CN115431100B - Cutting force monitoring and displacement control system of rapid cutter servo device - Google Patents

Cutting force monitoring and displacement control system of rapid cutter servo device Download PDF

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CN115431100B
CN115431100B CN202211212019.3A CN202211212019A CN115431100B CN 115431100 B CN115431100 B CN 115431100B CN 202211212019 A CN202211212019 A CN 202211212019A CN 115431100 B CN115431100 B CN 115431100B
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cutting force
piezoelectric stack
displacement
cutting
piezoelectric
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CN115431100A (en
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王文
张恒毅
王嘉辉
王瑞金
岳树清
王家豪
方威
陈占锋
王传勇
卢科青
杨贺
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Hangzhou Dianzi University
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23QDETAILS, 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
    • B23Q17/00Arrangements for observing, indicating or measuring on machine tools
    • B23Q17/09Arrangements 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
    • B23Q17/0952Arrangements 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

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Machine Tool Sensing Apparatuses (AREA)

Abstract

The invention discloses a cutting force monitoring and displacement control system of a quick cutter servo device, which is applied to a machine tool for adjusting the back cutting amount of a cutter through a piezoelectric stack. The system comprises a displacement and cutting force self-sensing module, a cutting force monitoring module and a feedback control module. The displacement and cutting force self-sensing module is used for obtaining a displacement value and three-way cutting force of the cutter according to the driving voltage and charge signals of the piezoelectric stack in the cutting process; the cutting force monitoring module is used for forming a three-way cutting force map according to the input cutting force; the feedback control module is used for converting a feedback signal obtained according to displacement into control voltage and outputting the control voltage to the piezoelectric driver to form feedback control. According to the invention, the piezoelectric stack is used as a driver and a sensor simultaneously by utilizing the piezoelectric self-sensing principle in a machine tool for adjusting the back cutting tool draft of the piezoelectric stack, and the radial cutting force and the displacement value can be measured in real time without introducing an additional force sensor and a displacement sensor, so that the integration of a tool system is facilitated.

Description

Cutting force monitoring and displacement control system of rapid cutter servo device
Technical Field
The invention belongs to the technical field of ultra-precise cutting and cutting force measurement, and relates to a cutting force monitoring and displacement control system of a rapid cutter servo device.
Background
In the field of ultra-precision machining, the fabrication of microstructured array surfaces is a very important aspect. Microstructure arrays have become key components in the fields of optoelectronics, information communication and precision engineering with their excellent properties. The manufacturing technology suitable for the microstructure array surface mainly comprises a photoetching technology, a high-energy beam manufacturing technology, an ultra-precise machining technology based on a diamond cutter and the like. The ultra-precise machining technology based on the diamond cutter has the advantages of capability of machining ultra-smooth and high-precision complex surfaces. The Fast Tool Servo (FTS) is a technology which is developed faster in ultra-precision machining of diamond by virtue of the characteristics of high rigidity, high frequency response and high positioning precision.
The fast tool servo requires precise control of the tool motion during operation. In addition, in the machining process, the cutting force is taken as an important factor affecting the servo machining precision of the quick cutter, and the abrasion condition of the cutter in the machining process, the quality of the machined surface of the part and the like can be reflected in real time. Therefore, the accurate and comprehensive monitoring of the cutting force of the cutter and the improvement of the positioning precision of the cutter in the cutting process are of great significance in processing and production.
Disclosure of Invention
The invention provides a cutting force monitoring and displacement control system of a rapid cutter servo device, which adopts the principle of piezoelectric self-sensing, so that a piezoelectric stack is used as a driver and a sensor at the same time. The self-sensing module for the displacement and the cutting force is constructed, and the three-way cutting force and the displacement of the cutter are measured without an external force sensor and a displacement sensor, so that the cutting force monitoring and displacement control system is constructed.
The system obtains a three-way cutting force value through a three-way cutting force self-sensing model, monitors the three-way cutting force value in real time and judges whether an abnormal cutting state exists in the cutting process of the cutter; the displacement value obtained by the self-sensing displacement model is used for feedback control of the piezoelectric stack, so that the control accuracy of driving displacement is improved.
The cutting force monitoring and displacement control system of the rapid cutter servo device is applied to a machine tool for adjusting the back cutting amount of a cutter through a piezoelectric stack. The cutting force monitoring and displacement control system comprises a displacement and cutting force self-sensing module, a cutting force monitoring module and a feedback control module.
The displacement self-sensing model for obtaining the cutter displacement value X according to the driving voltage signal U and the charge signal Q of the piezoelectric stack in the cutting process is as follows:
obtaining radial cutting force F from driving voltage signal U and charge signal Q p Tangential cutting force F c Axial cutting force F f The three-way cutting force self-sensing model of (2) is as follows:
wherein n is the number of layers of the piezoelectric stack; a is the piezoelectric wafer area of the piezoelectric stack; t is the thickness of a single piezoelectric wafer in the piezoelectric stack.Is the elastic compliance coefficient of piezoelectric ceramics, +.>Is the dielectric coefficient of the piezoelectric stack; d, d 33 Is the piezoelectric constant of the piezoelectric stack. />Cutting condition coefficients respectively; />The correction coefficients are tangential and axial respectively;back cutting index, tangential, axial respectively,/->Respectively tangential and axial feed indexes;respectively tangential and axial cutting speed indexes; f is the feed; v c Is the cutting speed.
The three-way cutting force value obtained by the displacement and cutting force self-sensing module is input into the cutting force monitoring module; the cutting force monitoring module is used for constructing a three-way cutting force map according to the input cutting force; and the three-way cutting force spectrum is monitored in real time. When the cutting force is monitored to be suddenly changed, the cutting force monitoring module judges that the surface of the machined part has micro defects; defects include cracks and voids; when the cutting force is monitored to exceed a preset critical value, the cutting force monitoring module judges that the abrasion degree of the cutter has an influence on the surface quality of the machined part and prompts the replacement of the cutter.
The displacement value X obtained by the displacement and cutting force self-sensing module and the expected displacement value form a feedback signal to be input into the feedback control module. The feedback control module is used for converting the feedback signal into a driving voltage signal and outputting the driving voltage signal to the piezoelectric stack to form feedback control, so that the control precision of the piezoelectric stack is further improved.
Preferably, the charge signal Q is obtained by detecting the working current I of the piezoelectric stack during the cutting process of the machine tool, and performing an integral operation on the working current I.
Preferably, the quick tool servo in a machine tool for adjusting the tool back draft by the piezoelectric stack comprises a frame structure, the piezoelectric stack, a tool rest, a tool and a data acquisition module. The tool holder is mounted on the frame structure and moves under the drive of the piezoelectric stack. The tool is mounted on the tool holder. The data acquisition module comprises a voltage regulation module, a precision resistor, a voltage sensor and a software current integrator. The voltage output interface of the voltage regulating module, the power supply interface of the piezoelectric stack and the precise resistor with known resistance are connected into a serial loop. The charge signal Q is obtained by a software current integration method, a voltage sensor is connected in parallel to the precision resistor, and the collected voltage value is input into a software current integrator. The displacement and cutting force self-sensing module obtains a driving voltage signal U from the controller and obtains a charge signal Q from the software current integrator.
Preferably, the frame structure comprises integrally formed frame side beams, frame back beams, frame front beams and straight beam type flexible hinges. Two ends of the frame front beam are connected with opposite sides of the two frame side beams through straight beam type flexible hinges respectively; both frame side beams are fixed with the frame back beam. The frame back beam, the frame front beam and the two frame side beams are encircled to form a stack mounting groove. The piezoelectric stack is fixed in the stack mounting groove. The two ends of the piezoelectric stack are respectively fixed with the middle parts of the frame back beam and the frame front beam. The tool rest is fixed on the frame front beam.
Preferably, the frame back beam is screwed with an adjusting bolt. The adjusting bolt is contacted against the end part of the piezoelectric stack and is used for adjusting the pretightening force between the piezoelectric stack and the front beam of the frame.
Preferably, a washer is arranged between the adjusting bolt and the piezoelectric stack.
The beneficial effects of the invention are as follows:
1. according to the invention, the piezoelectric stack is used as a driver and a sensor simultaneously by utilizing the piezoelectric self-sensing principle in a machine tool for adjusting the back cutting tool draft of the piezoelectric stack, and the radial cutting force and the displacement value can be measured in real time without introducing an additional force sensor and a displacement sensor, so that the integration of a tool system is facilitated.
2. The three-way cutting force monitoring and displacement control system is constructed, the three-way cutting force can be comprehensively monitored, the measuring comprehensiveness of the cutting force is improved, the cutter abrasion condition and the processing surface quality can be monitored, and workers can find and intervene in time in the early stage of processing problems. Meanwhile, the displacement control system improves the control precision and the control speed.
Drawings
FIG. 1 is a schematic diagram of a fast tool servo employed in the present invention.
Fig. 2 is a schematic structural diagram of a frame structure in a fast tool servo apparatus according to the present invention.
Fig. 3 is an exploded view of the cutting forces during cutting by the tool.
Fig. 4 is a schematic circuit diagram of a data acquisition module according to the present invention.
Fig. 5 is a signal flow diagram of the operation of the present invention.
Detailed Description
The invention is further described below with reference to the accompanying drawings.
As shown in fig. 1 and 5, a cutting force monitoring and displacement control system of a rapid tool servo device is applied to a machine tool with a piezoelectric stack for adjusting the back cutting tool draft. The cutting force monitoring and displacement control system comprises a displacement and cutting force self-sensing module 14, a cutting force monitoring module 15 and a feedback control module 16. The displacement and cutting force self-sensing module 14, the cutting force monitoring module 15 and the feedback control module 16 are integrated in the controller 13. The controller 13 employs PID control.
The quick tool servo device adopted in the machine tool comprises a frame structure 1, a piezoelectric stack 2, a tool rest 3, a diamond lathe tool 4, a lathe tool fixing piece 5, a screw 6, an adjusting bolt 7, a gasket 8 and a data acquisition module.
The frame structure 1 comprises a frame side beam 1-1, a frame rear beam 1-2, a frame front beam 1-3 and a straight beam type flexible hinge which are integrally formed. Two ends of the frame front beam 1-3 are respectively connected with opposite sides of the two frame side beams 1-1 through straight beam type flexible hinges; two straight beam type flexible hinges are arranged at any one end of the frame front beam 1-3 side by side. Both frame side beams 1-1 are fixed to the frame back beam 1-2. The frame back beam 1-2, the frame front beam 1-3 and the two frame side beams 1-1 are surrounded to form a stack mounting groove. The piezoelectric stack 2 is fixed in the stack mounting groove. The two ends of the piezoelectric stack 2 are respectively fixed with the middle parts of the frame back beams 1-2 and the frame front beams 1-3.
The middle part of the frame back beam is provided with a central threaded hole for installing an adjusting bolt 7. The adjusting bolt 7 is contacted with the end part of the piezoelectric stack 2 through the central threaded hole and is used for adjusting the pretightening force between the piezoelectric stack 2 and the frame front beam 1-1, and the gasket 8 is arranged between the adjusting bolt 7 and the piezoelectric stack 2 to protect the piezoelectric stack 2 from being damaged.
Two symmetrical connecting threaded holes are formed in the outer side of the frame front beam 1-3 and are fixed with the tool rest 3 through screws; the turning tool fixing piece 5 is fixedly arranged on the tool rest 3. The diamond turning tool 4 is fixed to the turning tool fixing member 5 by a screw.
As shown in fig. 4 and 5, the data acquisition module includes a voltage regulation module 9, a precision resistor 10, a voltage sensor 11, and a software current integrator 12. The voltage output interface of the voltage regulating module 9, the power supply interface of the piezoelectric stack 2 and the precision resistor 10 are connected into a series circuit. The precision resistor 10 is connected in parallel with a voltage sensor 11. The voltage value acquired by the voltage sensor 11 is input into the software current integrator 12. The charge signal output by the software current integrator 12 is fed to a displacement and cutting force self-sensing module 14 in the controller 13.
The controller 13 controls the driving voltage signal U input to the piezoelectric stack 2 through the voltage regulating module 9. The voltage regulating module 9 outputs a driving voltage signal U to act on the piezoelectric stack 2, so that the piezoelectric stack 2 generates micro displacement and pushes the cutter to cut a workpiece, and the cutter is subjected to the action of three-way cutting force. Wherein the radial force F p Is parallel to the extension and retraction direction of the piezoelectric stack 2 and acts on the piezoelectric stack 2 through a cutter and a flexible hinge, so that the piezoelectric stack 2 generates piezoelectric charges due to the positive piezoelectric effect.
Since the precision resistor 10 is connected in series with the piezoelectric stack 2, the current signal through the piezoelectric stack 2 is the same as the current signal through the precision resistor 10, while the precision resistor 10 converts the current signal of the piezoelectric stack 2 into a voltage signal. The voltage sensor 11 collects the voltage signal of the precision resistor 10 and transmits the voltage signal to the software current integrator 12, the voltage value is divided by the resistance value of the precision resistor 10 in the software current integrator 12 to obtain a piezoelectric current value, and then the piezoelectric current is integrated point by point to obtain a charge signal Q. The displacement and cutting force self-sensing module 14 obtains a driving voltage signal U from the controller 13 and a charge signal Q from the software current integrator 12, so as to calculate the displacement value of the cutter and the cutting force value acting on the cutter. The displacement value and the desired displacement value constitute a feedback control module 16 in the controller 13, which feedback control module acts on the feedback signal; the three-way cutting force value is input into a cutting force monitoring module 15 in the controller 13 to form a three-way cutting force map and monitor the three-way cutting force map in real time.
As shown in fig. 5, the working process of the cutting force monitoring and displacement control system of the fast tool servo device comprises the following steps:
step one, the controller 13 inputs a driving signal to the piezoelectric stack 2 through the pressure regulating module 9 to control the position of the diamond turning tool 4. The machine tool cuts a workpiece with a diamond turning tool 4.
Step two, as shown in fig. 3, during the cutting process, the cutting force acting on the diamond turning tool 4 can be decomposed into three mutually perpendicular components, namely tangential force F perpendicular to the tool base surface in the cutting speed direction c Radial force F perpendicular to the feed direction in a plane parallel to the base plane p An axial force F parallel to the feed direction in a plane parallel to the base plane f . Wherein the radial force F p Acts on the piezoelectric stack and is parallel to the direction of the piezoelectric stack. The radial force F of the cutter is obtained by using a displacement and cutting force self-sensing module through a three-way cutting force self-sensing model by a driving voltage signal U and a charge signal Q p Tangential force F c Axial force F f The method comprises the steps of carrying out a first treatment on the surface of the And obtaining a displacement value of the piezoelectric stack under the action of the driving voltage through a displacement self-sensing model.
And thirdly, inputting the three-way cutting force signals obtained by the displacement and cutting force self-sensing module 14 into a cutting force monitoring module 15 in the controller 13 to form a three-way cutting force map and monitoring the three-way cutting force map in real time. When the cutting force is monitored to be suddenly changed, the cutting force monitoring module 15 judges that micro defects such as cracks, holes and the like possibly exist on the surface of the workpiece; when it is detected that the cutting force increases beyond a certain threshold value, the cutting force monitoring module 15 determines that the tool wear degree at this time begins to affect the surface quality of the workpiece, and the tool should be replaced. The displacement value obtained by the displacement and cutting force self-sensing module 14 is input as a feedback signal to a feedback control module 16 in the controller 13. The feedback control module 16 converts the feedback signal and the desired displacement into a driving voltage signal and outputs the driving voltage signal to the piezoelectric stack 2, thereby forming feedback control and further improving the control accuracy of the piezoelectric stack 2.
The displacement and cutting force self-sensing model derivation process in the displacement and cutting force self-sensing module 14 is as follows:
since in three-way cutting forces only radial force F p Directly acts on the piezoelectric stack and is parallel to the direction of the piezoelectric stack. Only the piezoelectric stack is considered to be subjected to the driving voltage U and the radial force F p Other components are ignored, and the relationship between the strain S, the stress T, the displacement D, and the electric field strength E of the piezoelectric stack can be described by a first type of piezoelectric equation, which is shown as follows:
wherein D is 3 Is the displacement of the piezoelectric stack; t (T) 3 Is the stress to which the piezoelectric stack is subjected; s is S 3 Is the strain of the piezoelectric stack; e (E) 3 Is the electric field strength generated by the piezoelectric stack;is the dielectric coefficient of the piezoelectric stack; />Is the elastic compliance coefficient of the piezoelectric stack; d, d 33 Is the piezoelectric constant of the piezoelectric stack.
The piezoelectric ceramic consists of n layers of piezoelectric wafers with the electrode plate area of A and the thickness of t, and the piezoelectric wafers are as follows:
U=tE 3 (4)
F p =AT 3 (5)
X=ntS 3 (6)
wherein Q is the measured charge, U is the driving voltage, F p For radial cutting force applied to the piezoelectric ceramics, substitution of formulas (1) to (4) into formulas (5) to (6) can be obtained:
the radial cutting force F is represented by (7) p The relation between the driving voltage U and the piezoelectric charge Q is expressed by the relation between the displacement X and the driving voltage U and the piezoelectric charge Q, namely the displacement self-perception model.
Then, the tangential force F is obtained by an empirical formula of cutting force calculation c Axial force F f The empirical formula for calculating tangential and axial forces, in relation to the drive voltage U and the piezoelectric charge Q, is as follows:
tangential force
Axial force
In the method, in the process of the invention,cutting condition coefficients respectively; />The correction coefficients are tangential and axial respectively;back cutting index, tangential, axial respectively,/->Respectively tangential and axial feed indexes;respectively tangential and axial cutting speed indexes; a is the back draft (in mm); f is the feed (in mm/r); v c The cutting speed (unit is m/min).
The back draft a in the empirical formula is the displacement value X of the cutter in the cutting process, so that the tangential force F is obtained by substituting the formula (5) into the formulas (9) - (10) c And axial force F f A model of the relationship between the driving voltage U and the piezoelectric charge Q is as shown in equations (11) - (12):
formulas (7), (11) and (12) are three-way cutting force F c ,F p ,F f The relation between the value and the driving voltage U and the piezoelectric charge Q, namely the cutting force self-sensing model.

Claims (4)

1. A cutting force monitoring and displacement control system of a quick cutter servo device is characterized in that: the piezoelectric stack is applied to a machine tool for adjusting the back cutting tool draft of a cutter; the cutting force monitoring and displacement control system comprisesThe device comprises a displacement and cutting force self-sensing module, a cutting force monitoring module and a feedback control module; the displacement and cutting force self-sensing module is used for obtaining a displacement value X and a radial cutting force F of the cutter according to a driving voltage signal U and an electric charge signal Q of the piezoelectric stack in the cutting process p Tangential cutting force F c Axial cutting force F f The following are provided:
wherein n is the number of layers of the piezoelectric stack; a is the piezoelectric wafer area of the piezoelectric stack; t is the thickness of a single piezoelectric wafer in the piezoelectric stack;is the elastic compliance coefficient of piezoelectric ceramics, +.>Is the dielectric coefficient of the piezoelectric stack; d, d 33 Is the piezoelectric constant of the piezoelectric stack; />Cutting condition coefficients respectively; />The correction coefficients are tangential and axial respectively; />Back cutting index, tangential, axial respectively,/->Respectively tangential and axial feed indexes; />Respectively tangential and axial cutting speed indexes; f is the feed; v c Is the cutting speed;
the charge signal Q is obtained by detecting the working current I of the piezoelectric stack in the cutting process of a machine tool and carrying out integral operation on the working current I;
the three-way cutting force value obtained by the displacement and cutting force self-sensing module is input into the cutting force monitoring module; the cutting force monitoring module is used for forming a three-way cutting force map according to the input cutting force; real-time monitoring is carried out on the three-dimensional cutting force map; when the cutting force is monitored to be suddenly changed, the controller judges that the surface of the machined part has micro defects; defects include cracks and voids; when the cutting force is monitored to exceed a preset critical value, judging that the abrasion degree of the cutter has an influence on the surface quality of the machined part, and prompting the cutter to be replaced by a cutting force monitoring module;
the displacement value X obtained by the displacement and cutting force self-sensing module and the expected displacement value form a feedback signal to be input into the feedback control module; the feedback control module is used for converting the feedback signal into control voltage and outputting the control voltage to the piezoelectric stack to form feedback control;
the quick cutter servo device in the machine tool for adjusting the cutter back draft through the piezoelectric stack comprises a frame structure (1), the piezoelectric stack (2), a cutter rest (3), a cutter and a data acquisition module; the tool rest (3) is arranged on the frame structure (1) and moves under the drive of the piezoelectric stack (2); the cutter is arranged on the cutter rest (3); the data acquisition module comprises a voltage regulation module (9), a precision resistor (10), a voltage sensor (11) and a software current integrator (12); the voltage output interface of the voltage regulating module (9), the power supply interface of the piezoelectric stack (2) and the precision resistor (10) with known resistance are connected into a serial loop; the resistor is connected with a voltage sensor (11) in parallel; the voltage value acquired by the voltage sensor (11) is input into the software current integrator (12); the displacement and cutting force self-sensing module obtains a driving voltage signal U from the controller and a charge signal Q from the software current integrator (12).
2. The cutting force monitoring and displacement control system of a fast tool servo according to claim 1, wherein: the frame structure (1) comprises a frame side beam (1-1), a frame rear beam (1-2), a frame front beam (1-3) and a straight beam type flexible hinge which are integrally formed; two ends of the frame front beam (1-3) are connected with opposite sides of the two frame side beams (1-1) through straight beam type flexible hinges respectively; the two frame side beams (1-1) are fixed with the frame back beam (1-2); the frame rear beam (1-2), the frame front beam (1-3) and the two frame side beams (1-1) are encircled to form a stack mounting groove; the piezoelectric stack (2) is fixed in the stack mounting groove; two ends of the piezoelectric stack (2) are respectively fixed with the middle parts of the frame back beam (1-2) and the frame front beam (1-3); the tool rest (3) is fixed on the frame front beam (1-3).
3. The cutting force monitoring and displacement control system of a fast tool servo according to claim 2, wherein: an adjusting bolt (7) is screwed on the frame back beam; the adjusting bolt (7) is contacted against the end part of the piezoelectric stack (2) and is used for adjusting the pretightening force between the piezoelectric stack (2) and the frame front beam.
4. A cutting force monitoring and displacement control system for a fast tool servo as set forth in claim 3, wherein: a gasket (8) is arranged between the adjusting bolt (7) and the piezoelectric stack (2).
CN202211212019.3A 2022-09-30 2022-09-30 Cutting force monitoring and displacement control system of rapid cutter servo device Active CN115431100B (en)

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