CN111158315B - Milling stability prediction method based on spline-Newton formula - Google Patents
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Abstract
The invention discloses a milling stability prediction method based on a spline-Newton formula, which comprises the following steps: (1) establishing a system dynamic model considering regeneration flutter; (2) dispersing the time-lapse differential equation; (3) interpolating the equation discrete interval; (4) establishing a milling system transfer matrix; (5) performing stability analysis on the milling system based on the Floque theory; (6) and optimizing the prediction method. The method greatly improves the precision and the calculation efficiency, and saves about 70 percent of calculation time compared with the prior calculation method under the same calculation condition; meanwhile, the algorithm is optimized, so that the accuracy of the algorithm is not lost under the condition of ensuring high efficiency.
Description
Technical Field
The invention belongs to the technical field of manufacturing of complex thin-wall parts, and particularly relates to a spline-Newton formula-based milling stability prediction method which is mainly applied to stability prediction of complex thin-wall parts machined by numerical control multiple shafts.
Background
With the rapid development of the modern aviation and aerospace industries, various high-performance products need to be developed to meet the market demands. In order to better reduce the self weight of the airplane and meet the structural strength requirement, a large number of thin-wall parts are applied to the aerospace field, such as integral blade discs, blades and the like of the airplane. When the thin-wall parts are milled, the thin-wall parts have extremely poor processing manufacturability due to the reasons of complex structure, thin wall, poor rigidity, complex time-varying dynamic characteristics in the processing process and the like, and are very easy to generate flutter and processing deformation, so that the requirements on the position precision and the surface quality of the parts are finally difficult to meet. Therefore, important engineering application value is achieved in order to better inhibit the vibration in the machining process, accurately predict the milling machining stability and then preferably select reasonable cutting parameters to avoid milling vibration.
In general, in the milling process, a milling process dynamic model considering the regeneration effect is expressed by a multi-dimensional time-lag differential equation, the differential equation is solved by different methods, a system stable lobe graph is calculated, and high system stability prediction efficiency and accuracy are obtained. At present, the most widely used method is a time domain stability analysis method based on a differential equation, in which a milling system is dispersed in a time domain, and then the stability of a control equation is directly analyzed to judge whether the milling process is stable. See for details the references [ Y. Ding, L.M. Zhu, X.J. Zhang, H. Ding, A full-differentiation method for prediction of milking stability, international Journal of Machine Tools and Manual 50 (2010) 502-509]. Because the matrix index involved in the method is calculated only in the outer ring of the scanning spindle speed range and does not need to be updated in the inner ring of the scanning cutting depth range, the efficiency and the accuracy of the method are remarkably improved. However, when the method performs interpolation processing on the state term and the time lag term of the time lag differential equation, linear interpolation is adopted, the precision of the method only depends on two points of boundary values, and meanwhile, the derivative term is not considered, so that the precision of the method can be further improved.
Disclosure of Invention
The invention provides a spline-Newton formula-based milling stability prediction method capable of improving milling efficiency and accuracy, aiming at overcoming the defects in the prior art.
In order to solve the technical problems, the invention adopts the following technical scheme: a milling stability prediction method based on a spline-Newton formula comprises the following steps,
(1) establishing a system dynamic model considering regeneration flutter;
(2) dispersing the time-lapse differential equation;
(3) interpolating the equation discrete interval;
(4) establishing a milling system transfer matrix;
(5) performing stability analysis on the milling system based on the Floquet theory;
(6) and optimizing the prediction method.
The specific process of the step (1) is that,
first establishing formula (1)
Wherein, the first and the second end of the pipe are connected with each other,M、C、Krespectively representing the modal mass, relative damping and stiffness matrices of the tool,、、respectively representing the acceleration, velocity and displacement vectors of the tool,is a matrix of periodic coefficients and is,Tfor a single tooth transfer cycle, and,Nthe number of the cutter teeth of the cutter is,the main shaft rotating speed;
a in the formula (2) 0 Is a constant coefficient matrix of the cutter teeth, A (t) is a periodic coefficient matrix of the cutter teeth, and has:
the step (2) is specifically that,
in one tooth revolution periodTInterior, willTAre equally divided intomBetween cells, and the time length of each cell ishThen there isT=mhTaking the periodTWithin a certain time periodkh≤t≤(k+1)h,(k=0,1…,m) The initial condition of this period is known asRecord ofFor equation (2), the direct integration over this interval is:
order tot=kh+hComprises the following steps:
the simplification has:
the step (3) is specifically that,
by using, , , Four point to state itemsCarrying out cubic spline interpolation; in addition, when spline interpolation is adopted, two additional constraint conditions are required to be added, and the constraint conditions can be selectedAndtwo known conditions are as follows
The status item can be expressed as:
wherein:
Iis an identity matrix;
wherein:
the linear interpolation used for the periodic coefficient matrix is:
wherein:
and (3) bringing the interpolated state item, the interpolated time lag item and the interpolated periodic coefficient matrix item into a formula (6), wherein the time lag differential equation becomes an ordinary differential equation, and the expression is as follows:
wherein:
meanwhile, define:
the integral transform formula (17) includes:
the coefficient matrix term in equation (16) can be expressed as follows:
the concrete step (4) is that,
defining a mapping relation:
wherein:
then there are:
therefore, the method comprises the following steps:
solving a system transfer matrix as follows:
the concrete step (5) is that,
calculating all characteristic values of transfer matrixQ(V) If the moduli of all the characteristic values are less than 1, the system is stable, otherwise, the system is unstable, that is:
the concrete step (6) is that,
in the method, during calculation, 7 items of numerical values in the transfer matrix need to be calculated in each discrete interval, and the method in the reference only needs to calculate 4 items of numerical values, so theoretically, the method in the reference is slightly higher than the method in the aspect of calculation efficiency; in order to solve the problem, a simple optimization method is proposed to improve the calculation speed; when calculating the eigenvalue of the transfer matrix, the traditional method needs to calculate the corresponding eigenvalue of all the main shaft rotating speeds and cutting depths, and then finds out the critical point with the corresponding eigenvalue of 1 to make a contour line, thereby drawing a milling stability lobe graph; the optimized prediction method comprises the steps of adding a judgment instruction into an algorithm, sequentially calculating a characteristic value of each cutting depth from the minimum cutting depth under the condition of a certain spindle rotation speed, judging whether the characteristic value is less than or equal to 1, continuing to calculate downwards if the characteristic value is less than or equal to 1, jumping out of the spindle rotation speed if the characteristic value is greater than 1, entering the next cycle, and calculating the characteristic value of another spindle rotation speed state; the method only calculates the characteristic values of the transfer matrixes in the stable area and the critical stable area, and omits the calculation of the characteristic values of the unstable area; and finally, drawing a milling stability lobe graph according to a calculation result of the critical stability region.
By adopting the technical scheme, the invention has the following beneficial effects:
(1) In the aspect of precision, a cubic spline and a Newton formula are adopted to carry out interpolation processing on a state term and a time lag term of a dynamic time lag differential equation respectively, a plurality of known terms are utilized to approximate an approximate unknown term, and meanwhile, the cubic spline uses the derivative term, so that the result is more accurate. Compared with the first-order fully-discrete method in the reference, the precision and the convergence rate of the method are obviously improved.
(2) In terms of calculation efficiency, the calculation of the unstable region is omitted by calculating the characteristic values of the stable region and the critical stable region, and the contour line can be drawn only by knowing the position of the critical stable region. In the experiment, under the same computing environment, the time required by the first-order full discretization method is 48s, the prediction method only needs 15s, the computing time is saved by about 70%, and the accuracy of the algorithm is not lost under the condition of ensuring high efficiency.
Drawings
FIG. 1 is a flow chart of the steps of the present invention;
FIG. 2 is a graph of the stability lobe of the present invention at a dip ratio of 0.05 for a single degree of freedom;
FIG. 3 is a graph of the stability lobe of the present invention at a dip ratio of 0.1 for a single degree of freedom;
FIG. 4 is a graph of the stability lobe of the present invention at an immersion ratio of 1 for a single degree of freedom.
Detailed Description
The feasibility and the effectiveness of the method are illustrated by taking a single-degree-of-freedom system as an example, as shown in fig. 1, the method for predicting the milling stability based on the spline-newton formula comprises the following operation steps:
(1) establishing a system dynamics model considering regenerative flutter
In the formula (I), the compound is shown in the specification,q(t) is the system vibration response,m t 、z、w n respectively representing modal mass, relative damping factor and angular natural frequency,wthe depth of cut is indicated by a scale,h(t) is the cutting force coefficient equation, having:
in the formula (I), the compound is shown in the specification,k t 、k n all the coefficients of the cutting force are the coefficients of the cutting force,Nthe number of the cutter teeth is shown,is a firstjThe angular position of each cutter tooth, and having:
wherein the content of the first and second substances,、respectively represent the firstjThe angular position at which each tooth begins and ends cutting.
The forward milling comprises the following steps:
the reverse milling is carried out by:
wherein a/D is the radial immersion ratio.
a in the formula (7) 0 Is a constant coefficient matrix of the cutter teeth, A (t) is a periodic coefficient matrix of the cutter teeth, and has:
(2) discretizing time-lapse differential equations
In one tooth revolution periodTIn the interior, willTAre equally divided intomBetween cells, and the time length of each cell ishThen there isT=mhTaking a periodTWithin a certain time periodkh≤t≤(k+1)h,(k=0,1…, m) The initial condition of this period is known asMemory for recordingFor equation (7), the direct integration over this interval is:
let t = kh + h have:
the simplification is as follows:
(3) interpolating equation discrete interval
By usingFour point to state itemsCubic spline interpolation is performed. In addition, when spline interpolation is adopted, two additional constraint conditions are required to be added, and the constraint conditions can be selectedAndtwo known conditions are as follows
The status item can be expressed as:
wherein:
Iis an identity matrix.
wherein:
the linear interpolation used for the periodic coefficient matrix is:
wherein:
the interpolated state item, the interpolated time lag item and the interpolated periodic coefficient matrix item are brought into a formula (11), and the time lag differential equation becomes an ordinary differential equation at the moment, wherein the expression is as follows:
wherein:
meanwhile, define:
the integral transformation formula (22) includes:
the coefficient matrix term in equation (16) can be expressed as follows:
(4) establishing a system transfer matrix
defining a mapping relation:
wherein:
then there are:
therefore, the method comprises the following steps:
solving a system transfer matrix as follows:
(5) stability analysis of system based on Floquet theory
Calculating all characteristic values of transfer matrixQ(V) If the moduli of all the characteristic values are less than 1, the system is stable, otherwise, the system is unstable, that is:
(6) optimization prediction method
In the calculation of the method, the values of 7 items in the transfer matrix need to be calculated in each discrete interval, and the method in the reference only needs to calculate 4 items, so theoretically, the method in the reference is slightly higher than the method in the aspect of calculation efficiency. To solve this problem, a simple optimization method is proposed to increase the calculation speed. When the eigenvalue of the transfer matrix is calculated in the traditional method, the corresponding eigenvalue of all the main shaft rotating speeds and cutting depths needs to be calculated, and then the critical point with the corresponding eigenvalue of 1 is found out to be taken as a contour line, so that a milling stability lobe graph is drawn. The optimization prediction method comprises the steps of adding a judgment instruction into an algorithm, sequentially calculating a characteristic value of each cutting depth from the minimum cutting depth under the condition of a certain spindle rotation speed, judging whether the characteristic value is less than or equal to 1, continuing to calculate downwards if the characteristic value is less than or equal to 1, jumping out of the spindle rotation speed if the characteristic value is greater than 1, entering the next cycle, and calculating the characteristic value of the other spindle rotation speed state. That is, the proposed prediction method calculates only the eigenvalues of the transfer matrix in the stable region and the critical stable region, and omits the eigenvalue calculation of the unstable region. And finally, drawing a milling stability lobe graph according to the calculation result of the critical stability region.
The process parameters were chosen in accordance with the data in the reference, where: the forward milling is carried out, the number of the cutter teeth is 2,0.03993kg, 0.11 kg and,The tangential force coefficient Kt and the normal phase force coefficient Kn are respectivelyAndthe rotation speed of the tool spindle is from 5000rpm to 25000rpm, and the cutting depth is from 0 to 10mm.
The formula and the data are used for calculating a milling stability lobe graph, the radial immersion ratio a/D is respectively selected to be 0.05, 0.1 and 1, and the milling stability lobe graph is obtained and is shown in figures 2, 3 and 4.
The present embodiment is not intended to limit the shape, material, structure, etc. of the present invention in any way, and any simple modification, equivalent change and modification made to the above embodiments according to the technical spirit of the present invention are within the scope of the technical solution of the present invention.
Claims (3)
1. A milling stability prediction method based on a spline-Newton formula is characterized in that: comprises the following steps of (a) preparing a solution,
(1) establishing a system dynamic model considering regeneration flutter;
(2) dispersing the time-lapse differential equation;
(3) interpolating the equation discrete interval;
(4) establishing a milling system transfer matrix;
(5) performing stability analysis on the milling system based on the Floque theory;
(6) optimizing the prediction method;
the specific process of the step (1) is that,
first establishing formula (1)
Wherein M, C and K respectively represent modal mass, relative damping and rigidity matrix of the cutter,q (t) represents the acceleration, velocity and displacement vector of the tool, respectively, K c (T) is a periodic coefficient matrix, T is a single cutter tooth transmission period, T =60/N Ω, N is the number of cutter teeth of the cutter, and Ω is the rotation speed of the main shaft;
let X (t) = [ q (t) p (t)] T ,By simplification, the formula (1) can be reduced to the following form:
a in the formula (2) 0 Is a constant coefficient matrix of the cutter teeth, A (t) is a periodic coefficient matrix of the cutter teeth, and has:
the step (2) is specifically that,
in the rotation period T of one cutter tooth, dividing T into m small partsInterval, and the time length of each small interval is h, then T = mh, a certain time period kh in the period T is not less than T and not more than (k + 1) h, (k =0,1 \8230;, m), and the initial condition of the time period is X k Record X k = X (kh), and the direct integral over this interval for equation (2) is:
let t = kh + h have:
the simplification is as follows:
the concrete step (3) is that,
by X k+1 ,X k ,X k-1 ,X k-2 Carrying out cubic spline interpolation on the state item X (kh + h-epsilon) by four points; in addition, when spline interpolation is adopted, two additional constraint conditions are required to be added, and the constraint conditions can be selectedAndtwo known conditions are as follows
The status item can be expressed as:
X(kh+h-ε)=μ 1 X k+1 +μ 2 X k +μ 3 X k-1 +μ 4 X k-2 (9)
wherein:
i is an identity matrix;
by X k-m ,X k-m+1 ,X k-m+2 ,X k-m+3 Carrying out Newton interpolation on the time lag term X (kh + h-epsilon-T) by four points; then there are:
X(kh+h-ε-T)=λ 1 X k-m +λ 2 X k-m+1 +λ 3 X k-m+2 +λ 4 X k-m+3 (11)
wherein:
the linear interpolation used for the periodic coefficient matrix is:
A(kh+h-ε)=A u +A v ε (13)
wherein:
A u =A k+1 A v =(A k -A k+1 )/h (14)
and (3) bringing the interpolated state term, the interpolated time lag term and the interpolated periodic coefficient matrix term into an equation (6), wherein the time lag differential equation becomes an ordinary differential equation, and the expression is as follows:
wherein:
meanwhile, define:
the integral transformation formula (17) includes:
the coefficient matrix term in equation (16) can be expressed as follows:
the step (4) is specifically that,
if the matrix P k+1 Is singular, then equation (15) can be:
defining a mapping relation:
N k+1 =D k N k (21)
wherein:
N k =[X k ,X k-1 ,…,X k-m+1 ,X k-m ] T (22)
then there are:
therefore, the method comprises the following steps:
N m =VN 0 (24)
solving a system transfer matrix as follows:
V=D m-1 D m-2 …D 0 (25)。
2. the spline-Newton formula-based milling stability prediction method of claim 1, wherein: the concrete step (5) is that,
calculating the modulus of all eigenvalues Q (V) of the transfer matrix, if the modulus of all eigenvalues is less than 1, the system is stable, otherwise, the system is unstable, namely:
3. the milling stability prediction method based on the spline-Newton formula according to claim 2, wherein: the concrete step (6) is that,
in the method, during calculation, 7 items of numerical values in the transfer matrix need to be calculated in each discrete interval, and the method in the reference only needs to calculate 4 items of numerical values, so theoretically, the method in the reference is slightly higher than the method in the aspect of calculation efficiency; in order to solve the problem, a simple optimization method is proposed to improve the calculation speed; when calculating the eigenvalue of the transfer matrix, the traditional method needs to calculate the corresponding eigenvalue of all the main shaft rotating speeds and cutting depths, and then finds out the critical point with the corresponding eigenvalue of 1 to make a contour line, thereby drawing a milling stability lobe graph; the optimization prediction method comprises the steps of adding a judgment instruction into an algorithm, sequentially calculating a characteristic value of each cutting depth from the minimum cutting depth under the condition of a certain spindle rotation speed, judging whether the characteristic value is less than or equal to 1, continuing to calculate downwards if the characteristic value is less than or equal to 1, jumping out of the spindle rotation speed if the characteristic value is greater than 1, entering the next cycle, and calculating the characteristic value of the other spindle rotation speed state; the method only calculates the characteristic values of the transfer matrixes in the stable area and the critical stable area, and omits the calculation of the characteristic values of the unstable area; and finally, drawing a milling stability lobe graph according to a calculation result of the critical stability region.
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