CN111843630B - Magnetorheological deterministic shaping method and device for outer circle surface of shaft part - Google Patents
Magnetorheological deterministic shaping method and device for outer circle surface of shaft part Download PDFInfo
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- CN111843630B CN111843630B CN202010763016.3A CN202010763016A CN111843630B CN 111843630 B CN111843630 B CN 111843630B CN 202010763016 A CN202010763016 A CN 202010763016A CN 111843630 B CN111843630 B CN 111843630B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
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- B24B1/005—Processes of grinding or polishing; Use of auxiliary equipment in connection with such processes using a magnetic polishing agent
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Abstract
The invention discloses a magnetorheological deterministic shape modifying method and device for the outer circle surface of a shaft part. The method of the invention comprises the following steps: measuring by using a cylindricity instrument to obtain shape error data of the surface of the shaft part to be processed; filtering the shape error data; selecting a magnetorheological polishing wheel with a proper size according to the processed shape error data, and processing the shaft part to be processed by using a shaft type magnetorheological shape-modifying machine tool under the given processing parameters to obtain a removal function; calculating residence time in process software according to the processed shape error data and the obtained removal function to perform simulation processing until the requirements are met; and generating a processing code of the numerical control machine tool by using process software, and importing the processing code into the shaft type magneto-rheological modification machine tool for processing. The invention applies the magneto-rheological deterministic shaping method on the plane and free-form surface parts to the cylindrical surface ultrahigh-precision shaping of the shaft parts so as to meet the high-precision part processing requirement which cannot be realized by the ultra-precision cylindrical grinding.
Description
Technical Field
The invention relates to the field of ultra-precision machining of the excircle surface of a shaft part, in particular to a magnetorheological deterministic shape-modifying method and device for the excircle surface of a shaft part.
Background
Shaft parts are widely used for various mechanical equipment, and high-precision shaft parts are widely used in the fields of ultra-precision machine tools, precision instruments, aerospace industry, high-end optical manufacturing and the like along with the high-speed development of industry since the 20 th century. For example, a main shaft in an ultra-precise machine tool, an EUV and X-ray wolfter type grazing incidence type reflecting lens barrel core mold, a rotor of an ultra-high precision gyroscope and the like all have ultra-high precision processing requirements on shaft parts. Taking an air-float spindle mandrel as an example, the revolving precision of the spindle of the existing ultra-precision machine tool can reach 25-50 nm, and the required roundness error of the spindle which can reach the revolving precision is about 0.1 μm and the cylindricity error is about 1 μm; the core mould of the EUV grazing incidence type reflector lens barrel requires that the roundness error reaches submicron level, the surface roughness reaches nanometer level, and the precision requirement of the X-ray reflector lens barrel is higher.
The existing high-precision shaft part process generally comprises the working procedures of turning, grinding and manual grinding and polishing, wherein various surface treatments are inserted in the working procedures. Taking shaft workpieces with phi 100mm x 150mm as an example, the processing limit precision of the prior ultra-precise cylindrical grinding machine can reach roundness error of 0.2-0.3 μm and cylindricity of 0.5-0.6 μm. Because the traditional machining mode follows a 'mother principle', the precision of a machined part cannot exceed the self motion precision of a machine tool, so that the high requirement is put on the machine tool when higher precision is pursued, and the high requirement is finally realized by depending on a manual grinding mode. The manual grinding is non-deterministic processing, the grinding precision is highly dependent on the processing experience of workers, and the processing efficiency is low.
The patent of national defense science and technology university publication No. CN110202418A discloses a deterministic abrasive belt modification method for the outer circle surface of a shaft part, and the deterministic modification method is introduced into the modification of the shaft part. According to the method, the dwell time of the measured surface shape error data is calculated by using a pulse iteration method, the abrasive belt vibrating along the direction parallel to the axis of the workpiece is used for removing materials, and the machining effect of reaching the machining precision of the high-precision excircle grinding machine is realized on a modified numerical control lathe. In order to ensure the stability of the abrasive belt polishing removal function and better shaping efficiency, the open abrasive belt is adopted for shaping. When the surface is to great axle type part of surface area, a roll of abrasive band can't realize traversing the processing on whole axle surface. The magnetorheological finishing technology is a novel high-precision processing method of optical elements, which is produced by QED company in America, has the advantages of high processing precision, high processing efficiency, small subsurface damage, small surface residual stress, good long-time processing stability and the like, and can meet the part processing requirements of high shape precision and high surface quality, so the magnetorheological finishing technology is widely used for high-precision finishing of planar and free-form optical elements at present. The magnetorheological modification can be used for modifying monocrystalline silicon, silicon carbide, aluminum and alloy thereof, non-magnetic stainless steel and other materials.
Disclosure of Invention
The technical problem to be solved by the invention is as follows: aiming at the technical problems in the prior art, the invention provides a magnetorheological deterministic shaping method and device for the excircle surface of a shaft part, which introduces the planar and free-form surface magnetorheological shaping technology into the shaping of the shaft part, realizes the quantitative removal of each position by controlling the residence time of each position on the surface through a numerical control system, deterministically corrects the outline shape of the shaft workpiece, can realize the processing effect exceeding the self motion precision of a machine tool, and can achieve good surface quality.
In order to solve the technical problems, the technical scheme provided by the invention is as follows:
a magnetorheological deterministic shaping method for the outer circle surface of a shaft part comprises the following steps:
1) measuring by using a cylindricity instrument to obtain shape error data of the surface of the shaft part to be processed;
2) filtering the shape error data;
3) selecting a magnetorheological polishing wheel with a proper size according to the processed shape error data, and processing the shaft part to be processed by using a shaft type magnetorheological shape-modifying machine tool under the given processing parameters to obtain a removal function;
4) calculating residence time in process software according to the processed shape error data and the obtained removal function to perform simulation machining, and entering step 5) if the precision meets the requirement and the dynamic performance of the machine tool meets the requirement, or returning to step 3);
5) and generating a processing code of the numerical control machine tool by using process software, and importing the processing code into the shaft type magneto-rheological modification machine tool for processing.
Further, the step 1) specifically comprises the following steps:
1.1) marking a measurement starting point on the shaft part to be processed, wherein the measurement starting point is simultaneously used as a processing starting point;
1.2) carrying out multi-roundness measurement on the shaft part to be processed from a measurement starting point to obtain measurement data, wherein the distance between adjacent sections of the multi-roundness measurement is 5-10 mm;
1.3) calculating the measurement data in cylindricity instrument measurement software and process software to obtain roundness error data and cylindricity error data, and processing the measurement data in the process software to obtain an expanded cylindrical surface error morphology graph of the shaft part to be processed.
Further, the step 2) specifically comprises the following steps:
2.1) Gaussian low-pass filtering of different thresholds is carried out on the shape error data, the data are expanded to draw an error distribution diagram after filtering, the position where the error amplitude exceeds the target precision and the existing main frequency interval in the error distribution diagram are extracted, and the filtering parameter range T1 is determined;
2.2) obtaining a filtering parameter range T2 according to the requirements of part design and processing conditions on the surface morphology;
and 2.3) taking T2 as a reference of the final filtering range T, adjusting the range of the final filtering range T by combining the filtering parameter range of T1 to obtain the final filtering range T, and filtering the shape error data by using the final filtering range T.
Further, the step 3) specifically comprises the following steps:
3.1) solving a normalized amplitude spectrum of the roundness error data in the processed shape error data by utilizing Fourier transform, and taking a frequency corresponding to a position with a maximum amplitude of 10% as a contour cut-off frequency of the shaft part in the circumferential direction;
3.2) solving a normalized amplitude spectrum of the cylindricity error data in the processed shape error data by utilizing Fourier transform, and taking the frequency corresponding to the position with the maximum amplitude of 10% as the profile cut-off frequency of the axial part along the axial direction;
3.3) selecting the diameter and the width of the corresponding magnetorheological polishing wheel according to the contour cut-off frequency of the shaft parts in the axial direction and the circumferential direction;
and 3.4) mounting the selected magnetorheological polishing wheel on a shaft type magnetorheological shaping machine tool, adjusting processing parameters, and removing the shaft type part to be processed at a fixed point by the shaft type magnetorheological shaping machine tool under the processing parameters to obtain a removal function.
Further, the step 4) specifically comprises the following steps:
4.1) measuring the processed shaft parts by using a cylindricity instrument, and extracting a removal function;
4.2) importing the removal function into process software for simulation processing, if the processing result does not meet the precision requirement, skipping to execute the step 3.3) to start to reselect the diameter and the width of the magnetorheological polishing wheel and readjust the processing parameters, and if the processing result meets the precision requirement, entering the next step;
4.3) processing the residence time calculated by the process software, judging whether the rotating speed of the spindle of the shaft part, the moving speed of the Z axis parallel to the direction of the spindle and the moving speed of the X axis vertical to the direction of the spindle exceed the highest moving speeds of the spindle, the Z axis and the X axis of the machine tool, if so, skipping to execute the step 3.3), and beginning to reselect the diameter and the width of the magnetorheological polishing wheel and readjust the processing parameters, and if not, skipping to execute the step 5).
The invention also provides a magnetorheological deterministic shape correcting device for the outer circle surface of the shaft part, which comprises a shaft type magnetorheological shape correcting machine tool, wherein the shaft type magnetorheological shape correcting machine tool is a numerical control machine tool provided with a magnetorheological deterministic shape correcting module, the numerical control machine tool comprises a C-axis main shaft, a tailstock, a Z-axis slide carriage and an X-axis slide carriage, a gap for installing the shaft part to be processed is arranged between the C-axis main shaft and the tailstock, tops which are oppositely arranged are respectively arranged on the C-axis main shaft and the tailstock, the magnetorheological deterministic shape correcting module is arranged on the X-axis slide carriage, the X-axis slide carriage is arranged on the Z-axis slide carriage, the magnetorheological deterministic shape correcting module comprises a magnetorheological polishing wheel the surface of which is covered with magnetorheological fluid, and the magnetorheological polishing wheel is contacted with the shaft part to be processed.
Further, the magnetorheological deterministic shape modification module comprises a magnetorheological fluid circulation system.
The invention also proposes a system for magnetorheological deterministic shaping of the outer circumferential surface of a shaft part, comprising a computer device programmed or configured to carry out the steps of the method for magnetorheological deterministic shaping of the outer circumferential surface of a shaft part as claimed above.
The invention also provides a magnetorheological deterministic shaping system for the outer circular surface of the shaft part, which comprises computer equipment, wherein a storage medium of the computer equipment is stored or configured with a computer program for executing the magnetorheological deterministic shaping method for the outer circular surface of the shaft part.
The invention also provides a computer readable storage medium, which stores a computer program programmed or configured to execute the magnetorheological deterministic shaping method for the outer circular surface of the shaft part.
Compared with the prior art, the invention has the advantages that:
the method of the invention uses the magneto-rheological deterministic shaping method which is used for the high-precision deterministic processing of the plane and the free-form surface to process the shaft parts, and can process the shaft parts with higher shape precision than that of the ultra-precision cylindrical grinder; and secondly, due to the processing characteristics of small subsurface damage and small surface residual stress caused by magnetorheological modification, the surface quality of the modified part is better, so that the method can be expanded to the deterministic modification of some optical cylindrical surface parts.
The magnetorheological fluid used for magnetorheological processing in the device has large capacity, and simultaneously has a self-circulation function, so that long-time stable processing can be realized, and the device can be used for processing high-precision shaft parts with large cylindrical surface areas.
Drawings
FIG. 1 is a schematic diagram of a basic flow of a method according to an embodiment of the present invention.
FIG. 2 is a top view of a three-dimensional topography of a removal function of magnetorheological modification in an embodiment of the invention.
FIG. 3 is a top view of the three-dimensional topography of the MR trimming removal function under different processing parameters in the embodiment of the present invention.
FIG. 4 is a three-dimensional and expanded topographical view of a surface to be machined in accordance with an embodiment of the present invention.
FIG. 5 is a surface topography of a shaft after MR modification in accordance with an embodiment of the present invention.
FIG. 6 is a comparison of roundness data of the cross-section of the shaft surface after magnetorheological modification and before magnetorheological modification in accordance with an embodiment of the present invention.
FIG. 7 is a schematic diagram of a magnetorheological deterministic shaping apparatus according to an embodiment of the invention.
FIG. 8 is a schematic view illustrating a process of modifying a magnetorheological counter shaft part according to an embodiment of the invention.
Illustration of the drawings: the device comprises a 1-C shaft main shaft, a 2-tailstock, a 3-centre, a 4-processed shaft part, a 5-Z shaft slide carriage, a 6-X shaft slide carriage and a 7-magnetorheological deterministic shape modification module.
Detailed Description
The invention is further described below with reference to the drawings and specific preferred embodiments of the description, without thereby limiting the scope of protection of the invention.
As shown in FIG. 1, the magnetorheological deterministic shaping method for the excircle surface of the shaft part comprises the following steps:
1) measuring by using a cylindricity instrument to obtain shape error data of the surface of the shaft part to be processed;
2) filtering the shape error data;
3) selecting a magnetorheological polishing wheel with a proper size according to the processed shape error data, and processing the shaft part to be processed by using a shaft type magnetorheological shape-modifying machine tool under the given processing parameters to obtain a removal function;
4) calculating residence time in process software according to the processed shape error data and the obtained removal function to perform simulation machining, and entering step 5) if the precision meets the requirement and the dynamic performance of the machine tool meets the requirement, or returning to step 3);
5) and generating a processing code of the numerical control machine tool by using process software, and importing the processing code into the shaft type magneto-rheological modification machine tool for processing.
The magnetorheological deterministic shape-modifying method which is used for high-precision deterministic processing of the plane and the free-form surface is used for processing the shaft parts, so that the shaft parts with higher shape precision than that of the ultra-precision cylindrical grinding machine can be processed; and secondly, due to the processing characteristics of small subsurface damage and small surface residual stress caused by magnetorheological modification, the surface quality of the modified part is better, so that the method can be expanded to the deterministic modification of some optical cylindrical surface parts.
In this embodiment, step 1) specifically includes the following steps:
1.1) marking a measurement starting point on the shaft part to be processed, wherein the measurement starting point is simultaneously used as a processing starting point;
1.2) carrying out multi-roundness measurement on the shaft part to be processed from a measurement starting point to obtain measurement data, wherein the distance between adjacent sections of the multi-roundness measurement is 5-10 mm;
1.3) calculating the measurement data in cylindricity instrument measurement software and process software to obtain roundness error data and cylindricity error data, and processing the measurement data in the process software to obtain an expanded cylindrical surface error morphology graph of the shaft part to be processed.
In this embodiment, step 2) specifically includes the following steps:
2.1) Gaussian low-pass filtering of different thresholds is carried out on the shape error data, the data are expanded to draw an error distribution diagram after filtering, the position where the error amplitude exceeds the target precision and the existing main frequency interval in the error distribution diagram are extracted, and the filtering parameter range T1 is determined;
2.2) obtaining a filtering parameter range T2 according to the requirements of part design and processing conditions on the surface morphology;
and 2.3) taking T2 as a reference of the final filtering range T, adjusting the range of the final filtering range T by combining the filtering parameter range of T1 to obtain the final filtering range T, and filtering the shape error data by using the final filtering range T.
In the case that the surface quality of the shaft allows, the smaller the range of the filter parameters is, the more beneficial the processing is, and the correlation between the T2 and the profile property of the shaft is the largest, so the T2 is selected as a reference.
Under the condition that T1 is smaller than T2, the final filtering range T is kept unchanged on the basis of T2, for example, the filtering parameter range T1 is 1-5 UPR, the filtering parameter range T2 is 1-10 UPR, and the filtering range of T1 (1-5 UPR) is combined by taking T2 (1-10 UPR) as a reference, and the filtering range of T is 1-10 UPR;
when T1 is greater than T2 but the difference between T1 and T2 is smaller than the threshold, the final filtering range T is kept unchanged on the basis of T2, for example, the filtering parameter range T1 is 1-12 UPR, the filtering parameter range T2 is 1-10 UPR, the threshold is 5UPR, the filtering range of T1 (1-12 UPR) is combined by taking T2 (1-10 UPR) as the reference, and the filtering range of T is 1-10 UPR because the difference between T1 and T2 is smaller than 5 UPR;
when T1 is greater than T2 but the difference between T1 and T2 is smaller than the threshold, the final filtering range T is adjusted to be the filtering range of T1, for example, the filtering parameter range T1 is 1-20 UPR, the filtering parameter range T2 is 1-10 UPR, the threshold is 5UPR, the T2 (1-10 UPR) is used as the main reference, and the filtering range of T1 (1-20 UPR) is combined, because the difference between T1 and T2 is greater than 5UPR, the final filtering range T is adjusted to be the filtering range 1-20 UPR of T1.
In this embodiment, step 3) specifically includes the following steps:
3.1) solving a normalized amplitude spectrum of the roundness error data in the processed shape error data by utilizing Fourier transform, and taking a frequency corresponding to a position with a maximum amplitude of 10% as a contour cut-off frequency of the shaft part in the circumferential direction;
3.2) solving a normalized amplitude spectrum of the cylindricity error data in the processed shape error data by utilizing Fourier transform, and taking the frequency corresponding to the position with the maximum amplitude of 10% as the profile cut-off frequency of the axial part along the axial direction;
and 3.3) selecting the diameter and the width of the corresponding magnetorheological polishing wheel according to the contour cut-off frequency of the shaft part in the axial direction and the circumferential direction. The smaller the diameter and width of the polishing wheel, the smaller the size of the length and width of the removal function, and the higher the cut-off frequency;
and 3.4) mounting the selected magnetorheological polishing wheel on a shaft type magnetorheological shaping machine tool, adjusting processing parameters, and removing the shaft type part to be processed at a fixed point by the shaft type magnetorheological shaping machine tool under the processing parameters to obtain a removal function.
The three-dimensional appearance and the two-dimensional appearance of the removal function of the magnetorheological modification are shown in FIG. 2, and the overlooking visual angle is in a letter 'D' shape. Under the condition that the diameter and the width of the magnetorheological polishing wheel are not changed, the length and the width of a removal function are mainly related to the depth of pressure of the polishing wheel, the flow rate of magnetorheological fluid, the rotating speed of the polishing wheel and the magnetic field intensity, the larger the depth of pressure of the polishing wheel is, the higher the rotating speed of the polishing wheel is, the higher the flow rate of the magnetorheological fluid is, the smaller the length and the width of the removal function are, the higher the cut-off frequency of the corresponding removal function is, and vice versa; the magnetic field strength mainly influences the width of the removal function, the magnetic field strength is about large, the smaller the width is, and the higher the contour cut-off frequency in the width direction is. Therefore, in the embodiment, the depth of the polishing wheel, the flow rate of the magnetorheological fluid, the rotation speed of the polishing wheel and the magnetic field intensity are used as processing parameters, and the removal functions with different sizes in fig. 3 can be obtained by adjusting the processing parameters, and the removal functions with different sizes have different cut-off frequencies and different shaping capabilities.
The reshaping ability of the removal function can be described by a normalized magnitude spectrum of the fourier transform of the removal function. When the cut-off frequency of the removal function is higher than the cut-off frequency of the shape error data of the shaft parts, the removal function theoretically has the capability of correcting the surface errors of the shaft parts. The removal function with low cut-off frequency generally has higher correction efficiency and is suitable for correcting macroscopic surface shape errors with longer space wavelength; the high cut-off frequency of the removing function corrects the surface shape error in a larger frequency range, but a middle-high frequency error can be left on the surface shape due to the existence of the positioning error, and the shape correcting effect is greatly influenced by the positioning accuracy of the removing function. And aiming at the contour cut-off frequency of the shaft part in the axial direction and the circumferential direction, the machining parameters are reasonably selected, so that the modification precision and the modification efficiency of the removal function can be optimized.
In this embodiment, step 4) specifically includes the following steps:
4.1) measuring the processed shaft parts by using a cylindricity instrument, and extracting a removal function;
4.2) importing the removal function into process software for simulation processing, if the processing result does not meet the precision requirement, skipping to execute the step 3.3) to start to reselect the diameter and the width of the magnetorheological polishing wheel and readjust the processing parameters, so that the cut-off frequency of the removal function is reduced to improve the shaping precision, and if the processing result meets the next step;
4.3) processing the residence time calculated by the process software, judging whether the rotating speed of the spindle of the shaft part, the moving speed of the Z axis parallel to the direction of the spindle and the moving speed of the X axis vertical to the direction of the spindle exceed the highest moving speeds of the spindle, the Z axis and the X axis of the machine tool, if so, skipping to execute the step 3.3), and starting to reselect the diameter and the width of the magnetorheological polishing wheel and readjust the processing parameters, so that the cut-off frequency of the removal function is increased to reduce the shaping efficiency, and if not, skipping to execute the step 5).
In this embodiment, the spindle rotation speed, the Z-axis moving speed, and the X-axis moving speed of the shaft part are respectively calculated according to a speed calculation model, and a function expression of the speed calculation model is as follows:
in the above equation, dL is a discrete interval of the shape error data, axial discrete intervals of the shape error data with respect to the main axis, the Z axis, and the X axis are all 1mm, circumferential discrete intervals of the shape error data with respect to the main axis, the Z axis, and the X axis are all 1 °, and dt is a dwell time.
In the embodiment, the residence time corresponding to each position of the surface of the main shaft, the Z shaft and the X shaft can be obtained when the residence time is calculated by the process software, therefore, the speeds of the spindle of the shaft part, the position of the shortest residence time of the Z axis and the X axis are respectively calculated and compared with the highest movement speeds of the spindle of the machine tool, the Z axis and the X axis, if the speed of the spindle of the shaft part, the position of the shortest residence time of the Z axis and the X axis is higher than the speed of the spindle of the machine tool, the Z axis and the X axis, skipping to execute the step 3.3), reducing the modification efficiency of the removal function by reselecting the diameter and the width of the magnetorheological polishing wheel and readjusting the processing parameters, and if the speeds of the spindle of the shaft part, the Z axis and the X axis at the shortest residence time position are less than the speeds of the spindle of the machine tool, the Z axis and the X axis, which indicates that the dynamic performance of the machine tool can meet the requirements, skipping to execute the step 5).
In the embodiment, a shaft workpiece which is subjected to ultra-precision grinding and has the diameter of 100mm and the length of 140mm is selected as a shaft part to be processed. The initial roundness error of the shaft part to be processed is 0.3-0.6 μm, the cylindricity error is 0.72 μm, and the three-dimensional error morphology and the cylindrical surface shape development diagram of the part are shown in fig. 4(a) and 4 (b). According to the method of the embodiment, the processing is carried out according to the steps 1) to 4), after simulation processing is carried out in process software by using a magnetorheological removal function, the shape is trimmed for 242min, and the final shape trimming result is shown in fig. 5, wherein the cylindricity error converges to 0.07 μm, the roundness error reaches 0.04-0.06 μm, and the roundness of 5 sections on the front and rear axes of the shape trimming is opposite to that shown in fig. 6. Because the ultra-precise cylindrical grinding machine with the highest cylindrical machining precision can only achieve the machining precision with the roundness error of 0.2-0.3 mu m and the cylindricity error of 0.6 mu m at present. Therefore, the method of the embodiment can realize the digital modification of the ultra-precise shaft parts which cannot be achieved by the traditional mechanical processing at present.
As shown in figure 7, the invention provides a magnetorheological deterministic shaping device for the outer circular surface of a shaft part, which comprises a shaft magnetorheological shaping machine tool, wherein the shaft magnetorheological shaping machine tool is a numerical control machine tool provided with a magnetorheological deterministic shaping module 7, the numerical control machine tool is provided with a C shaft controlled by an angle servo, a linear motion shaft Z shaft which is parallel to the main shaft direction of the shaft part and carries a tool rest, and a linear motion shaft X shaft which is vertical to the main shaft direction of the shaft part, specifically, the numerical control machine tool comprises a C shaft main shaft 1, a tailstock 2, a Z shaft slide carriage 5 and an X shaft slide carriage 6, a gap for mounting the shaft part to be processed is arranged between the C shaft main shaft 1 and the tailstock 2, tops 3 which are oppositely arranged are respectively arranged on the C shaft main shaft 1 and the tailstock 2, the magnetorheological shaping module 7 is mounted on the X shaft slide carriage 6, the X shaft slide carriage 6 is mounted on the Z shaft slide carriage 5, the magnetorheological deterministic shaping module 7 is mounted on the X shaft slide carriage in a horizontal posture, therefore, the magneto rheological certainty shape modifying module 7 can move along the Z axis and the X axis, because the processed shaft part main shaft and the C axis main shaft 1 are parallel, so the magneto rheological certainty shape modifying module 7 does not need to add extra rotational freedom, and when the shaft part main shaft and the C axis main shaft 1 are not parallel, the rotational freedom is added between the magneto rheological certainty shape modifying module 7 and the X axis slide carriage 6.
As shown in fig. 8, in the present embodiment, the magnetorheological deterministic shaping module 7 includes a magnetorheological polishing wheel whose surface is covered with magnetorheological fluid, and the magnetorheological polishing wheel is in contact with the processed shaft-like part. During machining, the magneto-rheological deterministic shape modification module 7 feeds along an X axis, and the magneto-rheological fluid forms a controllable flexible polishing film under the action of a high-strength gradient magnetic field to perform plastic shearing removal on a machined shaft part. The servo main shaft and the Z shaft where the machined shaft part is located are linked to achieve quantitative removal of different positions of the shaft surface, and then deterministic shape correction of the whole part surface is traversed. The magnetorheological deterministic shape modification module 7 of the embodiment further comprises a magnetorheological fluid circulating system to realize recovery and circulation of magnetorheological fluid, and the magnetorheological fluid circulating system can also perform online detection on the magnetorheological fluid and control the flow, viscosity and temperature of the magnetorheological fluid, so that stable shape modification efficiency for a long time can be provided.
The invention also proposes a system for magnetorheological deterministic shaping of the outer circumferential surface of a shaft part, comprising a computer device programmed or configured to carry out the steps of the method for magnetorheological deterministic shaping of the outer circumferential surface of a shaft part as claimed above.
The invention also provides a magnetorheological deterministic shaping system for the outer circular surface of the shaft part, which comprises computer equipment, wherein a storage medium of the computer equipment is stored or configured with a computer program for executing the magnetorheological deterministic shaping method for the outer circular surface of the shaft part.
The invention also provides a computer readable storage medium, which stores a computer program programmed or configured to execute the magnetorheological deterministic shaping method for the outer circular surface of the shaft part.
The foregoing is considered as illustrative of the preferred embodiments of the invention and is not to be construed as limiting the invention in any way. Although the present invention has been described with reference to the preferred embodiments, it is not intended to be limited thereto. Therefore, any simple modification, equivalent change and modification made to the above embodiments according to the technical spirit of the present invention should fall within the protection scope of the technical scheme of the present invention, unless the technical spirit of the present invention departs from the content of the technical scheme of the present invention.
Claims (10)
1. The magnetorheological deterministic shape modifying method for the outer circle surface of the shaft part is characterized by comprising the following steps of:
1) measuring by using a cylindricity instrument to obtain shape error data of the surface of the shaft part to be processed;
2) filtering the shape error data;
3) selecting a magnetorheological polishing wheel with a proper size according to the processed shape error data, and processing the local position of the shaft part to be processed by using a shaft type magnetorheological shaping machine tool to move along a Z axis and an X axis under the given processing parameters to obtain a removal function, wherein the Z axis is along the main shaft direction of the shaft part to be processed, and the X axis is vertical to the main shaft direction of the shaft part to be processed;
4) calculating residence time in process software according to the processed shape error data and the obtained removal function to perform simulation machining, and entering step 5) if the precision meets the requirement and the dynamic performance of the machine tool meets the requirement, or returning to step 3);
5) and generating a processing code of the numerical control machine tool by using process software, and importing the processing code into the shaft type magneto-rheological modification machine tool for processing.
2. The magnetorheological deterministic shaping method for the outer circumferential surface of the shaft part according to claim 1, wherein the step 1) comprises the following steps:
1.1) marking a measurement starting point on the shaft part to be processed, wherein the measurement starting point is simultaneously used as a processing starting point;
1.2) carrying out multi-roundness measurement on the shaft part to be processed from a measurement starting point to obtain measurement data, wherein the distance between adjacent sections of the multi-roundness measurement is 5-10 mm;
1.3) calculating the measurement data in cylindricity instrument measurement software and process software to obtain roundness error data and cylindricity error data, and processing the measurement data in the process software to obtain an expanded cylindrical surface error morphology graph of the shaft part to be processed.
3. The magnetorheological deterministic shaping method for the outer circumferential surface of the shaft part according to claim 1, wherein the step 2) comprises the following steps:
2.1) Gaussian low-pass filtering of different thresholds is carried out on the shape error data, the data are expanded to draw an error distribution diagram after filtering, the position where the error amplitude exceeds the target precision and the existing main frequency interval in the error distribution diagram are extracted, and the filtering parameter range T1 is determined;
2.2) obtaining a filtering parameter range T2 according to the requirements of part design and processing conditions on the surface morphology;
and 2.3) taking T2 as a reference of the final filtering range T, adjusting the range of the final filtering range T by combining the filtering parameter range of T1 to obtain the final filtering range T, and filtering the shape error data by using the final filtering range T.
4. The magnetorheological deterministic shaping method for the outer circumferential surface of shaft parts according to claim 1, wherein the step 3) comprises the following steps:
3.1) solving a normalized amplitude spectrum of the roundness error data in the processed shape error data by utilizing Fourier transform, and taking a frequency corresponding to a position with a maximum amplitude of 10% as a contour cut-off frequency of the shaft part in the circumferential direction;
3.2) solving a normalized amplitude spectrum of the cylindricity error data in the processed shape error data by utilizing Fourier transform, and taking the frequency corresponding to the position with the maximum amplitude of 10% as the profile cut-off frequency of the axial part along the axial direction;
3.3) selecting the diameter and the width of the corresponding magnetorheological polishing wheel according to the contour cut-off frequency of the shaft parts in the axial direction and the circumferential direction;
and 3.4) mounting the selected magnetorheological polishing wheel on a shaft type magnetorheological shaping machine tool, adjusting processing parameters, and removing the shaft type part to be processed at a fixed point by the shaft type magnetorheological shaping machine tool under the processing parameters to obtain a removal function.
5. The magnetorheological deterministic shaping method for the outer circumferential surface of shaft parts according to claim 4, wherein the step 4) comprises the following steps:
4.1) measuring the processed shaft parts by using a cylindricity instrument, and extracting a removal function;
4.2) importing the removal function into process software for simulation processing, if the processing result does not meet the precision requirement, skipping to execute the step 3.3) to start to reselect the diameter and the width of the magnetorheological polishing wheel and readjust the processing parameters, and if the processing result meets the precision requirement, entering the next step;
4.3) processing the residence time calculated by the process software, judging whether the rotating speed of the spindle of the shaft part, the moving speed of the Z axis parallel to the direction of the spindle and the moving speed of the X axis vertical to the direction of the spindle exceed the highest moving speeds of the spindle, the Z axis and the X axis of the machine tool, if so, skipping to execute the step 3.3), and beginning to reselect the diameter and the width of the magnetorheological polishing wheel and readjust the processing parameters, and if not, skipping to execute the step 5).
6. The magnetorheological deterministic shape correcting device for the outer circle surface of the shaft part is characterized by comprising a shaft type magnetorheological shape correcting machine tool, wherein the shaft type magnetorheological shape correcting machine tool is a numerical control machine tool provided with a magnetorheological deterministic shape correcting module (7), the numerical control machine tool comprises a C-shaft main shaft (1), a tailstock (2), a Z-shaft slide carriage (5) and an X-shaft slide carriage (6), a gap for installing the shaft part to be processed is formed between the C-shaft main shaft (1) and the tailstock (2), tops (3) which are oppositely arranged are respectively arranged on the C-shaft main shaft (1) and the tailstock (2), the magnetorheological deterministic shape correcting module (7) is arranged on the X-shaft slide carriage (6), the X-shaft slide carriage (6) is arranged on the Z-shaft slide carriage (5), and the magnetorheological deterministic shape correcting module (7) comprises a magnetorheological polishing wheel of which the magnetorheological fluid covers the surface, the magnetorheological polishing wheel is in contact with a processed shaft part, the magnetorheological deterministic shape modifying module (7) can move along a Z axis and an X axis, and a servo main shaft where the processed shaft part is located is linked with the Z axis to achieve quantitative removal of different positions of the surface of the shaft.
7. The magnetorheological deterministic shaping device for the outer circumferential surface of shaft parts according to claim 6, wherein the magnetorheological deterministic shaping module (7) comprises a magnetorheological fluid circulation system.
8. A magnetorheological deterministic shaping system for the outer circumferential surface of a shaft part, characterized by comprising a computer device programmed or configured to perform the steps of the magnetorheological deterministic shaping method for the outer circumferential surface of a shaft part according to any one of claims 1 to 5.
9. A magnetorheological deterministic shaping system for the outer circumferential surface of a shaft part, characterized by comprising a computer device, wherein a storage medium of the computer device stores or is configured to execute a computer program of the magnetorheological deterministic shaping method for the outer circumferential surface of a shaft part according to any one of claims 1 to 5.
10. A computer readable storage medium having stored thereon a computer program programmed or configured to perform the method of magnetorheological deterministic shaping of an outer circumferential surface of a shaft part according to any one of claims 1 to 5.
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