.
The vibration horn generates a bending vibration mode by a pair of first piezoelectric actuators 4 arranged in the Y direction, and the bending vibration mode is expressed in the x direction on the blade edge, that is, in the chip thickness direction of the cutting process. And through the amplification effect of the fourth connecting piece mounting section 25 and the connecting section 29, faster x-direction vibration speed and amplitude are formed at the cutter point.
When the vibration amplitude transformer receives cutting force, the cutting thickness is changed due to the vibration in the cutting process, so that the cutting force is changed alternately, after the fourth connecting piece mounting section 25 receives the cutting force, the transmission path of the cutting force is changed due to the action of the groove hole 252, the cutting force can cause the torsional motion of the vibration amplitude transformer 2, the alternating cutting force causes the repeated torsional motion of the vibration amplitude transformer 2, and the non-resonant torsional vibration is realized. The force transmission path is shown in detail in fig. 4. The vibration amplitude transformer 2 can be used for ultrasonic vibration auxiliary processing of various curved surfaces and can also be used for milling.
Ultrasonic vibration can generate ultrasonic cavitation, namely, the air pressure at the contact part of the cutter and the material is changed in the cutting process, so that the cutting fluid can deeply permeate into the contact part, the temperature of the contact area of the workpiece and the cutter is further reduced, the surface quality of the workpiece is improved, and the service life of the cutter is prolonged. In the Y direction, at a certain broaching speed, machining at a relatively low Y-direction vibration speed helps to further promote cycle-to-cycle machining and non-machining. And because the specific structure of the vibration amplitude transformer comprises a Gaussian structure with stress uniformly distributed along the rod piece, high displacement amplitude is obtained; in addition, the integral bending rigidity is enough, so that the transverse vibration of the broaching tool is reduced, the cutter is prevented from deviating from a preset path due to the transverse vibration, and the possibility that the cutter collides with a workpiece when the cutter retracts from uncut materials is avoided.
The control system includes a controller and a charge amplifier. The charge amplifier is used for amplifying the voltage signal and is connected with the piezoelectric actuator and the piezoelectric stack actuator.
The controller is used to eliminate the following interference from the vibration horn caused by the piezoelectric actuator:
(1) when a displacement in the cutting depth direction (defined as the x direction) occurs during bending vibration, a vibration displacement in the Y direction is caused.
(2) Axial vibration causes vibration displacements in the depth of cut direction (defined as the x-direction) and in the tangential direction (the y-direction).
(3) The vibration displacement in the cutting depth direction (defined as x-direction), tangential direction (y-direction), and cutting speed (z-direction) due to the torsional vibration.
The invention also provides a real-time compensation method for the comprehensive error of the ultrasonic vibration auxiliary machining gear, which comprises the following steps:
firstly, a cutter gear 261 and a workpiece gear 91 are installed on a machine tool, the machine tool comprises the ultrasonic vibration auxiliary machining gear comprehensive error real-time compensation system, namely the cutter gear 261 is installed at the tail end of a vibration amplitude transformer 2, the cutter gear 261 can vibrate together with the vibration amplitude transformer 2, and the workpiece gear 91 is installed on a workpiece fixing shaft 9 to be machined.
Secondly, controlling the tool worktable to move and simultaneously starting an ultrasonic generator to drive a corresponding piezoelectric actuator to work so as to enable a vibration amplitude transformer to carry out corresponding vibration, amplifying the vibration by the vibration amplitude transformer 2 and then transmitting the amplified vibration to the tool gear 261, and enabling the tool gear 261 and the workpiece to realize a cycle period of part-time processing and part-time non-processing in one vibration period; the cutter gear 261 and the workpiece are machined at a low cutting speed to ensure that the machining and non-machining cyclic process in a vibration period is completely realized, and after the cutter gear and the workpiece completely enter a cutting state, the cutting speed is increased and/or the cutting depth between the cutter and the workpiece is increased, so that high-efficiency machining is realized.
Thirdly, the control system calculates the voltage required by the corresponding tangential piezoelectric laminated actuator to compensate the vibration displacement according to the real-time tangential vibration displacement of the vibration amplitude transformer 2 acquired by the first piezoelectric sensor; meanwhile, calculating voltages required by the piezoelectric laminated actuators in three directions to compensate the displacement deviation according to the real-time displacement deviation of the workpiece gear acquired by the second piezoelectric sensor;
when the displacement bending vibration is acquired by the first piezoelectric sensor, the displacement in the cutting depth direction is x (t), the tangential displacement is y (t), and the vibration amplitude transformerInfluence coefficient k of displacement generated in the cutting depth direction on tangential displacement after bending vibration is generated under excitation of piezoelectric actuatorxyComprises the following steps:
ly1＝kxy·E·P1·a1·B
the voltage required by the piezoelectric stack actuator corresponding to the tangential direction to compensate the vibration displacement is a positive value if the tangential displacement caused by the bending vibration is consistent with the positive direction of the y axis, and a negative value if the tangential displacement is opposite to the positive direction of the y axis:
kxythe influence coefficient of displacement generated in the cutting depth direction on tangential displacement after the vibration amplitude transformer generates bending vibration under the excitation of the piezoelectric actuator is disclosed.
B is the displacement of the vibration amplitude transformer in the cutting depth direction after the piezoelectric actuator generates unit displacement;
P1amplification of a piezo-electric actuator connected to a charge amplifier for generating flexural vibrations
a1Generating displacement (um) in a cutting depth direction for the piezoelectric actuator under the excitation of unit voltage (V);
e is power supply input voltage and is connected with a piezoelectric actuator generating bending vibration through a charge amplifier;
Ly1the vibration displacement which needs to be compensated for in the upward direction of the piezoelectric stack actuator Y;
P2a magnification of a charge amplifier that is a connection of the piezoelectric stack actuator;
a2is the displacement (um) per unit voltage (V) of the piezo-electric stack actuator.
The voltage calculation required for the three-directional piezo-stack actuator to compensate for this displacement deviation is as follows:
during the cutting process, the clothThe number of the piezoelectric sensors arranged on the shaft fixedly connected with the workpiece gear is 4, the position sensors can detect displacement changes and transmit the displacement changes through the wireless transmitting device, the wireless receiving device receives signals, the signals are decoded by the decoder and processed by the signal processor, 3 directions (x, y and z directions) of displacement information of the cutter gear and the workpiece are obtained, and x is set as2，y2，z2. In the process of processing gears with different tooth shapes, the position information of the relative motion in the processing track set in the processing process of the cutter gear and the workpiece is x3，y3，z3. Then the deformation after cutter and work piece atress contact in the course of working, the transmission cooperation of lathe each part, factors such as the drier of not equidirectional vibration among the ultrasonic vibration process have caused the vibration interference deviation in 3 directions of processing route skew predetermined route respectively:
Δx＝x3-x2
Δy＝y3-y2
Δz＝z3-z2
P2a magnification of a charge amplifier that is a connection of the piezoelectric stack actuator;
a2is the displacement (um) produced by the piezo-electric stack actuator at a unit voltage (V).
The voltages generated by the piezoelectric stack actuators in the 3 directions in compensating for the displacement deviation are respectively as follows: ex3，Ey3，Ez3。Ex3，Ey3，Ez3The method specifically comprises the following steps:
step four, adding the voltage generated for compensating the real-time tangential vibration displacement of the vibration amplitude transformer 2, the voltage generated for compensating the real-time displacement deviation of the workpiece gear 91 and the voltage for avoiding the movement of the piezoelectric laminated actuator in the step three according to the corresponding directions to obtain the voltages of the piezoelectric laminated actuator in the three directions;
the voltage for avoiding the movement of the piezoelectric stack actuator is obtained by the following means: in the debugging process, cutting forces F in 3 directions are obtained in advance according to the relative motion track of a cutter gear and a workpiece in the cutting process and a cutting force calculation methodx2，Fy2，Fz2And to obtain a real-time cutting force during cutting that coincides with a cutting path that varies with time, which is obtained in advance as a cutting force that varies with time or cutting path. The real-time cutting force transmitted to the wafer body of the piezo-electric stack actuator can cause the piezo-electric actuator to generate displacement and voltage, which we need to avoid, we need to apply voltage to the piezo-electric actuator to avoid the movement of the piezo-electric stack actuator. Compensating the voltage and displacement changes of the movement of the piezoelectric laminated actuator, and adjusting to obtain voltages E respectively connecting the piezoelectric laminated actuator in three directions with a power supply through charge amplifiersx2，Ey2，Ez2。
If the cutting force in a certain direction is increased in the cutting process, the voltage is a negative value; the cutting force decreases and the voltage is positive.
The error compensation is added according to the corresponding directions to obtain the voltages of the piezoelectric laminated actuators in three directions, after the deviation of a processing path deviating from a preset path is compensated due to factors such as bending vibration interference of a vibration amplitude transformer, deformation of a cutter and a workpiece after stressed contact in the processing process, transmission fit of parts of a machine tool, dryness of vibration in different directions in the ultrasonic vibration process and the like, the voltages connected with the piezoelectric laminated actuators in 3 directions are respectively as follows:
Ex＝Ex2-Ex3
Ey＝Ey2-Ey3-Ey1
Ez＝Ez2-Ez3
and step five, the control system applies real-time pressure to the piezoelectric laminated actuators in the corresponding directions according to the voltages of the piezoelectric laminated actuators in the three directions obtained in the step four, so that the second connecting piece 3 moves, and error real-time compensation is completed.
The above embodiments are only for illustrating the technical solutions of the present invention and are not limited thereto, and any modification or equivalent replacement without departing from the spirit and scope of the present invention should be covered within the technical solutions of the present invention.
Claims (7)
1. The utility model provides a real-time compensation system of ultrasonic vibration auxiliary machining gear composite error which characterized in that: comprises a first connecting piece (1), a vibration amplitude transformer (2), a second connecting piece (3), a workpiece fixing shaft (9) and a control system;
the first connecting piece (1) is provided with an inner cavity (11) with a polygonal section, and the first connecting piece (1) is fixedly connected with the second connecting piece (3);
the vibration amplitude transformer (2) is inserted into the inner cavity (11) and can transmit torque to the first connecting piece (1), the tail end, far away from the inner cavity (11), of the vibration amplitude transformer (2) is used for mounting a cutter gear (261), the vibration amplitude transformer (2) is provided with a plurality of piezoelectric actuators, the vibration amplitude transformer (2) can amplify vibration displacement and speed generated by the piezoelectric actuators, ultrasonic energy is gathered on the cutter gear (261) and can generate axial-bending-torsional coupling vibration, the piezoelectric actuators are connected with an ultrasonic generator, and the tail end, in contact with the cutter gear (261), of the vibration amplitude transformer (2) is provided with four first piezoelectric sensors which are arranged in a cross mode;
three groups of piezoelectric laminated actuators which are arranged vertically are embedded in the second connecting piece (3); the workpiece fixing shaft (9) is opposite to the vibration amplitude transformer (2) and is used for mounting a workpiece gear (91), and four second piezoelectric sensors corresponding to the first piezoelectric sensors are mounted on the workpiece fixing shaft (9);
the control system is connected with the ultrasonic generator, the first piezoelectric sensor, the second piezoelectric sensor and the piezoelectric stack actuator so as to control the whole system to work.
2. The ultrasonic vibration assisted machining gear comprehensive error real-time compensation system of claim 1, characterized in that: the vibration amplitude transformer (2) comprises a matching positioning section (21), a first actuator mounting section (22), a third connecting piece mounting section (23), a second actuator mounting section (24), a fourth connecting piece mounting section (25) and a cutter gear mounting section (26) which are sequentially arranged; the piezoelectric actuator comprises a first piezoelectric actuator (4) and a second piezoelectric actuator (6);
the matching positioning section (21) and the cutter gear mounting section (26) are positioned at two ends of the vibration amplitude transformer (2), the matching positioning section (21) is connected with the bottom of the inner cavity (11) in a matching way, the cutter gear mounting section (26) is used for mounting a cutter gear (261), and the first piezoelectric sensor is mounted on the cutter gear mounting section (26);
the first actuator mounting section (22) is provided with a pair of first piezoelectric actuators (4) which are opposite in position, a third connecting piece (5) is mounted between the third connecting piece mounting section (23) and the inner wall of the inner cavity (11), the outer ring of the section of the third connecting piece (5) is a polygon matched with the inner cavity (11), the sections of the inner ring of the section of the third connecting piece (5) and the third connecting piece mounting section (23) are polygons matched with each other, and the third connecting piece (5) is fixedly connected with the first connecting piece (1);
the second actuator mounting section (24) is provided with a pair of second piezoelectric actuators (6), and the two first piezoelectric actuators (4) and the two second piezoelectric actuators (6) are arranged in a crossed manner; fourth connecting piece installation section (25) is provided with first recess (251), install fourth connecting piece (7) between first recess (251) and inner chamber (11) outer wall, fourth connecting piece (7) and first connecting piece (1) fixed connection, the outer lane of fourth connecting piece (7) cross-section is the polygon that matches with inner chamber (11), fourth connecting piece (7) cross-section inner circle is circular, fourth connecting piece installation section (25) are provided with axis evenly distributed and slant recess hole (252) that set up.
3. The ultrasonic vibration assisted machining gear comprehensive error real-time compensation system of claim 2, characterized in that: the cross-section of inner chamber (11) is regular hexagon, third connecting piece (5) cross-section inner circle and third connecting piece erection section (23) cross-section are regular octagon, third connecting piece (5) are provided with corresponding bolt hole in order to fix and the pretension through bolted connection with first connecting piece (1), install first packing ring (8) of adaptation between third connecting piece (5) and third connecting piece erection section (23), third connecting piece (5) are provided with disconnection department, second gasket (51) are installed to disconnection department, second gasket (51) one end and first packing ring (8) contact, the other end and first connecting piece (1) contact.
4. The ultrasonic vibration assisted machining gear comprehensive error real-time compensation system of claim 2, characterized in that: the groove holes (252) are arranged in two groups, each group of groove holes (252) is provided with four grooves which are uniformly distributed around the axis, and the first groove (251) and the fourth connecting piece (7) are correspondingly arranged in two and are arranged at intervals along the axis.
5. The ultrasonic vibration assisted machining gear comprehensive error real-time compensation system of claim 4, characterized in that: and the vibration mode node of the vibration amplitude transformer (2) is superposed with the positions of the third connecting piece (5) and the two fourth connecting pieces (7).
6. The ultrasonic vibration assisted machining gear comprehensive error real-time compensation system of claim 2, characterized in that: an extension section (27) and a middle shaft section (28) are sequentially arranged between the second actuator mounting section (24) and the fourth connector mounting section (25), the diameter of the middle shaft section (28) in the whole vibration amplitude transformer (2) is the largest, a connecting section (29) is arranged between the fourth connector mounting section (25) and the cutter gear mounting section (26), and the outer ring extension curve of the connecting section (29) is a Gaussian curve and the diameter of the connecting section (29) gradually decreases from the fourth connector mounting section (25) to the cutter gear mounting section (26).
7. The real-time compensation method for the comprehensive error of the ultrasonic vibration-assisted machining gear is characterized by comprising the following steps of:
step one, a cutter gear (261) and a workpiece gear (91) are installed on a machine tool, wherein the machine tool comprises the ultrasonic vibration assisted machining gear comprehensive error real-time compensation system of any one of the claims 1 to 6, namely the cutter gear (261) is installed at the tail end of a vibration amplitude transformer (2), the cutter gear (261) can vibrate along with the vibration amplitude transformer (2), and the workpiece gear (91) is installed on a workpiece fixing shaft (9) to be machined;
controlling the tool workbench to move and simultaneously starting the ultrasonic generator to drive the corresponding piezoelectric actuator to work, so that the vibration amplitude transformer performs corresponding vibration, amplifying the vibration by the vibration amplitude transformer (2) and then transmitting the amplified vibration to the tool gear (261), and realizing a cycle period of partial-time machining and partial-time non-machining between the tool gear (261) and the workpiece in one vibration period;
thirdly, the control system calculates the voltage required by the corresponding tangential piezoelectric laminated actuator to compensate the vibration displacement according to the real-time tangential vibration displacement of the vibration amplitude transformer (2) acquired by the first piezoelectric sensor; meanwhile, calculating voltages required by the piezoelectric laminated actuators in three directions to compensate the displacement deviation according to the real-time displacement deviation of the workpiece gear acquired by the second piezoelectric sensor;
adding the voltage generated for compensating the real-time tangential vibration displacement of the vibration amplitude transformer (2), the voltage generated for compensating the real-time displacement deviation of the workpiece gear (91) and the voltage for avoiding the movement of the piezoelectric laminated actuator in the third step according to corresponding directions to obtain the voltages of the piezoelectric laminated actuator in the three directions;
and step five, the control system applies real-time pressure to the piezoelectric laminated actuators in the corresponding directions according to the voltages of the piezoelectric laminated actuators in the three directions obtained in the step four, so that the second connecting piece (3) moves, and error real-time compensation is completed.
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