CN110091216B - Milling noise and milling vibration monitoring and correlation analysis system and method - Google Patents
Milling noise and milling vibration monitoring and correlation analysis system and method Download PDFInfo
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- B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
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- B23Q17/0952—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool during machining
- B23Q17/098—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool during machining by measuring noise
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- B23Q17/0971—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool during machining by measuring mechanical vibrations of parts of the machine
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Abstract
The invention relates to a milling noise and milling vibration monitoring and correlation analysis system, which comprises a numerical control machine tool and workpiece system, an acoustic and vibration measuring system and an acoustic and vibration correlation analysis system, wherein the numerical control machine tool and workpiece system mainly comprises a numerical control milling machine, a milling cutter and a processed workpiece; the acoustic and vibration measuring system mainly comprises a sound calibrator, a sound level meter, an acceleration sensor, a charge amplifier and a high-speed data acquisition instrument; the acoustic and vibration correlation analysis system mainly comprises a computer. The invention can simultaneously measure the noise and vibration generated by the workpiece in the milling process, monitor the noise and vibration state in real time during the processing, analyze the correlation between the noise signal and the vibration signal, establish a noise sound pressure level prediction model and provide theoretical guidance for noise reduction and vibration reduction of the milling process.
Description
Technical Field
The invention relates to a system and a method for monitoring milling noise and milling vibration and analyzing correlation of the milling noise and the milling vibration, in particular to a system and a method for testing and analyzing noise signals and vibration signals synchronously acquired in a milling process, and belongs to the technical field of machining.
Background
The milling is a machining mode that a milling cutter is used as a machining tool, the milling cutter is arranged on a main shaft of a machine tool and rotates along with the main shaft, and a workpiece is clamped on a workbench and moves in a feeding mode, so that the machining process that the milling cutter cuts the surface of the workpiece is completed. Milling can produce many more specific or complex surfaces, and thus milling is widely used in machining. Milling noise and milling vibration are common phenomena in the milling process. In the milling process, noise mainly comes from the background noise of a machine tool, the noise of friction between a workpiece and a cutter and the noise caused by the vibration of a milling system, and strong noise restricts the improvement of the productivity and influences the health of workers; the vibration in the milling process mainly has two forms of forced vibration and self-excited vibration, and is mainly caused by unbalanced motion of a rotating part on a machine tool and friction or impact between a workpiece and a cutter, so that the strong vibration can influence the processing precision of the surface of the workpiece, shorten the service life of the machine tool and easily cause the cutter to be worn. Since the sound is caused by the vibration of the object, the vibration generated during the milling process also causes the generation of noise, and thus it is known that the milling noise and the milling vibration affect each other. At present, many scholars research the milling process, but generally the change rule of noise or the change rule of vibration in the milling process is only analyzed by angles such as theoretical knowledge, experiments or numerical simulation, and the like, and no system related to synchronous acquisition of the milling noise and the vibration and correlation analysis of the two is available. Therefore, a system for monitoring and analyzing milling noise and milling vibration in real time is needed to be designed, so that the characteristics of the milling noise and the milling vibration can be researched on the basis, the change rule of the milling noise and three-way milling vibration acceleration under different milling parameters and the correlation between the noise and the vibration are further researched, and scientific guidance is provided for monitoring the milling state.
Disclosure of Invention
The invention aims to: aiming at the defects in the prior art, the system and the method for reasonably monitoring the milling noise and the milling vibration and analyzing the correlation of the milling noise and the milling vibration are provided, the system can synchronously acquire the noise signal and the vibration signal in real time during milling, monitor the state of the milling system in real time, and analyze the correlation between the noise and the vibration signal.
In order to achieve the above purpose, the technical scheme of the invention is as follows:
a milling noise and milling vibration monitoring and correlation analysis system comprises a numerical control machine tool and workpiece system, an acoustic and vibration measuring system and an acoustic and vibration correlation analysis system, wherein the numerical control machine tool and workpiece system mainly comprises a numerical control milling machine, a milling cutter and a processed workpiece; the acoustic and vibration measuring system mainly comprises a sound calibrator, a sound level meter, an acceleration sensor, a charge amplifier and a high-speed data acquisition instrument, and is used for acquiring noise signals and vibration signals in the workpiece processing process in real time; the acoustic and vibration correlation analysis system mainly comprises a computer and is used for carrying out real-time domain analysis, frequency domain analysis and correlation analysis on the collected noise signals and vibration signals.
The system for measuring the milling noise and the milling vibration can synchronously measure and collect noise and vibration signals, and the correlation analysis system can draw time domain and frequency domain curve graphs of acoustic signals and three-way vibration acceleration signals under different milling parameters in real time; the noise and vibration states of the milling system can be monitored in real time, and the states can be evaluated; establishing a correlation model between the milling sound pressure level and the milling parameters and a milling three-way vibration acceleration, and predicting a milling sound pressure level signal according to milling vibration under the given milling parameters; the law of interaction between milling noise and vibration at given milling parameters can be analyzed. The invention can simultaneously measure the noise and vibration generated by the workpiece in the milling process, monitor the noise and vibration state in real time during the processing, analyze the correlation between the noise signal and the vibration signal, establish a noise sound pressure level prediction model and provide theoretical guidance for noise reduction and vibration reduction of the milling process.
The further optimized technical scheme of the invention is as follows:
preferably, the sound calibrator is primarily used to calibrate the sound level meter; the sound level meter is arranged below the workpiece and is at a certain distance from the workpiece, and is used for acquiring a sound pressure signal in the milling process; the acceleration sensor is arranged on a milling machine workbench and is arranged close to a workpiece and used for acquiring X, Y, Z three-way vibration signals in the milling process; the high-speed data acquisition instrument is provided with at least four voltage input signal channels, wherein one voltage input signal channel is connected with the alternating current signal output end of the sound level meter, and the rest voltage input signal channels are connected with the output end of the charge amplifier; the acceleration sensor is provided with three output ends which are respectively connected with the input ends of the three charge amplifiers.
Preferably, the milling cutter is installed on a main shaft of a vertical milling machine, the milling cutter is made of a high-speed steel aluminum-containing material, and the workpiece is clamped on a workbench of the milling machine.
Preferably, the sound level meter is a precision sound level meter model HS 5661; a microphone is arranged at the top end of the sound level meter, and tail threads are arranged at the tail of the microphone; the top end of the front pole of the sound level meter is provided with top end threads, the tail threads of the microphone align with the top end threads of the front pole of the sound level meter, the microphone and the front pole of the sound level meter are coaxial, the microphone is rotated into the front pole of the sound level meter in a clockwise direction, and the top end of the microphone is rotated into a bottom end hole of the sound calibrator.
Preferably, the acceleration sensor is a piezoelectric three-way acceleration sensor, and the piezoelectric three-way acceleration sensor is fixedly connected with a clamp platform for clamping a workpiece on a milling machine workbench through a magnetic seat.
Preferably, the output interface of the high-speed data acquisition instrument is connected with the interface of a computer through a USB data transmission line, and the computer is internally provided with acoustic and vibration measurement acquisition software.
The invention also provides a method for monitoring milling noise and milling vibration and analyzing the correlation of the milling noise and the milling vibration, which comprises the following steps of:
the method comprises the following steps of firstly, establishing a milling test system, wherein the milling test system comprises a numerical control machine tool and workpiece system, an acoustic and vibration measurement system and an acoustic and vibration correlation analysis system, and the numerical control machine tool and workpiece system mainly comprises a numerical control milling machine, a milling cutter and a processed workpiece; the acoustic and vibration measuring system mainly comprises a sound calibrator, a sound level meter, an acceleration sensor, a charge amplifier and a high-speed data acquisition instrument, wherein the sound calibrator is used for calibrating a sound pressure level, the sound level meter is connected with the high-speed data acquisition instrument and then used for acquiring a noise signal, the measured noise signal is a signal obtained by deducting background noise, the acceleration sensor is connected with the high-speed data acquisition instrument through the charge amplifier and then used for acquiring a vibration signal, and the measured vibration signal is a signal obtained by deducting background vibration; the acoustic and vibration correlation analysis system mainly comprises a computer;
secondly, after a workpiece, namely a square aluminum alloy material, is prepared as a workpiece to be processed, clamping the selected workpiece on a milling machine workbench;
thirdly, connecting and calibrating test equipment;
fourthly, a milling test, namely starting a milling machine tool to process the workpiece, and acquiring a noise signal and a vibration signal in the milling process;
fifthly, obtaining a root mean square value of sound pressure level, a root mean square value of sound power level, a root mean square value of three-way acceleration, velocity and displacement from the collected data of the noise signal and the vibration signal based on the characteristic value required by milling test data arrangement;
sixthly, drawing a noise signal and vibration signal curve;
and seventhly, analyzing the mutual influence between the milling noise and the milling vibration, namely changing the rotation speed, the feed speed and the milling depth of the milling spindle, drawing the change rule of the sound pressure level and the three-way acceleration under different milling parameters, carrying out regression model analysis on variables in a milling test, and establishing a regression model between the sound pressure level and the milling parameter as well as the milling vibration, thereby carrying out correlation analysis between the milling noise and the milling vibration and obtaining the influence rule of the milling parameter and the milling vibration on the milling noise.
In the third step, the specific method for connecting and calibrating the test equipment is as follows:
(1) after the power supply of the high-speed data acquisition instrument is turned off, the high-speed data acquisition instrument is connected with a computer provided with acoustic and vibration measurement acquisition software through a USB data transmission line;
(2) the method comprises the following steps that an acceleration sensor is adsorbed on a clamp platform for clamping a workpiece through a magnetic seat, three X, Y, Z directions of the acceleration sensor respectively correspond to the X, Y, Z directions of a numerically controlled milling machine, three output ends of the acceleration sensor are respectively connected to the input ends of three charge amplifiers, and then the output end of the charge amplifier is connected with a high-speed data acquisition instrument;
(3) the sound level meter is arranged at a certain distance from the workpiece and is connected with the high-speed data acquisition instrument through a special data line;
(4) turning on a power supply of the high-speed data acquisition instrument, turning on acoustic and vibration measurement software on a computer desktop, rotating the top end of a microphone into the bottom end of a sound calibrator, starting a button switch of the sound calibrator, calibrating a sensor of a sound level meter after 3-5 seconds, indicating that the instrument can be normally used when a sound pressure value is displayed as 6.66, and taking down the sound calibrator after calibration is finished;
(5) setting acoustic and vibration measurement acquisition parameters, defining a file and a file storage path, and then setting sampling frequency, acquisition time and sampling number;
(6) before the test is formally started, the milling machine is started, background measurement is carried out, and the background measurement is deducted.
In the seventh step, the milling speed v and the feeding speed v are givenfMilling depth apAcceleration root mean square value
And sound pressure level LpAnd establishing a fitting relation of the milling sound pressure level relative to the milling parameters and the milling vibration acceleration:
establishing a milling sound pressure level model,
wherein the content of the first and second substances,
predicting the sound pressure level value;
is the acceleration root mean square value; v is the milling speed; v. offIs the feed rate; a ispMilling depth; c is a coefficient constant; x, y, z, w are indices;
taking logarithm of both ends of the formula (a) to obtain the following formula,
and obtaining the values of C, x, y, z and w by using a least square method based on data obtained by the milling test.
Furthermore, in the seventh step, a fitting model of the milling sound pressure level with respect to the milling parameters and the milling vibration is established as follows,
wherein the content of the first and second substances,
in order to predict the sound pressure level value,
is the root mean square value of the acceleration,v is the milling speed, vfFor the feed rate, apThe milling depth is C is a coefficient constant, and x, y, z and w are indexes;
taking logarithm at two ends of the formula (a) to obtain:
the sum of the squares of the errors is obtained by the least square method,
the general calculation formula of the correlation coefficient R is:
wherein x isi，yiTwo data sequences;
is the average of two data sequences.
The value of the correlation coefficient R is directly calculated by referring to MATLAB program [ R, P ] ═ corrcoef (x1, y 1).
Outputting the measured noise signal as sound pressure, and outputting effective value p of the sound pressureeAnd a reference sound pressure p0Is taken as the base 10 logarithm and multiplied by 20, i.e.
The sound pressure level L can be obtainedpAnd outputting the measured vibration signals as vibration acceleration in x, y and z directions, and performing time domain analysis and frequency domain analysis on the measured noise signals and vibration signals.
Carrying out data processing on the measured noise signal and the measured vibration signal, and selecting a sound pressure level root mean square value and x, y and z three-dimensional vibration acceleration root mean square values as characteristic values; and based on the principle of least square method, a regression model of the sound pressure level between the milling parameter and the three-way vibration acceleration is established, and the influence of the milling parameter and the milling vibration on the milling noise sound pressure level is analyzed.
The invention has the advantages that a set of complete and reasonable monitoring and correlation analysis system for milling noise and milling vibration is provided, and the change rules of the milling noise signal and the vibration signal along with milling time, frequency and milling parameters in the milling process of the aluminum alloy can be observed in real time; after the milling test is finished, characteristic values of the noise signal and the vibration signal can be extracted, and a time domain curve and a frequency domain curve of sound pressure of the noise signal and three-way vibration acceleration can be drawn; meanwhile, the change curves of the sound pressure level and the three-way vibration acceleration under different milling parameters can be drawn; in addition, a regression model of the milling noise sound pressure level relative to the milling parameters and the three-way milling vibration acceleration can be analyzed and established according to the measured test data, and the rule of mutual influence between the milling parameters and the three-way milling vibration acceleration is analyzed.
Drawings
The invention is further described below with reference to the accompanying drawings.
Fig. 1 is a schematic diagram of a milling noise and milling vibration monitoring and correlation analysis system according to the present invention.
Fig. 2 is a time domain diagram of the milling noise sound pressure within the acquisition time of 60s in the present invention.
Fig. 3 is a frequency domain plot of the mill noise sound pressure level of the present invention.
FIG. 4 is a time domain diagram of the milling three-way vibration acceleration of the present invention; wherein (a) is a time domain diagram of the x-direction vibration acceleration, the diagram (b) is a time domain diagram of the y-direction vibration acceleration, and the diagram (c) is a time domain diagram of the z-direction vibration acceleration.
Fig. 5 is a curve showing the variation of sound pressure level at different spindle speeds in the present invention.
Fig. 6 is a graph showing the variation of sound pressure level at different feed rates according to the present invention.
Fig. 7 is a graph showing the variation law of sound pressure level at different milling depths in the present invention.
Fig. 8 is a curve of the variation law of three-directional vibration acceleration under different spindle speeds in the present invention.
Fig. 9 is a curve of the change rule of three-direction vibration acceleration under different feeding speeds in the invention.
Fig. 10 is a curve of the change rule of three-direction vibration acceleration under different milling depths in the invention.
FIG. 11 is a comparison graph of the measured and fitted values of the RMS values of the sound pressure levels of the present invention.
Detailed Description
Example 1
The embodiment provides a milling noise and milling vibration monitoring and correlation analysis system, as shown in fig. 1, which comprises a numerical control machine tool and workpiece system, an acoustic and vibration measurement system and an acoustic and vibration correlation analysis system, wherein the numerical control machine tool and workpiece system mainly comprises a numerical control milling machine, a milling cutter and a processed workpiece; the acoustic and vibration measuring system mainly comprises a sound calibrator, a sound level meter, an acceleration sensor, a charge amplifier and a high-speed data acquisition instrument, and is used for acquiring noise signals and vibration signals in the workpiece processing process in real time; the acoustic and vibration correlation analysis system mainly comprises a computer and is used for carrying out real-time domain analysis, frequency domain analysis and correlation analysis on the collected noise signals and vibration signals. The sound level meter is arranged below the workpiece and is away from the workpiece by a certain distance and used for collecting sound pressure (noise) signals in the milling process; the acceleration sensor is arranged on a milling machine workbench and is arranged close to a workpiece and used for acquiring X, Y, Z three-way vibration signals in the milling process; the high-speed data acquisition instrument is provided with four voltage input signal channels which respectively receive a sound pressure signal and a three-way vibration signal, wherein one voltage input signal channel (channel 1) is connected with an alternating current signal output end of the sound level meter through a special data line, and the rest voltage input signal channels ( channels 2, 3 and 4) are connected with an output end of the charge amplifier; the acceleration sensor is provided with three output ends which are respectively connected with the input ends of the three charge amplifiers, and the current signals are converted into voltage signals through the connected charge amplifiers. The milling cutter is arranged on a main shaft of the vertical milling machine, the material of the milling cutter is a high-speed steel aluminum-containing material, the milling cutter is a high-speed steel straight shank end milling cutter, and a workpiece is clamped on a workbench of the milling machine. The sound level meter is an HS5661 type precision sound level meter; a microphone is arranged at the top end of the sound level meter, and tail threads are arranged at the tail part of the microphone; the top end of the front pole of the sound level meter is provided with top end threads, the tail threads of the microphone are aligned with the top end threads of the front pole of the sound level meter, the microphone and the front pole of the sound level meter are coaxial, and the microphone is rotated into the front pole of the sound level meter in a clockwise direction; the top end of the microphone is screwed into a bottom hole of the sound calibrator which is mainly used for calibrating the sound level meter, and the sound calibrator is taken down after the calibration is finished. The acceleration sensor is a piezoelectric type three-way acceleration sensor, the piezoelectric type three-way acceleration sensor is fixedly connected with a clamp platform for clamping a workpiece on a milling machine workbench through a magnetic base, and the acceleration sensor amplifies collected charge signals and outputs voltage signals through being connected with a charge amplifier. The output interface of the high-speed data acquisition instrument is connected with the interface of a computer through a USB data transmission line, and acoustic and vibration measurement acquisition software is installed in the computer.
A milling noise and milling vibration monitoring and correlation analysis method comprises the following steps:
first step, build milling test system
The milling test system comprises a numerical control machine tool and workpiece system, an acoustic and vibration measurement system and an acoustic and vibration correlation analysis system, wherein the numerical control machine tool and workpiece system mainly comprises a numerical control milling machine, a milling cutter and a processed workpiece; the acoustic and vibration measuring system mainly comprises a sound calibrator, a sound level meter, an acceleration sensor, a charge amplifier and a high-speed data acquisition instrument, wherein the sound calibrator is used for calibrating a sound pressure level, the sound level meter is connected with the high-speed data acquisition instrument and then used for acquiring a noise signal, the measured noise signal is a signal obtained by deducting background noise, the acceleration sensor is connected with the high-speed data acquisition instrument through the charge amplifier and then used for acquiring a vibration signal, and the measured vibration signal is a signal obtained by deducting background vibration; the acoustic and vibration correlation analysis system is mainly composed of a computer.
Second, prepare the workpiece
Firstly, according to a milling test scheme and the existing materials in a laboratory, selecting a square aluminum alloy material with the length of 100mm, the width of 40mm and the height of 100mm as a workpiece to be processed, and then clamping the selected workpiece on a milling machine workbench.
Thirdly, connecting and calibrating the test equipment
(1) After the power supply of the high-speed data acquisition instrument is turned off, the high-speed data acquisition instrument is connected with a computer provided with acoustic and vibration measurement acquisition software through a USB data transmission line;
(2) the method comprises the steps that an acceleration sensor is adsorbed on a clamp platform for clamping a workpiece through a super-strong magnetic seat, X, Y, Z three directions of the acceleration sensor respectively correspond to X, Y, Z three directions of a numerically controlled milling machine, three output ends of the acceleration sensor are respectively connected to input ends of three charge amplifiers, the sensitivity of the charge amplifiers is adjusted, the sensitivity of the three charge amplifiers respectively corresponds to the sensitivity of the acceleration sensor in three directions, then the output ends of the three charge amplifiers are respectively connected with 2 channels, 3 channels and 4 channels of a high-speed data acquisition instrument, voltage output is realized, and the channels 1, 2, 3 and 4 of the high-speed data acquisition instrument are changed into voltage input during testing;
(3) the sound level meter is arranged at a position 0.85 meters away from the workpiece, and is connected with a channel 1 of the high-speed data acquisition instrument through a special data line and is used for outputting voltage;
(4) turning on a power supply of the high-speed data acquisition instrument, turning on acoustic and vibration measurement software on a computer desktop, rotating the top end of a microphone into the bottom end of a sound calibrator, starting a button switch of the sound calibrator, calibrating a sensor of the precise sound level meter after 3-5 seconds, indicating that the instrument can be normally used when a sound pressure value is displayed to be about 6.66, and taking down the sound calibrator after calibration is finished;
(5) setting acoustic and vibration measurement acquisition parameters, defining a file and a file storage path, and then setting sampling frequency, acquisition time, sampling number and the like;
(6) before the test is formally started, the milling machine is started, background measurement is carried out, if background noise and background vibration are to be deducted, and a background deduction measurement button is clicked.
Fourthly, designing the operator work division scheme and carrying out milling test
By formulating a milling test scheme, a milling test is carried out according to different milling parameters, and the milling noise signal and the vibration signal are synchronously acquired in the test. In the milling test process, four persons are needed to cooperate and finish together. Wherein, 1 person is responsible for operating the numerical control milling machine and changing milling parameters to finish noise and vibration measurement under different conditions; 1 person is responsible for reading and reporting the milling parameters of each test and recording the test condition in the milling test process; 1 person is responsible for operating acoustic and vibration measurement software and storing data, a time domain diagram and a frequency domain diagram of each test; and 1 person is responsible for taking a picture in the test process and taking a picture of the workpiece processed each time in the test process. The steps of the task allocation and the milling test of the personnel are as follows:
(1) before the test, a photographer takes a picture of a workpiece which is not processed for comparison with the processed workpiece, and simultaneously takes the relative positions of the sound level meter, the acceleration sensor and the workpiece;
(2) the device is responsible for recording the numerical value of the milling parameter of the test read and reported by a person in the test before the test starts each time;
(3) a person in charge of operating the numerical control milling machine inputs a machining program and milling parameters corresponding to the test on a control panel of the milling machine and inquires whether the person in the field is ready to start the test;
(4) a person in charge of operating the acoustic and vibration measurement software firstly makes background noise and vibration deduction, and after completion, the person is ready to start a test;
(5) when all personnel are ready for testing, the personnel in charge of operating the numerically controlled milling machine display the data "start" according to the operating panel;
(6) the personnel responsible for operating the acoustic and vibration measurement software click the 'acquisition' button on the software interface;
(7) after the collection is finished, the collected data of the test is stored, and the storage position and the name of the next test are set.
Fifthly, sorting the required characteristic values based on milling test data
From the acoustic and vibration measurement software and the correlation analysis system thereof, time domain analysis and frequency domain analysis of the acoustic signal and the three-way vibration acceleration signal can be carried out, and a time domain graph (see fig. 2) of the sound pressure variation with time, a frequency domain graph (see fig. 3) of the sound pressure variation with frequency and a time domain graph (see fig. 4) of the three-way acceleration can be obtained. From the collected data of the noise signal and the vibration signal, the root mean square value of the sound pressure level, the root mean square value of the sound power level, and the root mean square values of three-way acceleration, speed and displacement can be obtained.
Sixthly, drawing a noise signal and vibration signal curve
And drawing a change curve of sound pressure level and three-way acceleration under different milling parameters based on the acquired milling test data.
Seventhly, analyzing the mutual influence between milling noise and milling vibration
The change rules of sound pressure level and three-way acceleration under different milling parameters can be drawn by changing the rotation speed, the feed speed and the milling depth of the milling spindle, regression model analysis is carried out on variables in a milling test, and a regression model between the sound pressure level and the milling parameters as well as between the milling vibrations can be established, so that correlation analysis between milling noises and the milling vibrations is carried out, and the influence rules of the milling parameters and the vibrations on the milling noises are obtained.
Knowing the milling speed v, the feed speed vfMilling depth apAcceleration root mean square value
And sound pressure level LpAnd establishing a fitting relation of the milling sound pressure level relative to the milling parameters and the milling vibration acceleration:
establishing a milling sound pressure level model,
wherein the content of the first and second substances,
predicting the sound pressure level value;
is the acceleration root mean square value; v is the milling speed; v. offIs the feed rate; a ispMilling depth; c is a coefficient constant; x, y, z, w are indices;
taking logarithm of both ends of the formula (a) to obtain the following formula,
based on the data obtained from the milling experiments, the values for C, x, y, z, w were obtained using the least squares method and MATLAB programming (see appendix).
In the milling test process, the milling parameters comprise milling speed v and feeding speed vfAnd milling depth ap(ii) a An aluminum alloy square body with the length of 100mm, the width of 40mm and the height of 100mm is adopted as a milling material; a three-way acceleration sensor, a sound level meter and an acoustic and vibration measuring instrument of YD-21 model manufactured by Beijing spectral company are adopted. Wherein, four levels are selected to main shaft rotational speed n, and are respectively: 800 rpm, 1200 rpm, 1600 rpm, 2000 rpm; feed velocity vfFour levels of 10mm/min, 15 mm/min, 20 mm/min, 25 mm/min; milling depth apThe sampling time is 60s, and the sampling frequency is 2000 Hz. The specific test protocol is shown in table 1.
TABLE 1 milling test protocol
(1) Law of sound pressure level change under different milling parameters
The change rule of the milling sound pressure level under different milling parameters can be compared. FIG. 5 shows the feed speed v being maintainedfIs 10mm/min, milling depth apThe curve is a change rule curve of sound pressure levels under different main shaft rotating speeds under the condition of not changing 5 mm; FIG. 6 shows that the rotation speed n of the spindle is maintained at 800r/min, and the milling depth a is maintainedpThe curve is a change rule curve of sound pressure levels at different feeding speeds under the condition of not changing 5 mm; FIG. 7 shows the principle of keeping the spindle speed n at 800r/min and the feed speed vfThe curve is the change rule curve of the sound pressure level under different milling depths under the condition of keeping 10mm/min unchanged.
(2) Rule of change of three-dimensional vibration acceleration under different milling parameters
The change rule of the three-direction vibration acceleration under different milling parameters can be compared. FIG. 8 shows the feed speed v being maintainedfIs 10mm/min, milling depth apThe curve is a change rule curve of three-dimensional vibration acceleration under different main shaft rotating speeds under the condition of not changing 5 mm; FIG. 9 shows the milling depth a with the spindle speed n maintained at 800r/minpThe curve is a change rule curve of three-dimensional vibration acceleration under different feeding speeds under the condition of not changing 5 mm; FIG. 10 shows the principle of keeping the spindle speed n at 800r/min and the feed speed vfThe three-direction vibration acceleration curve is a change rule curve of three-direction vibration acceleration under different milling depths under the condition that 10mm/min is not changed.
As can be seen from the graph, the acceleration value in the x direction is large, the vibration generated in the x direction is large, and the vibration generated in the y direction and the z direction is small.
(3) Analysis of correlation between milling sound pressure level and milling parameter and milling vibration
Due to the fact that
The diameter of the milling tool is 10mm, so that a value of the milling speed v can be obtained, the unit of the milling speed v is m/min, the unit of the sound pressure level and the sound power level is dB, and the unit of the acceleration is m/s2. The test data obtained by the milling test are shown in table 2.
TABLE 2 milling test data
Therefore, a fitting model of the milling sound pressure level relative to the milling parameters and the milling vibration is established,
wherein the content of the first and second substances,
in order to predict the sound pressure level value,
is the acceleration root mean square value, v is the milling speed, vfFor the feed rate, apThe milling depth is C is a coefficient constant, and x, y, z and w are indexes;
taking logarithm at two ends of the formula (a) to obtain:
the sum of the squares of the errors is obtained by the least square method,
the general calculation formula of the correlation coefficient R is:
wherein x isi，yiTwo data sequences;
is the average of two data sequences.
The value of the correlation coefficient R is directly calculated by referring to MATLAB program [ R, P ] ═ corrcoef (x1, y 1).
Taking x-direction acceleration root mean square value as an example, based on the principle of least square method, using MATLAB programming in the appendix, C is 72.6151, x is 0.05843, y is 0.00525, z is-0.05205, w is 0.06567, and R is 0.90, so it can be seen that the correlation coefficient R between the milling sound pressure level and the milling parameter, milling vibration is high, and fig. 11 is a comparison graph of the sound pressure level fitting value and the measured value.
Claims (8)
1. A milling noise and milling vibration monitoring and correlation analysis method is characterized by comprising the following steps:
the method comprises the following steps of firstly, establishing a milling test system, wherein the milling test system comprises a numerical control machine tool and workpiece system, an acoustic and vibration measurement system and an acoustic and vibration correlation analysis system, and the numerical control machine tool and workpiece system mainly comprises a numerical control milling machine, a milling cutter and a processed workpiece; the acoustic and vibration measuring system mainly comprises a sound calibrator, a sound level meter, an acceleration sensor, a charge amplifier and a high-speed data acquisition instrument, wherein the sound calibrator is used for calibrating sound pressure level, the sound level meter is connected with the high-speed data acquisition instrument and then used for acquiring noise signals, and the acceleration sensor is connected with the high-speed data acquisition instrument through the charge amplifier and then used for acquiring vibration signals; the acoustic and vibration correlation analysis system mainly comprises a computer;
secondly, preparing a workpiece, namely selecting a square aluminum alloy material as the workpiece to be processed, and clamping the selected workpiece on a milling machine workbench;
thirdly, connecting and calibrating test equipment;
fourthly, a milling test, namely starting a milling machine tool to process the workpiece, and acquiring a noise signal and a vibration signal in the milling process;
fifthly, obtaining a root mean square value of sound pressure level, a root mean square value of sound power level, a root mean square value of three-way acceleration, velocity and displacement from the collected data of the noise signal and the vibration signal based on the characteristic value required by milling test data arrangement;
sixthly, drawing a noise signal and vibration signal curve;
seventhly, analyzing the mutual influence between the milling noise and the milling vibration, namely changing the rotation speed, the feeding speed and the milling depth of the milling spindle, drawing the change rule of sound pressure level and three-way acceleration under different milling parameters, carrying out regression model analysis on variables in a milling test, and establishing a regression model between the sound pressure level and the milling parameter as well as the milling vibration, thereby carrying out correlation analysis between the milling noise and the milling vibration and obtaining the influence rule of the milling parameter and the milling vibration on the milling noise; given a milling speed v, a feed speed vfMilling depth apAcceleration root mean square value
And sound pressure level LpAnd establishing a fitting relation of the milling sound pressure level relative to the milling parameters and the milling vibration acceleration:
establishing a milling sound pressure level model,
wherein the content of the first and second substances,
predicting the sound pressure level value;
is the acceleration root mean square value;
is the milling speed;
is the feed rate; a ispMilling depth;
is a coefficient constant;
is an index;
taking logarithm of both ends of the formula (a) to obtain the following formula,
based on data obtained by a milling test, obtaining values of C, x, y, z and w by MATLAB programming in an appendix by using a least square method;
establishing a fitting model of the milling sound pressure level relative to the milling parameters and the milling vibration,
wherein the content of the first and second substances,
in order to predict the sound pressure level value,
is the root mean square value of the acceleration,
in order to be the milling speed, the milling speed is,
for the feed rate, apIn order to mill the depth of the hole,
is a constant of the coefficient(s),
is an index;
taking logarithm at two ends of the formula (a) to obtain:
the sum of the squares of the errors is obtained by the least square method,
the general calculation formula of the correlation coefficient R is:
wherein the content of the first and second substances,
two data sequences;
is the average of two data sequences;
the value of the correlation coefficient R is directly calculated by referring to MATLAB program [ R, P ] = corrcoef (x1, y 1).
2. The method for monitoring and analyzing the milling noise and the milling vibration according to claim 1, wherein in the third step, the specific method for connecting and calibrating the test equipment is as follows:
(1) after the power supply of the high-speed data acquisition instrument is turned off, the high-speed data acquisition instrument is connected with a computer provided with acoustic and vibration measurement acquisition software through a USB data transmission line;
(2) the method comprises the following steps that an acceleration sensor is adsorbed on a clamp platform for clamping a workpiece through a magnetic seat, three X, Y, Z directions of the acceleration sensor respectively correspond to the X, Y, Z directions of a numerically controlled milling machine, three output ends of the acceleration sensor are respectively connected to the input ends of three charge amplifiers, and then the output end of the charge amplifier is connected with a high-speed data acquisition instrument;
(3) the sound level meter is arranged at a certain distance from the workpiece and is connected with the high-speed data acquisition instrument through a special data line;
(4) turning on a power supply of the high-speed data acquisition instrument, turning on acoustic and vibration measurement software on a computer desktop, rotating the top end of a microphone into the bottom end of a sound calibrator, starting a button switch of the sound calibrator, calibrating a sensor of a sound level meter after 3-5 seconds, indicating that the sound level meter can be normally used when a sound pressure value is displayed as 6.66, and taking down the sound calibrator after calibration is finished;
(5) setting acoustic and vibration measurement acquisition parameters, defining a file and a file storage path, and then setting sampling frequency, acquisition time and sampling number;
(6) before the test is formally started, the milling machine is started, background measurement is carried out, and the background measurement is deducted.
3. Milling noise and milling vibration monitoring and correlation analysis system based on the method of claim 2, characterized in that: the system comprises a numerical control machine tool and workpiece system, an acoustic and vibration measurement system and an acoustic and vibration correlation analysis system, wherein the numerical control machine tool and workpiece system mainly comprises a numerical control milling machine, a milling cutter and a processed workpiece; the acoustic and vibration measuring system mainly comprises a sound calibrator, a sound level meter, an acceleration sensor, a charge amplifier and a high-speed data acquisition instrument, and is used for acquiring noise signals and vibration signals in the workpiece processing process in real time; the acoustic and vibration correlation analysis system mainly comprises a computer and is used for carrying out real-time domain analysis, frequency domain analysis and correlation analysis on the collected noise signals and vibration signals.
4. The milling noise and milling vibration monitoring and correlation analysis system of claim 3, wherein the system comprises: the sound calibrator is mainly used for calibrating the sound level meter; the sound level meter is arranged below the workpiece and is at a certain distance from the workpiece, and is used for acquiring a sound pressure signal in the milling process; the acceleration sensor is arranged on a milling machine workbench and is arranged close to a workpiece and used for acquiring X, Y, Z three-way vibration signals in the milling process; the high-speed data acquisition instrument is provided with at least four voltage input signal channels, wherein one voltage input signal channel is connected with the alternating current signal output end of the sound level meter, and the rest voltage input signal channels are connected with the output end of the charge amplifier; the acceleration sensor is provided with three output ends which are respectively connected with the input ends of the three charge amplifiers.
5. The milling noise and milling vibration monitoring and correlation analysis system of claim 4, wherein the system comprises: the milling cutter is installed on a main shaft of the vertical milling machine, the milling cutter is made of high-speed steel aluminum-containing materials, and the workpiece is clamped on a workbench of the milling machine.
6. The milling noise and milling vibration monitoring and correlation analysis system of claim 5, wherein the system comprises: the sound level meter is an HS5661 type precision sound level meter; a microphone is arranged at the top end of the sound level meter, and tail threads are arranged at the tail of the microphone; the top end of the front pole of the sound level meter is provided with top end threads, the tail threads of the microphone align with the top end threads of the front pole of the sound level meter, the microphone and the front pole of the sound level meter are coaxial, the microphone is rotated into the front pole of the sound level meter in a clockwise direction, and the top end of the microphone is rotated into a bottom end hole of the sound calibrator.
7. The milling noise and milling vibration monitoring and correlation analysis system of claim 6, wherein: the acceleration sensor is a piezoelectric type three-way acceleration sensor, and the piezoelectric type three-way acceleration sensor is fixedly connected with a clamp platform for clamping a workpiece on a milling machine workbench through a magnetic base.
8. The milling noise and milling vibration monitoring and correlation analysis system of claim 7, wherein: the output interface of the high-speed data acquisition instrument is connected with the interface of a computer through a USB data transmission line, and acoustic and vibration measurement acquisition software is installed in the computer.
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