WO2020107854A1 - 一种车削加工中刀具的对准方法、智能刀架及对刀方法 - Google Patents

一种车削加工中刀具的对准方法、智能刀架及对刀方法 Download PDF

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Publication number
WO2020107854A1
WO2020107854A1 PCT/CN2019/090334 CN2019090334W WO2020107854A1 WO 2020107854 A1 WO2020107854 A1 WO 2020107854A1 CN 2019090334 W CN2019090334 W CN 2019090334W WO 2020107854 A1 WO2020107854 A1 WO 2020107854A1
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WIPO (PCT)
Prior art keywords
tool
center
error
cutting
spindle
Prior art date
Application number
PCT/CN2019/090334
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English (en)
French (fr)
Inventor
张国庆
戴玉琦
Original Assignee
深圳大学
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
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Publication date
Priority claimed from CN201811425902.4A external-priority patent/CN109531263B/zh
Priority claimed from CN201811425937.8A external-priority patent/CN109531260B/zh
Priority claimed from CN201910038705.5A external-priority patent/CN109719314B/zh
Application filed by 深圳大学 filed Critical 深圳大学
Publication of WO2020107854A1 publication Critical patent/WO2020107854A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23B—TURNING; BORING
    • B23B25/00—Accessories or auxiliary equipment for turning-machines
    • B23B25/06—Measuring, gauging, or adjusting equipment on turning-machines for setting-on, feeding, controlling, or monitoring the cutting tools or work
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
    • B23Q15/00—Automatic control or regulation of feed movement, cutting velocity or position of tool or work
    • B23Q15/007—Automatic control or regulation of feed movement, cutting velocity or position of tool or work while the tool acts upon the workpiece
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
    • B23Q15/00—Automatic control or regulation of feed movement, cutting velocity or position of tool or work
    • B23Q15/20—Automatic control or regulation of feed movement, cutting velocity or position of tool or work before or after the tool acts upon the workpiece
    • B23Q15/22—Control or regulation of position of tool or workpiece
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
    • B23Q17/00—Arrangements for observing, indicating or measuring on machine tools
    • B23Q17/09—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
    • B23Q17/00—Arrangements for observing, indicating or measuring on machine tools
    • B23Q17/22—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring existing or desired position of tool or work

Definitions

  • the present application belongs to the technical field of single-point diamond turning, and particularly relates to a method for aligning tools, an intelligent tool holder, and a tool setting method in turning processing.
  • single-point diamonds have nano-level edge sharpness and extremely high hardness, they can be directly used to process ultra-smooth surfaces with nano-level surface roughness and sub-micron surface accuracy, so single-point diamond turning is now widely used In ultra-precision machining.
  • the tool and the spindle center of the machine tool where the workpiece is installed cannot be completely aligned, and a certain offset will occur.
  • the center offset error of the tool in the vertical direction includes the center tool height error and the center tool low error
  • the center deviation of the tool in the feed direction includes the tool under center deviation and the tool over center deviation. The above error will greatly affect the surface quality of the workpiece sample surface.
  • the present application provides a tool alignment method, an intelligent tool holder, and a tool setting method for turning in order to solve the problem that the tool alignment with the spindle center of the machine tool in the prior art cannot be online and inefficient.
  • the first aspect of the present application provides a tool alignment method in turning processing, including:
  • the error form includes a center knife height error and a center knife low error
  • the tool is aligned online.
  • the method for aligning tools in the turning process can obtain a cutting force curve by using the tools to perform pre-cutting on the surface of the workpiece. Then determine the error form of the cutter in the vertical direction of the center of the spindle according to the cutting force curve, and determine whether the cutter is a center cutter high error or a center cutter low error. Then according to the error form of the tool in the vertical direction of the spindle center, the error value of the tool in the vertical direction of the spindle center and the tool in the feed direction are obtained Center deviation value. Finally, according to the error value and the center deviation value, the tool is aligned online, so that the tool is aligned with the center of the spindle of the machine tool.
  • the alignment method provided by this application does not require the operator's experience to perform online alignment, but can accurately calculate the error value of the tool in the vertical direction and the tool in the feed direction according to the cutting force curve obtained after pre-cutting On the center deviation value, the tool can be aligned online based on the accurate error value and the center deviation value.
  • the alignment method provided by the present application is simple and can accurately identify the error value and the center deviation value online, which can greatly improve the efficiency of tool turning and the quality of the workpiece surface, and has great practicality.
  • a second aspect of the present application provides an intelligent tool holder.
  • the intelligent tool holder includes:
  • Tool table the tool table is used to install the cutter
  • a coarse adjustment module and a fine adjustment module are used to control the cutter to move in the vertical direction;
  • a collection module the collection module is used to collect the cutting force signal of the tool during turning
  • a processing module configured to receive the cutting force signal and process the cutting force signal according to the tool alignment method of any one of claims 1-16 to cause the tool to perform Align online.
  • the intelligent tool holder provided in the second aspect of the application adopts the alignment method provided in the first aspect of the application by using a processing module.
  • the The processing module can control the coarse adjustment module and the fine adjustment module to work, and then control the movement of the tool, and finally align the tool with the spindle center of the machine tool, improve the efficiency of tool turning and the quality of the workpiece surface, and have strong practicality. .
  • a third aspect of the present application provides an intelligent tool holder tool setting method.
  • the tool setting method includes:
  • the intelligent tool holder includes a tool post, the tool post is used to install the tool, a coarse adjustment module, and a fine adjustment module, and the coarse adjustment module and the fine adjustment module are used to control the tool to perform Movement, acquisition module, the acquisition module is used to collect the cutting force signal of the tool during turning, the processing module is used to receive the cutting force signal, and according to any one of claims 1-16 The method for aligning the cutter to process the cutting force signal;
  • the acquisition module collects the cutting force signal of the tool during turning
  • the processing module receives the cutting force signal and processes the cutting force signal, and then moves the cutter in the vertical direction through the coarse adjustment module and the fine adjustment module to make the cutter Perform online alignment.
  • the tool setting method of the intelligent tool holder provided in the third aspect of the application adopts the alignment method provided in the first aspect of the application by using a processing module.
  • the processing module can control the coarse adjustment module and the fine adjustment module to work, and then control the movement of the tool, and finally align the tool with the spindle center of the machine tool, realize online identification and compensation of the tool center error, and improve tool turning
  • the efficiency and the quality of the workpiece surface are highly practical.
  • FIG. 1 is a schematic structural diagram of a single-point diamond cutter in an embodiment of the present application.
  • FIG. 2 is a schematic diagram of the spindle coordinate system of the machine tool in the embodiment of the present application.
  • FIG. 3 is a process flow diagram of a method for aligning tools during turning in the embodiment of the present application.
  • FIG. 5 is a graph of the cutting force at the end of the cutting stroke when the center cutter height is incorrect in the embodiment of the present application.
  • FIG. 6 is a process flow diagram of a method for aligning a tool when the tool has a low center tool error in the embodiment of the present application.
  • FIG. 7 is a schematic diagram of a tool coordinate system and a spindle coordinate system when the tool has a low center tool error in the embodiment of the present application.
  • FIG. 8 is a schematic flowchart of S330 included in FIG. 6 according to an embodiment of the present application.
  • step S332 included in FIG. 8 is a schematic flowchart of step S332 included in FIG. 8 according to an embodiment of the present application.
  • FIG. 10 is a graph showing the change of cutting force with time within 6 seconds before the tool reaches the center of the spindle when the low error value of the center knife in the embodiment of the present application is -0.36 ⁇ m.
  • FIG. 11 is a graph showing the change of cutting force with time within 6 seconds before the tool reaches the center of the spindle when the low error value of the center knife in the embodiment of the present application is -19.92 ⁇ m.
  • FIG. 12 is a graph showing the variation of cutting force with time within 6 seconds before the tool reaches the center of the spindle when the low error value of the center knife in the embodiment of the present application is -41.21 ⁇ m.
  • FIG. 13 is a graph showing the change of cutting force with time within 6 seconds before the tool reaches the center of the spindle when the low error value of the center knife in the embodiment of the present application is -58.65 ⁇ m.
  • step S330 included in FIG. 6 according to another embodiment of the present application.
  • FIG. 15 is a schematic flowchart of S334 in FIG. 14 according to an embodiment of the present application.
  • 16 is a process flow chart of a method for aligning a tool when there is a center tool height error in another embodiment of the present application.
  • FIG. 17 is a schematic flowchart of S300 in FIG. 3 according to an embodiment of the present application.
  • FIG. 18 is a schematic flowchart of S300 in FIG. 3 according to another embodiment of the present application.
  • Fig. 19 is a graph of cutting force when the tool has a low center tool error and a tool under center deviation.
  • Fig. 20 is a graph of cutting force when the tool has only a low center tool error.
  • Fig. 21 is a graph of cutting force when the tool has a low center tool error and a tool over center deviation.
  • 22 is a schematic structural diagram of an intelligent tool holder in an embodiment of the present application.
  • Fig. 23 is an exploded view of Fig. 22.
  • FIG. 24 is a schematic structural diagram of a tool post in an embodiment of the present application.
  • FIG. 25 is a schematic structural diagram of a coarse adjustment module in an embodiment of the present application.
  • 26 is a schematic structural diagram of a fine-tuning module in an embodiment of the present application.
  • FIG. 27 is an exploded view of FIG. 26.
  • FIG. 28 is a schematic structural diagram of a braking module in an embodiment of the present application.
  • FIG. 29 is a schematic flowchart of a tool setting method in an embodiment of the present application.
  • the tools mentioned in this application may be, but not limited to, single-point diamond tools.
  • FIG. 1 is a schematic structural diagram of a single-point diamond tool in an embodiment of the present application.
  • the cutting part of the single-point diamond tool is mainly composed of the cutting face and the cutting edge.
  • the blade face is marked with a symbol consisting of the letter A and the subscript, and the cutting edge is marked with the letter S. Therefore, the main components of the single-point diamond tool are: front (rake face) Ar: the surface of the tool on which the chips flow out; rear (back face): the face of the tool opposite the newly formed surface of the workpiece; cutting edge S: The intersection line formed by the rake face and the flank face bears the cutting task during cutting; the blade tip: the arc cutting edge.
  • the tool back angle of the diamond tool is indicated by ⁇
  • the rake face is indicated by 110
  • the rake face is indicated by 120
  • the cutting edge is indicated by 130
  • the nose radius is indicated by R.
  • the reference planes used to form the tool angle in the cutting process of the tool mainly include: base plane, cutting plane, orthogonal plane, normal plane, assumed working plane and back plane.
  • the five planes are specifically: base plane Pr: A point passing through the cutting edge is perpendicular to the plane of the main cutting direction. Usually, it is parallel (or perpendicular) to the plane of the mounting surface (or axis) on the tool.
  • the base plane Pr of the tool can be understood as being parallel to the bottom surface of the tool;
  • the cutting plane Ps passing the selected point of the cutting edge, tangent to the cutting edge, and perpendicular to the plane of the base plane Pr.
  • the orthogonal plane Po passing through the selected point of the cutting edge, while being perpendicular to the plane of the base plane Pr and the cutting plane Ps
  • the normal plane Pn passing through the selected point of the cutting edge and perpendicular The plane of the cutting edge
  • the assumed working plane Pf passing the selected point of the cutting edge, parallel to the plane of the assumed feed motion and perpendicular to the base plane Pr
  • the back plane Pp passing the selected point of the cutting edge, while being perpendicular to the assumed The plane of the working plane Pf and the base plane Pr.
  • FIG. 2 is a schematic diagram of the spindle coordinate system of the machine tool in the embodiment of the present application.
  • the spindle coordinate system o-xyz will be established with the spindle center of the machine tool as the origin, where the positive direction of the x axis is opposite to the feed direction of the tool, and the positive direction of the z axis is perpendicular to the
  • the surface of the workpiece is outward, the positive direction of the y-axis is vertically upward, and the x-axis, the y-axis, and the z-axis are perpendicular to each other.
  • the tool is aligned with the origin o, then in the process of CNC turning, the turning of the workpiece by the tool can be accurately controlled.
  • the CNC machine tool cannot accurately control the position of the tool at the center of the workpiece, so it will greatly affect the quality of the workpiece surface.
  • the present application divides the error forms of the cutter in the vertical direction of the center of the spindle into: a center cutter height error (h high) and a center cutter low error (h).
  • the center tool height error indicates that the tool is higher than the spindle center in the vertical direction of the spindle center, that is, h high>0.
  • the center tool low error indicates that the tool is lower than the spindle center in the vertical direction of the spindle center, that is, h ⁇ 0.
  • the errors in the horizontal direction are divided into: tool under center deviation and tool over center deviation.
  • the tool under-center deviation means that the tool should be fed to the center of the spindle when cutting, but due to the error, the tool is not fed to the center of the spindle in the feed direction, that is, s ⁇ 0.
  • Tool over-center deviation means that when the tool is cutting, due to the error, the tool does not stop when it feeds to the center of the spindle, and continues to cut forward, resulting in the tool exceeding the center of the spindle in the feed direction, that is, s>0.
  • FIG. 3 is a process flow chart of a method for aligning tools during turning in an embodiment of the present application.
  • the embodiments of the present application provide a tool alignment method in turning, including S100, S200, S300, S400, and S500. Among them, S100, S200, S300, S400, S500 are described in detail as follows.
  • the tool and the workpiece separately, for example, install the tool on the intelligent tool holder, and install the workpiece on the spindle center of the machine tool.
  • the workpiece of the present application can be any shape and any material, and it is not specifically limited here.
  • the tool can be pre-aligned with the center of the spindle according to the operator's experience or tool setting method.
  • the pre-alignment cannot fully align the tool and the spindle center online. Therefore, an error has occurred in the tool and the spindle center at this time.
  • use a tool to pre-cut the surface of the workpiece that is, a knife.
  • the cutting force signal of the tool is collected in real time or regularly through sensors and other equipment, and then the cutting force signal is sent to the processing module, and the processing module can receive the cutting force signal and form the horizontal coordinate according to the obtained cutting force signal,
  • the cutting force is the cutting force graph of the ordinate.
  • the error form includes a center cutter height error and a center cutter low error.
  • FIG. 4 is the cutting force curve of the end of the cutting stroke when the center cutter has a low error in the embodiment of the present application; Force curve.
  • Force curve When the error form of the tool is the low error of the center tool, the cutting force will decrease due to the formation of the center cylinder.
  • the error form of the tool is the center tool height error, the cutting force will rise first and then fall to show a protruding state due to the formation of the center cone. Therefore, the cutting force curve can be used to easily determine the error form of the tool.
  • the cutting force amplitude can also be obtained from the cutting force curve, and the amplitude of the cutting force can also determine whether the existing error form is the center cutter high error or the center cutter low error.
  • the amplitude of the cutting force is greater than the average value of the cutting force in the previous stage, it is the center cutter height error; when the amplitude of the cutting force is less than the average value of the cutting force in the previous stage, it is the center cutter low error.
  • the error form of the tool in the vertical direction of the center of the spindle is a low center tool error, the error value of the tool in the vertical direction of the center of the spindle can be accurately obtained. If the error form of the cutter in the vertical direction of the spindle center is the center cutter height error, the error value of the cutter in the vertical direction of the spindle center can be accurately obtained. If the tool has no error in the vertical direction of the spindle center, the tool has been aligned with the spindle center in the vertical direction of the spindle center, and the error value is 0.
  • the center deviation value of the tool at the low error value of the center tool can be obtained. If the error form of the tool in the vertical direction of the center of the spindle is the center tool height error, the center deviation value of the tool at the center tool height error value can be obtained. If the tool has no error in the vertical direction of the spindle center, the center deviation value when the tool has no error in the vertical direction of the spindle center can be obtained. If there is no error in the feed direction of the tool, the tool has been aligned with the center of the spindle in the feed direction, and the center deviation value is 0.
  • moving the tool in the opposite direction to the absolute value of the error value and/or the center deviation value can accurately align the tool to the center of the spindle.
  • the error value of the tool is -3 and the center deviation value is +1, as long as the tool is moved vertically 3 and the tool is moved 1 in the feed direction, the tool can be aligned with the center of the spindle.
  • the method for aligning the tools in the turning process can obtain a cutting force curve by using the tools to pre-cut the surface of the workpiece. Then determine the error form of the cutter in the vertical direction of the center of the spindle according to the cutting force curve, and determine whether the cutter is a center cutter high error or a center cutter low error. Then according to the error form of the tool in the vertical direction of the spindle center, the error value of the tool in the vertical direction of the spindle center and the tool in the feed direction are obtained Center deviation value. Finally, according to the error value and the center deviation value, the tool is aligned online, so that the tool is aligned online with the center of the spindle of the machine tool.
  • the alignment method provided by this application does not need to rely on the experience of the operator to perform online alignment, but can accurately calculate the error value of the tool in the vertical direction and the tool in the feed direction according to the cutting force curve obtained after pre-cutting On the center deviation value, the tool can be aligned online based on the accurate error value and the center deviation value.
  • the alignment method provided by the present application is simple and can obtain accurate error values and center deviation values online, which greatly improves the efficiency of tool turning and the quality of the workpiece surface, and has great practicality.
  • FIG. 6 is a process flow diagram of a method for aligning a tool when the tool has a low center tool error in the embodiment of the present application.
  • S310, S320, and S330 is as follows.
  • the trajectory equation of the cutting edge of the tool in the tool coordinate system is established, and then the trajectory equation of the cutting edge of the tool in the spindle coordinate system is established according to the trajectory equation of the cutting edge of the tool in the tool coordinate system. Connect the trajectory of the cutting edge of the tool to the spindle coordinate system.
  • S330 Establish a simulated cutting force model according to the trajectory equation of the cutting force and the projected length of the generatrix of the side of the central circular table on the surface of the workpiece facing away from the machine tool in the spindle coordinate system, and establish a simulated cutting force model, according to the simulated cutting force
  • the model obtains the value of the center knife low error, and the value of the center knife low error is the error value.
  • the "the equation for establishing the trajectory of the cutting edge of the tool in the spindle coordinate system" that is, S310 includes S312.
  • S312 The detailed introduction of S312 is as follows.
  • the spindle coordinate system o-xyz is established with the spindle center as the origin, wherein the positive direction of the x-axis is opposite to the feed direction of the tool, and the positive direction of the z-axis is perpendicular to the surface of the workpiece,
  • the positive direction of the y-axis is vertically upward, and the x-axis, the y-axis, and the z-axis are perpendicular to each other;
  • the trajectory equation of the cutting edge of the tool in the spindle coordinate system is:
  • x, y and z are the coordinates of any point (x, y, z) on the cutting edge trajectory of the tool in the spindle coordinate system o-xyz
  • R is the radius of the tool tip arc
  • a p is the cutting depth when the tool is cutting
  • s is the horizontal distance between the center of the cutting edge of the tool and the y axis
  • h is the vertical distance between the center of the cutting edge of the tool and the x axis distance.
  • step S311 may be further included before S312.
  • the detailed introduction of S311 is as follows.
  • a movable tool coordinate system o′-x′y′z′ is established with the tool tip of the tool as the origin, wherein the positive direction of the x′ axis is opposite to the feed direction of the tool, and the z′ axis
  • the positive direction of is perpendicular to the surface of the workpiece outward
  • the positive direction of the y′ axis is vertically upward (that is, the direction in which the tool rises in the vertical direction)
  • the x′ axis, the y′ axis, and the z′ The axes are perpendicular to each other.
  • the trajectory equation for determining the cutting edge of the tool is: Where x′, y′ and z′ are the coordinates of any point (x′, y′, z′) on the cutting edge trajectory of the tool in the tool coordinate system o′-x′y′z′, R is the tip radius of the tool, and a p is the cutting depth when the tool is cutting. Then, the trajectory equation of the cutting edge of the tool in the spindle coordinate system is established according to the trajectory equation of the cutting edge of the tool in the tool coordinate system.
  • the trajectory equation of the projected length of the generatrix on the side of the central circular table on the surface of the workpiece facing away from the machine tool in the spindle coordinate system" that is, S320 includes S321.
  • the detailed introduction of S321 is as follows.
  • x, y and z are the coordinates of any point (x, y, z) on the cutting edge trajectory of the tool in the spindle coordinate system o-xyz
  • h is the center of the cutting edge of the tool and the The vertical distance between the x-axis
  • s is the horizontal distance between the center of the cutting edge of the tool and the y-axis
  • R is the radius of the tool tip arc
  • a p is the cutting time when the tool is cutting Depth
  • the radius of gyration at any point (x, y, z) on the cutting edge of the tool is
  • FIG. 7 is a schematic diagram of the tool coordinate system and the spindle coordinate system when the tool has a low center tool error in the embodiment of the present application.
  • the cutting edge boundary of the tool is located on the surface x'o'z', and the cutting edge curve (L 2 ) obtained by rotating the cutting edge (L 1 ) counterclockwise around the z axis by an angle ⁇ is also the generatrix equation of the central circular table .
  • the rotation angle ⁇ of the curves L 1 and L 2 is:
  • the expression of the simulated cutting force model is:
  • F′ is a component of the simulated cutting force, and the component of the simulated cutting force is parallel to the positive direction of the z-axis in the spindle coordinate system o-xyz, that is, F′ is perpendicular to the surface of the workpiece.
  • F is the cutting force
  • z is the coordinate of z in the spindle coordinate system o-xyz at any point (x, y, z) on the cutting edge trajectory of the tool
  • R is the radius of the tool tip arc
  • a p is the cutting depth when the tool is cutting
  • s is the horizontal distance between the center of the cutting edge of the tool and the y axis
  • h is the distance between the center of the cutting edge of the tool and the x axis vertical distance.
  • FIG. 8 is a schematic flowchart of step S330 included in FIG. 6 according to an embodiment of the present application.
  • S330 includes S331 and S332, where S331 is a trajectory equation in the spindle coordinate system according to the cutting force and the projection length of the generatrix of the side of the central circular table on the surface of the workpiece facing away from the machine tool in the spindle coordinate system
  • S332 is to obtain the value of the center knife low error according to the simulated cutting force model, and the value of the center knife low error is the error value.
  • FIG. 9 is a schematic diagram of a flowchart included in S332 in FIG. 8 according to an embodiment of the present application.
  • the "based on the simulated cutting force model, the value of the low error of the center knife" is obtained, that is, S332 includes S333.
  • the detailed introduction of S333 is as follows.
  • k is f r is the feed rate of the tool
  • S t is the time the tool moves to the center of the spindle during the simulation.
  • the total simulation time can be taken as 6 seconds, and the time range t of the required fitting period is (0, 4.687).
  • the data points (t i , y i ) of the cutting force change with time in 4.687 seconds before the inflection point are selected in the actual cutting force image.
  • only the knife low error h is an unknown quantity.
  • the least square method is used to fit the model.
  • a variety of algorithms can be used to fit the data points (t i , y i ) to the model curve, such as the Gauss-Newton iteration method, Levenberg-Marquardt, and so on.
  • the Levenberg-Marquardt algorithm is used as an example. Under the condition of the initial value of any given variable h, let J be the Jacobian matrix of the function f(t i , h), as shown in the following formula Shown as:
  • the parameter vector h is replaced by h+ ⁇ h, and ⁇ h can be obtained by linearization approximation by the function:
  • ⁇ is a positive parameter and I is the identity matrix.
  • FIG. 10 is a graph showing the change in cutting force with time within 6 seconds before the tool reaches the center of the spindle when the center cutter low error value is 0.36 ⁇ m.
  • FIG. 11 is a graph showing the change of cutting force with time within 6 seconds before the tool reaches the center of the spindle when the center cutter low error value is 19.92 ⁇ m in the embodiment of the present application.
  • FIG. 12 is a graph showing the change of cutting force with time within 6 seconds before the tool reaches the center of the spindle when the center cutter low error value is 41.21 ⁇ m in the embodiment of the present application.
  • FIG. 13 is a graph showing the variation of cutting force with time within 6 seconds before the tool reaches the center of the spindle when the low error value of the center knife in the embodiment of the present application is 58.65 ⁇ m.
  • the cutting parameter at this time is that the tool radius R is 1.0 mm, the tool clearance angle is 10°, and the cutting depth is 6 ⁇ m.
  • the simulated cutting force fitting curve is in good agreement with the actual curve, proving the accuracy of the simulated cutting force model.
  • FIG. 14 is a schematic flowchart of S330 included in FIG. 6 according to another embodiment of the present application.
  • the "based on the simulated cutting force model to obtain the value of the low error of the center knife" that is, S332 includes S334.
  • the detailed introduction of S334 is as follows.
  • FIG. 15 is a schematic flowchart of S334 in FIG. 14 according to an embodiment of the present application.
  • S334 includes S335.
  • the detailed introduction of S335 is as follows.
  • FIG. 16 is a process flow diagram of a method for aligning a tool when the tool has a center tool height error in another embodiment of the present application.
  • S340, S350 and S360 is as follows.
  • the interference force amplitude can be obtained according to the cutting force curve.
  • the interference force amplitude has a significant effect on the value of the center knife height error obtained later.
  • the amplitude of the interference force provided by the present application is the difference between the cutting force after the inflection point at the end of the cutting stroke reaches the maximum and the average value of the cutting force before the inflection point.
  • the mechanical properties of the workpiece and the cutting parameters of the workpiece will affect the value of the center knife height error, so according to the mechanical properties of the workpiece and the cutting parameters, the abscissa can be established as the value of the center knife height error, and the ordinate is the interference force amplitude Value of the interference force amplitude model.
  • the alignment method provided by the present application is simple, can accurately calculate the value of the center knife height error, and has strong practicability.
  • the mechanical properties of the workpiece include the material of the workpiece, the hardness of the workpiece, and the elastic modulus of the workpiece;
  • the cutting parameters include the radius of the tool tip arc and The clearance angle of the tool, the cutting depth when the tool is cutting, and the feed rate of the tool.
  • FIG. 17 is a schematic flowchart of S300 in FIG. 3 according to an embodiment of the present application.
  • S370 is as follows.
  • the cutting force shape can be obtained from the cutting force curve, and the amplitude of the cutting force after the inflection point at this time should be greater than the average value of the cutting force before the inflection point. Then move the tool down a certain distance in the vertical direction, and then cut the surface of the workpiece again, according to the cutting force curve to get the cutting force shape. Determine whether the amplitude of the cutting force after the inflection point at this time is less than the average value of the cutting force before the inflection point. If it is less than the average value of the cutting force at the front of the inflection point, it means that the error form at this time has been changed to the center cutter low error. If it is not less than the average value of the cutting force at the front of the inflection point, continue to move the tool down a distance in the vertical direction, and then repeat the operation.
  • FIG. 18 is a schematic flowchart of S300 in FIG. 3 according to another embodiment of the present application.
  • S380 is as follows.
  • the cutting force shape can be obtained from the cutting force curve, and the amplitude of the cutting force after the inflection point at this time should be less than the average value of the cutting force before the inflection point. Then move the cutter upward in the vertical direction for a distance, and then cut the surface of the workpiece once again, according to the cutting force curve to obtain the cutting force pattern. Determine whether the amplitude of the cutting force after the inflection point at this time is less than the average value of the cutting force before the inflection point. If it is greater than the average value of the cutting force at the front of the inflection point, it means that the error form at this time has been changed to the center cutter height error. If it is not greater than the average value of the cutting force in front of the inflection point, continue to move the tool up a distance in the vertical direction, and then repeat the operation.
  • the calculation method of the center knife height error is different from the center knife low error.
  • the calculation method of the center knife height error is simpler, and the calculation method of the center knife low error is more accurate. Therefore, if the error form is the center knife height error, the present application can first change it to the center knife low error, and then use the method of the center knife low error for more accurate calculation. If the error form is the low error of the center knife, the present application can first change it to the center knife height error, and then use the method of the center knife height error for faster calculation.
  • the embodiment of the present application also provides two specific empirical formulas for the center tool height error, and the parameters contained in this empirical formula will change with the wear of the tool.
  • the first embodiment of the present application is an empirical formula for the center knife height error of the 6061 aluminum alloy.
  • the second embodiment of the present application is an empirical formula for the center knife height error of a workpiece made of brass.
  • the specific formula obtained by calculation is:
  • the influence coefficients K 1 , K 2 , K 3 , K 4 and G 1 , G 2 , G 3 , G 4 are the tool radius, tool back angle, cutting depth, 6061 aluminum alloy and brass Feed rate.
  • the calculation when the center knife has a low error may also be performed first to obtain the value of the center knife low error. Then move the tool up a distance in the vertical direction to become the center tool height error, and then use the calculation method of the center tool height error to calculate the value of the center tool height error. Then compare the two to comprehensively judge the error value of the tool in the vertical direction.
  • the alignment method provided by another embodiment of the present application will increase the number of steps, it can calculate two values, and then compare the two values to comprehensively determine the vertical error value of the tool, which can further improve the tool The accuracy of the identification of the error value in the vertical direction.
  • the alignment method provided by still another embodiment of the present application, it is also possible to perform multiple pre-cuts, and then calculate the average value of each calculated value.
  • the method of averaging through multiple cuttings can greatly improve the accuracy of identifying the error value of the tool in the vertical direction.
  • the tool will not only have a vertical error in the vertical direction, but also a horizontal error in the feed direction of the tool.
  • the method of eliminating horizontal errors will be specifically described below.
  • the "according to the error form of the tool in the vertical direction of the spindle center, obtaining the center deviation value of the tool in the feed direction" includes:
  • the cutting force curve is established to establish a center deviation model
  • Figure 19 is the cutting force curve when the tool has a low center tool error and the tool is under center deviation
  • Figure 20 is the cutting force curve when the tool only has a low center tool error
  • Figure 21 is the tool with a low center tool error and tool over The cutting force curve when the center deviation.
  • the initial point of interference is the position corresponding to the first inflection point in the figure. Wherein the cutter feed rate f r are known. It can also be seen from the figure that the first interference time t is known, and its value can be obtained by measuring the time from the inflection point in the cutting force curve to when the cutting force is zero. However, the second interference time T is unknown, and the second interference time T is not exactly the same for the error of the tool in the vertical direction.
  • the cutter has a low center cutter error, and the cutter has the center deviation in the feed direction.
  • the tool has no error form in the vertical direction of the spindle center, but the tool has a center deviation in the feed direction.
  • the tool has the center tool height error, and the tool has a center deviation in the feed direction.
  • the second interference time T of these three error cases is not exactly the same. At the same time, if the tool has a center tool height error and the tool does not have an error in the vertical direction, the content of the center deviation is also applicable, and will not be repeated here.
  • the expression of the second interference time is Where R is the arc radius of the tool tip and a p is the cutting depth when the tool is cutting.
  • the expression of the second interference time is Where R is the arc radius of the tool tip and a p is the cutting depth when the tool is cutting.
  • the expression of the second interference time is wherein, R is the tool nose radius, a p when the cutting depth of the cutting tool, ⁇ is the angle of the tool, h is the height of the blade of the tool center height error.
  • FIG. 22 and FIG. 23, is a schematic structural diagram of an intelligent tool holder in an embodiment of the present application.
  • Fig. 23 is an exploded view of Fig. 22.
  • An embodiment of the present application provides an intelligent tool holder.
  • the intelligent tool holder 1 includes:
  • the tool post 10 is used for installing the tool 100.
  • the tool post 10 is mainly used to install and fix the tool 100.
  • the collection module 40 can also be installed on the knife table 10.
  • the coarse adjustment module 20 and the fine adjustment module 30 are used to control the cutter 100 to move in the vertical direction.
  • the acquisition module 40 is used for acquiring the cutting force signal of the tool 100 when turning.
  • the processing module 50 is configured to receive the cutting force signal and process the cutting force signal according to the method for aligning the tool 100 provided in the first aspect of the present application to make the tool 100 online alignment.
  • the intelligent tool holder 1 provided by the embodiment of the present application adopts the alignment method provided by the embodiment of the present application by using the processing module 50.
  • the alignment method provided by the embodiment of the present application accurately calculates the error value and the center deviation value
  • the error value of the tool in the vertical direction of the center of the spindle needs to control the processing module 50 to control the coarse adjustment module 20 and the fine adjustment module 30 to work, and then control the movement of the tool 100 in the vertical direction;
  • For the center deviation value in the direction you only need to control the processing module 50 to directly modify the coordinate values of the tool coordinates on the x-axis of the machine tool, and finally align the tool 100 with the spindle center of the machine tool online to improve the tool 100
  • the efficiency of turning and the quality of the surface of the workpiece have strong practicability.
  • the intelligent tool holder 1 is usually used in conjunction with the machine tool.
  • the machine tool can move along the x-axis direction in the spindle coordinate system, the tool setting device can move in the direction of the z-axis as a whole, or the machine tool can follow the The x-axis and z-axis directions move, or the intelligent tool post 1 can move along the x-axis and z-axis directions in the spindle coordinate system as a whole.
  • the above moving method is essentially equivalent to that the tool 100 can move in the x-axis and z-axis directions, but the tool 100 cannot move in the y-axis direction.
  • FIG. 24 is a schematic structural diagram of a tool post in an embodiment of the present application.
  • the tool post 10 includes a tool 100, a clamping plate 101, and a tool fastening bolt 102.
  • the tool 100 and the clamping plate 101 are fixed on the tool seat 10 by the tool fastening bolt 102.
  • FIG. 25 is a schematic structural diagram of a coarse adjustment module in an embodiment of the present application.
  • the coarse adjustment module 20 includes a coupling 200, a fixing plate fastening screw 201, an upper baffle 202, an elastic retaining ring 203 for holes, a first ball bearing 204, a guide rail 205, a key 207, a lower baffle 210, a second
  • the ball bearing 211, the fixed plate 212, the screw 208 and the slider 209, the servo motor 700 is connected to the screw 208 through the coupling 200, the screw 208 passes through the screw nut 206 and the slider 209 Connected, the slider 209 is connected to the tool post 10, and the screw 208 is preferably a ball screw 208.
  • the servo motor 700 can drive the screw 208 to rotate, and then the rotation of the screw 208 can drive the slider 209 to move in the vertical direction, and the movement of the slider 209 can drive the movement of the tool post 10.
  • the cutting tool 100 is installed on the cutting table 10. Therefore, the servo motor 700 controls the movement of the coarse adjustment module 20 to control the movement of the cutter 100 in the vertical direction.
  • This module is mainly used for the rapid adjustment of the cutter 100 in the vertical height direction, with a range resolution of about 5 ⁇ m.
  • the realization principle is the inching of the slider 209 under the control of the servo motor 700.
  • the servo motor 700 can realize a closed loop of motion control, and can accurately achieve the position of the slider 209.
  • FIG. 26 is a schematic structural diagram of a fine-tuning module in an embodiment of the present application.
  • FIG. 27 is an exploded view of FIG. 26.
  • the fine adjustment module 30 includes a knife holder 300, a knife holder fixing screw 301, a capacitive displacement sensor 303, a piezoelectric ceramic driver 302, a piezoelectric ceramic driver fastening screw 304, and a flexible hinge 305, and the flexible hinge 305 is disposed on the knife
  • the piezoelectric ceramic driver 302 is connected to the flexible hinge 305
  • the capacitive displacement sensor 303 is provided on the flexible hinge 305
  • the fixing plate 212 is provided on the flexible plate by a fixing plate fastening screw Hinge 305.
  • the flexible hinge 305 is a parallelogram flexible hinge 305.
  • the fine adjustment module 30 is mainly used for fine adjustment of the cutter 100 in the vertical height direction, and the range resolution is below 1 ⁇ m.
  • the realization principle is based on the micro movement of the flexible hinge 305 under the control of the piezoelectric ceramic driver 302 and the capacitive displacement sensor 30324.
  • the piezoelectric ceramic driver 302 and the capacitive displacement sensor can realize a closed loop of motion control, and can precisely control the fine movement of the position of the tool post 10.
  • FIG. 28 is a schematic structural diagram of a braking module according to an embodiment of the present application.
  • the intelligent tool holder 1 further includes a braking module 60, and the braking module 60 is used to control the connection and disconnection of the tool post 10 and the fine adjustment module 30.
  • the braking module 60 includes an electromagnet 600 and an electromagnet fastening screw 601.
  • the electromagnet 600 is fixed on the tool post 10 by the electromagnet fastening screw 601.
  • This module is mainly used to realize the locking of the fine adjustment module 30 and the knife table 10, that is, the tight connection and disconnection of the knife table 10 and the knife holder 300.
  • the realization principle is based on the magnetism of the electromagnet 600 when it is energized and the non-magnetism when it is powered off.
  • the electromagnet 600 When the electromagnet 600 is energized, due to the effect of magnetism, the tool post 10 is tightly connected to the fine adjustment module 30, and the tool post 10 is now tightly connected to the tool holder 300.
  • the tool table 10 is prevented from being displaced again after rough adjustment, thereby affecting the position accuracy of the tool, and at the same time it is convenient for the fine adjustment module 30 to make fine adjustments to the tool table 10.
  • the electromagnet 600 is powered off, because the electromagnet 600 is demagnetized, the tool post 10 and the fine adjustment module 30 are disconnected, that is, the tool post 10 and the tool holder 300 are disconnected.
  • the force signal acquisition module 40 includes a sensor 400 installed above the tool 100, and is used to collect cutting force signals for the tool 100 in real time or periodically.
  • This module is mainly used to detect various conditions of the tool 100. For example, the position of the tool 100, the cutting force signal of the tool 100, the wear and chipping of the surface of the tool 100 are detected, and a full range of signal acquisition is performed on the tool 100 when turning the workpiece.
  • the collected signal can be sent to the processing module 50 for corresponding processing.
  • the implementation principle is that the sensor 400 collects the turning force signal in real time and sends it to the module 50 to analyze the abnormality.
  • the processing module 50 can be disposed in the tool holder 300 and electrically connected to the collection module 40.
  • the processing module 50 is used to receive various signals sent by the collection module 40 and process related signals, and then perform corresponding control on the driving module 70, the coarse adjustment module 20, and the fine adjustment module 30 according to the processed results. At the same time, the processing module 50 can directly transmit the calculated error value and the center deviation value to the machine tool, thereby controlling the tool coordinate position of the machine tool.
  • the processing procedure of the present application is to use the above-mentioned alignment method for processing.
  • the intelligent tool holder 1 further includes a driving module 70, and the driving module 70 is used to control the coarse adjustment module 20 and the fine adjustment module 30 so that The cutter 100 moves in the vertical direction.
  • the driving module 70 of the present application may be but not limited to the servo motor 700.
  • FIG. 29 is a schematic flowchart of the tool setting method in the embodiment of the present application.
  • the embodiments of the present application provide a tool setting method of the intelligent tool holder 1, and the tool setting method includes S600, S700, and S800.
  • the detailed introduction of S600, S700, S800 is as follows.
  • an intelligent tool holder 1 is provided, and the intelligent tool holder 1 includes a tool table 10 for installing the tool 100, a coarse adjustment module 20, and a fine adjustment module 30, the coarse adjustment module 20 and all
  • the fine-tuning module 30 is used to control the tool 100 to move in the vertical direction
  • the acquisition module 40 is used to collect the cutting force signal of the tool 100 when turning
  • the processing module 50 the processing The module 50 is used to receive the cutting force signal and process the cutting force signal according to the alignment method of the tool 100 provided in the first aspect of the present application.
  • the tool 100 is used to pre-cut the surface of the workpiece, and the acquisition module 40 is used to collect the cutting force signal of the tool 100 during turning.
  • the processing module 50 receives the cutting force signal, processes the cutting force signal, and then moves the cutter 100 in the vertical direction through the coarse adjustment module 20 and the fine adjustment module 30 , So that the cutter 100 is aligned online.
  • the tool setting method of the intelligent tool holder 1 provided by the embodiment of the present application adopts the alignment method provided by the embodiment of the present application by using the processing module 50.
  • the alignment method provided by the embodiment of the present application accurately calculates the error value and the center deviation
  • For the center deviation value of the tool in the feed direction it is only necessary to control the processing module 50 to directly modify the coordinate value of the tool coordinate in the x-axis of the machine tool, and finally make the tool 100 be aligned with the spindle center of the machine tool online .
  • To improve the efficiency of tool 100 turning and the quality of the workpiece surface has a strong practicality.
  • the specific steps of the tool setting method provided in the present application may be:
  • the electromagnet 600 is powered off, and the locked state of the tool post 10 and the tool holder 300 is released.
  • the servo motor 700 is controlled to rotate, and the screw 208 is driven to rotate synchronously through the coupling 200, and the screw nut 206 is fixed in the slider 209.
  • the tool post 10 and the slider 209 are linked by screws, and the screw 208 rotates to drive the screw nut 206.
  • the slider 209 and the knife table 10 make a linear movement along the vertical direction of the knife holder 300 to realize the up and down movement of the knife table 10 and complete the coarse adjustment of the knife 100 to the knife.
  • the electromagnet 600 is controlled to be energized, and the tool post 10 is locked on the tool holder 300 by the electromagnet 600, so that the tool post 10 does not move after the rough adjustment, and the position accuracy is guaranteed. Then, by inputting a voltage to the piezoelectric ceramic driver 302 to control the piezoelectric ceramic driver 302 to expand and contract (as shown in FIG. 27), the capacitive displacement sensor 303 feeds back and forth the amount of expansion and contraction, thereby making the flexible hinge 305 on the tool holder 300 vertically small
  • the parallelogram movement of the machine realizes fine adjustment, and realizes that the cutter 100 is aligned with the center of the spindle of the machine tool. In order to achieve remote control, online tool setting, and ultimately achieve ultra-precision intelligent manufacturing, unmanned factory, meet the requirements of "Made in China 2025".

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Abstract

一种车削加工中刀具（100）的对准方法、智能刀架（1）及对刀方法，车削加工中刀具（100）的对准方法包括：安装刀具（100）和工件，将刀具（100）与安装工件的机床的主轴中心进行预对准，再进行预切削，得到切削力曲线图。根据切削力曲线图判断刀具（100）在主轴中心的竖直方向上存在的误差形式，误差形式包括中心刀高误差和中心刀低误差。根据刀具（100）在主轴中心的竖直方向上存在的误差形式，得到刀具（100）在主轴中心的竖直方向上存在的误差值，以及刀具（100）在进给方向上存在的中心偏差值。根据误差值和中心偏差值，将刀具（100）进行在线对准。

Description

一种车削加工中刀具的对准方法、智能刀架及对刀方法
本申请要求申请日为2018年11月27日的发明名称为“基于切削力的超精密加工中心误差在线辨识与补偿方法”，申请号为201811425937.8；申请日为2018年11月27日的发明名称为“超精密机床智能对刀仪、智能对刀机床及智能对刀方法”，申请号为201811425902.4；申请日为2019年01月11日的发明名称为“一种车削加工中刀具的对准方法、车削装置”，申请号为201910038705.5的在先申请优先权，上述在先申请的内容以引入的方式并入本文本中。
技术领域
本申请属于单点金刚石车削加工技术领域，具体涉及一种车削加工中刀具的对准方法、智能刀架及对刀方法。
背景技术
由于单点金刚石具有纳米级的边缘锋利度和极高的硬度，可直接用于加工具有纳米级表面粗糙度和亚微米级面形精度的超光滑表面，因此单点金刚石车削现已广泛应用于超精密加工中。但在实际加工过程中，刀具与安装工件的机床的主轴中心并不能完全对准，会产生一定的偏移。例如刀具在竖直方向上产生的中心偏移误差包括中心刀高误差和中心刀低误差；刀具在进给方向上产生的中心偏差包括刀具欠中心偏差和刀具过中心偏差。而上述误差会极大地影响工件样品表面的面形质量。
目前，为了实现刀具与机床主轴中心误差的消除，通常采用试切工件离线测量的方法进行中心误差的辨识，该方法依赖于高精密测量设备及操作人员的经验，效率低下，且无法实现刀具中心误差的在线辨识与补偿。因此，现在需要寻求一种新的在线刀具对准方法以及车削装置来解决上述问题。
申请内容
鉴于此，本申请为了解决现有技术中刀具对准机床的主轴中心无法实现在线、效率低下的问题，提供了一种车削加工中刀具的对准方法、智能刀架及对刀方法。
本申请第一方面提供了一种车削加工中刀具的对准方法，包括：
安装刀具和工件，将所述刀具与安装所述工件的机床的主轴中心进行预对准，再进行预切削，得到切削力曲线图；
根据所述切削力曲线图判断所述刀具在所述主轴中心的竖直方向上存在的误差形式、所述误差形式包括中心刀高误差和中心刀低误差；
根据所述刀具在所述主轴中心的竖直方向上存在的误差形式，得到所述刀具在所述主轴中心的竖直方向上存在的误差值；
根据所述刀具在所述主轴中心的竖直方向上存在的误差形式，得到所述刀具在进给方向上存在的中心偏差值；
根据所述误差值和所述中心偏差值，将所述刀具进行在线对准。
本申请第一方面提供的车削加工中刀具的对准方法，通过使用刀具在工件表面进行预切削，可得到切削力曲线图。再根据所述切削力曲线图判断所述刀具在所述主轴中心的竖直方向上存在的误差形式，确定刀具是为中心刀高误差还是中心刀低误差。然后根据所述刀具在所述主轴中心的竖直方向上存在的误差形式，得到所述刀具在所述主轴中心的竖直方向上存在的误差值，以及所述刀具在进给方向上存在的中心偏差值。最后根据所述误差值和所述中心偏差值，将所述刀具进行在线对准，使刀具与机床的主轴中心进行对准。本申请提供的对准方法，不需要靠操作人员的经验进行在线对准，而可根据预切削后得到的切削力曲线图准确计算出刀具在竖直方向上的误差值和刀具在进给方向上的中心偏差值，最后可根据准确的误差值和中心偏差值将刀具进行在线对准。本申请提供的对准方法，方法简单，可在线辨识得到精确的误差值和中心偏差值，可大大提高刀具车削的效率和工件表面的质量，具有极大的实用性。
本申请第二方面提供了一种智能刀架，所述智能刀架包括：
刀台，所述刀台用于安装所述刀具；
粗调模块、及微调模块，所述粗调模块和所述微调模块用于控制所述刀具在竖直方向上进行移动；
采集模块，所述采集模块用于采集所述刀具在车削时的切削力信号；
处理模块，所述处理模块用于接收所述切削力信号，并根据如权利要求1-16任一项所述的刀具的对准方法来对所述切削力信号进行处理，使所述刀具进行在线对准。
本申请第二方面提供的智能刀架，通过使用处理模块采用本申请第一方面提供的对准方法，当本申请第一方面提供的对准方法准确计算出误差值和中心偏差值后，所述处理模块可控制粗调模块和微调模块进行工作，进而控制刀具的移动，最终使刀具与机床的主轴中心进行在线对准，提高刀具车削的效率与工件表面的质量，具有很强的实用性。
本申请第三方面提供了一种智能刀架的对刀方法，所述对刀方法包括：
提供智能刀架，所述智能刀架包括刀台，所述刀台用于安装所述刀具，粗调模块、及微调模块，所述粗调模块和所述微调模块用于控制所述刀具进行移动，采集模块，所述采集模块用于采集所述刀具在车削时的切削力信号，处理模块，所述处理模块用于接收所述切削力信号，并根据如权利要求1-16任一项所述的刀具的对准方法来对所述切削力信号进行处理；
使用所述刀具对工件表面进行预切削，同时所述采集模块采集所述刀具在车削时的切削力信号；
所述处理模块接收所述切削力信号，并对所述切削力信号进行处理，再通过所述粗调模块和所述微调模块使所述刀具在竖直方向上进行移动，以使所述刀具进行在线对准。
本申请第三方面提供的智能刀架的对刀方法，通过使用处理模块采用本申请第一方面提供的对准方法，当本申请第一方面提供的对准方法准确计算出误差值和中心偏差值后，所述处理模块可控制粗调模块和微调模块进行工作，进而控制刀具的移动，最终使刀具与机床的主轴中心进行在线对准，实现刀具中心误差的在线辨识与补偿，提高刀具车削的效率与工件表面的质量，具有很强的实用性。
附图说明
为了更清楚地说明本申请实施方式中的技术方案，下面将对本申请实施方式中所需要使用的附图进行说明。
图1为本申请实施方式中单点金刚石刀具的结构示意图。
图2为本申请实施方式中机床的主轴坐标系的示意图。
图3为本申请实施方式中车削加工中刀具的对准方法的工艺流程图。
图4为本申请实施方式中中心刀低误差时切削行程末端的切削力曲线图。
图5为本申请实施方式中中心刀高误差时切削行程末端的切削力曲线图。
图6为本申请实施方式中刀具存在中心刀低误差时刀具的对准方法的工艺流程图。
图7为本申请实施方式中刀具存在中心刀低误差时刀具坐标系与主轴坐标系的示意图。
图8为本申请一实施方式图6中S330所包括的流程图示意图。
图9为本申请实施方式图8中S332所包括的流程图示意图。
图10为本申请实施方式中中心刀低误差值为-0.36μm时刀具到达主轴中心前6秒内切削力随时间变化的曲线。
图11为本申请实施方式中中心刀低误差值为-19.92μm时刀具到达主轴中心前6秒内切削力随时间变化的曲线。
图12为本申请实施方式中中心刀低误差值为-41.21μm时刀具到达主轴中心前6秒内切削力随时间变化的曲线。
图13为本申请实施方式中中心刀低误差值为-58.65μm时刀具到达主轴中心前6秒内切削力随时间变化的曲线。
图14为本申请另一实施方式图6中S330所包括的流程图示意图。
图15为本申请实施方式图14中S334所包括的流程示意图。
图16为本申请另一实施方式中刀具存在中心刀高误差时刀具的对准方法的工艺流程图。
图17为本申请一实施方式图3中S300所包括的流程示意图。
图18为本申请另一实施方式图3中S300所包括的流程示意图。
图19为刀具存在中心刀低误差和刀具欠中心偏差时的切削力曲线图。
图20为刀具仅存在中心刀低误差时的切削力曲线图。
图21为刀具存在中心刀低误差和刀具过中心偏差时的切削力曲线图。
图22为本申请实施方式中智能刀架的结构示意图。
图23为图22的爆炸图。
图24为本申请实施方式中刀台的结构示意图。
图25为本申请实施方式中粗调模块的结构示意图。
图26为本申请实施方式中微调模块的结构示意图。
图27为图26的爆炸图。
图28为本申请实施方式中制动模块的结构示意图。
图29为本申请实施方式中对刀方法的流程示意图。
附图标记：
智能刀架-1，刀台-10，刀具-100，夹板-101，刀具紧固螺栓-102，粗调模块-20，联轴器-200，固定板紧固螺钉-201，上挡板-202，孔用弹性挡圈-203，第一滚珠轴承-204，导轨-205，丝杆螺母-206，键-207，丝杆-208，滑块-209，下挡板-210，第二滚珠轴承-211，固定板-212，微调模块-30，刀座-300，刀架固定螺钉-301，压电陶瓷驱动器-302，电容位移传感器-303，压电陶瓷驱动器紧固螺钉-304，柔性铰链-305，采集模块-40，传感器-400，处理模块-50，制动模块-60，电磁铁-600，电磁铁紧固螺钉-601，驱动模块-70，伺服电机-700。
具体实施方式
以下是本申请的优选实施方式，应当指出，对于本技术领域的普通技术人员来说，在不脱离本申请原理的前提下，还可以做出若干改进和润饰，这些改进和润饰也视为本申请的保护范围。
本申请在在介绍对准方法之前，先介绍一下本申请提到的刀具的一些基本信息。本申请提到的刀具可以为但不限于单点金刚石刀具，下面首先对单点金刚石刀具进行简单的介绍：
请参考图1，图1为本申请实施方式中单点金刚石刀具的结构示意图。单点金刚石刀具的切削部分主要由刀面和切削刃两部分构成。刀面用字母A与下角标组成的符号标记，切削刃用字母S标记。因此单点金刚石刀具的主要构成部分为：前面(前刀面)Ar：刀具上切屑流出的表面；后面(后刀面)：刀具上与工件新形成的表面相对的刀面；切削刃S：前刀面与后刀面形成的交线，在切削中承担切削任务；刀尖：圆弧切削刃。在图1中所述金刚石刀具的刀具后角用δ表示，前刀面用110表示，后刀面用120表示，切削刃用130表示，刀尖半径用R表示。
另外，在刀具切削的过程中用于构成刀具角度的参考平面主要有：基面、切削平面、正交平面、法平面、假定工作平面和背平面，该五个平面具体为：基面Pr：过切削刃选定点，垂直于主切削方向的平面。通常，它平行(或垂直)于刀具上的安装面(或轴线)的平面。例如：刀具的基面Pr，可理解为平行于刀具的底面；切削平面Ps：过切削刃选定点，与切削刃相切，并垂直于基面Pr的平面。它也是切削刃与切削速度方向构成的平面；正交平面Po：过切削刃选定点，同时垂直于基面Pr与切削平面Ps的平面；法平面Pn：过切削刃选定点，并垂直于切削刃的平面；假定工作平面Pf：过切削刃选定点，平行于假定进给运动方向，并垂直于基面Pr的平面；背平面Pp：过切削刃选定点，同时垂直于假定工作平面Pf与基面Pr的平面。
接下来，本申请对刀具的误差形式进行简单的介绍：
刀具在加工工件之前需要将刀具与机床的主轴中心进行在线对准。请参考图2，图2为本申请实施方式中机床的主轴坐标系的示意图。因为通常情况下在数控机床中会以机床的主轴中心为原点建立主轴 坐标系o-xyz，其中，x轴的正方向与所述刀具的进给方向相反，z轴的正方向垂直于所述工件表面向外，y轴的正方向竖直向上，所述x轴，所述y轴和所述z轴两两互相垂直。如果刀具与原点o进行了对准，这样在数控车削的过程中，可以精确地控制刀具对工件的车削。但是如果刀具没有与机床的主轴中心对准，数控机床无法精确地控制刀具在工件中心的位置，因此会极大地影响工件表面的质量。
因此本申请将刀具在所述主轴中心的竖直方向上存在的误差形式分为：中心刀高误差(h高)和中心刀低误差(h)。中心刀高误差表示刀具在主轴中心的竖直方向上高于主轴中心，即h高>0。中心刀低误差表示刀具在主轴中心的竖直方向上低于主轴中心，即h<0。若刀具在主轴中心的竖直方向上不存在误差(h无)表示刀具在主轴中心的竖直方向上与主轴中心齐平，即刀具与所述主轴中心处于同一水平线上，也可以表示为h无＝0。
另外，刀具与主轴中心的水平方向上(即刀具的进给方向)也会存在误差的情况，水平方向上的误差情况(本申请统一采用s表示)分为：刀具欠中心偏差和刀具过中心偏差。刀具欠中心偏差表示刀具在切削时本应该进给至主轴中心处，但由于误差的存在导致刀具在进给方向上并未进给至主轴中心，即s<0。刀具过中心偏差表示刀具在切削时，由于误差的存在刀具进给至主轴中心时并未停止，又继续向前切削，导致刀具在进给方向上超过了主轴中心，即s>0。若刀具不存在中心偏差表示刀具在切削时正好进给至主轴中心处，即s＝0。以上为刀具在主轴坐标中xoy面的误差情况，也是本申请主要讨论的误差形式。而z轴方向上的误差在现有技术中有成熟的技术对其消除，在本文中并不做过多的阐述。
请参考图3，图3为本申请实施方式中车削加工中刀具的对准方法的工艺流程图。本申请实施方式提供了一种车削加工中刀具的对准方法，包括S100、S200、S300、S400、S500。其中，S100、S200、S300、S400、S500的详细介绍如下。
S100，安装刀具和工件，将所述刀具与安装所述工件的机床的主轴中心进行预对准，再进行预切削，得到切削力曲线图。
首先将刀具和工件分别安装好，例如将刀具安装至智能刀架上，而工件安装至机床的主轴中心上。本申请的工件可以为任意形状，任意材质的工件，在这里并不做具体限定。然后可以根据操作人员的经验或者对刀仪等方式方法先将刀具与主轴中心进行预对准。但是从前文可知预对准是无法完全将刀具与主轴中心进行在线对准的，因此，此时刀具与主轴中心已经产生了误差。然后再采用刀具对工件表面先进行预切削，即先走一刀。然后通过传感器等设备实时或定时采集刀具的切削力信号，再将所述切削力信号发送给处理模块，而处理模块可接收切削力信号，根据得到的切削力信号，形成以时间为横坐标，切削力为纵坐标的切削力曲线图。
S200，根据所述切削力曲线图判断所述刀具在所述主轴中心的竖直方向上存在的误差形式、所述误差形式包括中心刀高误差和中心刀低误差。
根据现有技术可知，中心刀高误差和中心刀低误差的切削力曲线图具有很明显的区别。请一并参考图4及图5，图4为本申请实施方式中中心刀低误差时切削行程末端的切削力曲线图；图5为本申请实施方式中中心刀高误差时切削行程末端的切削力曲线图。当刀具的误差形式为中心刀低误差时，切削力会由于形成中心圆柱而呈现下降的形态。而当刀具的误差形式为中心刀高误差时，切削力会由于形成中心圆锥而先上升后下降呈现突起状态。所以，通过切削力曲线图可很简单地判断出刀具存在的误差形式。可选地，还可以通过切削力曲线图得到切削力的幅值，而通过切削力的幅值也可以判断出存在的误差形式究竟是中心刀高误差还是中心刀低误差。当切削力的幅值大于前段切削力平均值时，为中心刀高误差；当切削力的幅值小于前段切削力平均值时，为中心刀低误差。
S300，根据所述刀具在所述主轴中心的竖直方向上存在的误差形式，得到所述刀具在所述主轴中心的竖直方向上存在的误差值。
若刀具在所述主轴中心的竖直方向上存在的误差形式为中心刀低误差时，可准确地得到所述刀具在所述主轴中心的竖直方向上存在的误差值。若刀具在所述主轴中心的竖直方向上存在的误差形式为中心刀高误差时，可准确地得到所述刀具在所述主轴中心的竖直方向上存在的误差值。若刀具在所述主轴中 心的竖直方向上不存在误差时，则刀具在所述主轴中心的竖直方向上已经对准了主轴中心，误差值即为0。
S400，根据所述刀具在所述主轴中心的竖直方向上存在的误差形式，得到所述刀具在进给方向上存在的中心偏差值。
若刀具在所述主轴中心的竖直方向上存在的误差形式为中心刀低误差时，可得到刀具在中心刀低误差值时的中心偏差值。若刀具在所述主轴中心的竖直方向上存在的误差形式为中心刀高误差时，可得到刀具在中心刀高误差值时的中心偏差值。若刀具在所述主轴中心的竖直方向上不存在误差时，可得到刀具在所述主轴中心的竖直方向上不存在误差时的中心偏差值。若刀具在进给方向上不存在误差时，则刀具在进给方向上已经对准了主轴中心，中心偏差值即为0。
S500，根据所述误差值和所述中心偏差值，将所述刀具进行在线对准。
根据上述得到的所述误差值和所述中心偏差值，将刀具往相反的方向移动误差值的绝对值和/或所述中心偏差值的绝对值，便可将刀具准确地对准主轴中心。例如刀具的误差值为-3，中心偏差值为+1时，只要将刀具沿竖直向上移动3，将刀具沿进给方向移动1，此时，刀具便可对准主轴中心了。
本申请实施方式提供的车削加工中刀具的对准方法，通过使用刀具对工件表面进行预切削，可得到切削力曲线图。再根据所述切削力曲线图判断所述刀具在所述主轴中心的竖直方向上存在的误差形式，确定刀具是为中心刀高误差还是中心刀低误差。然后根据所述刀具在所述主轴中心的竖直方向上存在的误差形式，得到所述刀具在所述主轴中心的竖直方向上存在的误差值，以及所述刀具在进给方向上存在的中心偏差值。最后根据所述误差值和所述中心偏差值，将所述刀具进行在线对准，使刀具与机床的主轴中心进行在线对准。本申请提供的对准方法，不需要依靠操作人员的经验进行在线对准，而可根据预切削后得到的切削力曲线图准确计算出刀具在竖直方向上的误差值和刀具在进给方向上的中心偏差值，最后可根据准确的误差值和中心偏差值将刀具进行在线对准。本申请提供的对准方法，方法简单，可在线得到精确的误差值和中心偏差值，极大地提高刀具车削的效率和工件表面的质量，具有极大的实用性。
接下来，本申请将对刀具在所述主轴中心的竖直方向上为中心刀低误差时进行讨论。具体地，请一并参考图6，图6为本申请实施方式中刀具存在中心刀低误差时刀具的对准方法的工艺流程图。本申请实施方式中，所述“根据所述刀具在所述主轴中心的竖直方向上存在的误差形式，得到所述刀具在所述主轴中心的竖直方向上存在的误差值”，即S300包括S310，S320，S330。S310，S320，S330的详细介绍如下。
S310，若所述刀具存在的所述误差形式为所述中心刀低误差时，建立所述刀具的切削刃在主轴坐标系中的轨迹方程。
当所述刀具存在的所述误差形式为所述中心刀低误差时。首先建立所述刀具的切削刃在刀具坐标系中的轨迹方程，再根据所述刀具的切削刃在刀具坐标系中的轨迹方程建立所述刀具的切削刃在主轴坐标系中的轨迹方程。将刀具的切削刃的轨迹与主轴坐标系联系起来。
S320，根据所述刀具的切削刃在主轴坐标系中的轨迹方程和所述刀具的切削刃的回转半径，建立所述刀具的切削刃在切削所述工件后形成的中心圆台侧面的母线在所述工件背离所述机床的表面上的投影长度在所述主轴坐标系中的轨迹方程。
首先建立刀具的切削刃的回转半径模型，然后根据所述刀具的切削刃在主轴坐标系中的轨迹方程和所述刀具的切削刃的回转半径，建立所述刀具的切削刃在切削所述工件后形成的中心圆台侧面的母线在所述工件背离所述机床的表面上的投影长度在所述主轴坐标系中的轨迹方程。
S330，根据切削力和所述中心圆台侧面的母线在所述工件背离所述机床的表面上的投影长度在所述主轴坐标系中的轨迹方程，建立模拟切削力模型，根据所述模拟切削力模型，得到中心刀低误差的值，所述中心刀低误差的值即为所述误差值。
通过上述得到的轨迹方程，建立模拟切削力模型，通过模拟切削力模型，最后便可得到中心刀低误差的值，而此时中心刀低误差的值便为误差值。
本申请一实施方式中，所述“所述建立所述刀具的切削刃在主轴坐标系中的轨迹方程”，即S310包 括S312。S312的详细介绍如下。
S312，以所述主轴中心为原点建立所述主轴坐标系o-xyz，其中，x轴的正方向与所述刀具的进给方向相反，z轴的正方向垂直于所述工件表面向外，y轴的正方向竖直向上，所述x轴，所述y轴和所述z轴两两互相垂直；
根据所述主轴坐标系o-xyz确定所述刀具的切削刃在所述主轴坐标系中的轨迹方程为：
Figure PCTCN2019090334-appb-000001
其中，x,y和z为所述刀具的切削刃轨迹上任意点(x,y,z)在所述主轴坐标系o-xyz中的坐标，R为所述刀具的刀尖圆弧半径，a p为所述刀具切削时的切削深度，s为所述刀具的切削刃中心与所述y轴之间的水平距离，h为所述刀具的切削刃中心与所述x轴之间的垂直距离。
本申请一实施方式中，在S312之前还可包括S311步骤，S311的详细介绍如下。
S311，首先以所述刀具的刀尖为原点建立可移动的刀具坐标系o′-x′y′z′，其中，x′轴的正方向与所述刀具的进给方向相反，z′轴的正方向垂直于所述工件表面向外，y′轴的正方向竖直向上(即刀具沿竖直方向升高的方向)，所述x′轴、所述y′轴和所述z′轴两两互相垂直。
根据所述刀具坐标系o′-x′y′z′确定所述刀具的切削刃的轨迹方程为：
Figure PCTCN2019090334-appb-000002
其中，x′、y′和z′为所述刀具的切削刃轨迹上任意点(x′，y′，z′)在所述刀具坐标系o′-x′y′z′中的坐标，R为所述刀具的刀尖圆弧半径，a p为所述刀具切削时的切削深度。然后再根据所述刀具的切削刃在刀具坐标系中的轨迹方程建立所述刀具的切削刃在主轴坐标系中的轨迹方程。
本申请实施方式中，所述“根据所述刀具的切削刃在主轴坐标系中的轨迹方程和所述刀具的切削刃的回转半径，建立所述刀具的切削刃在切削所述工件后形成的中心圆台侧面的母线在所述工件背离所述机床的表面上的投影长度在所述主轴坐标系中的轨迹方程”，即S320包括S321。S321的详细介绍如下。
S312，根据所述刀具的切削刃在主轴坐标系中的轨迹方程和所述刀具的切削刃的回转半径，建立所述刀具的切削刃在切削所述工件后形成的中心圆台的侧面在所述主轴坐标系中的轨迹方程：
Figure PCTCN2019090334-appb-000003
其中，x,y和z为所述刀具的切削刃轨迹上任意点(x,y,z)在所述主轴坐标系o-xyz中的坐标，h为所述刀具的切削刃中心与所述x轴之间的垂直距离，s为所述刀具的切削刃中心与所述y轴之间的水平距离，R为所述刀具的刀尖圆弧半径，a p为所述刀具切削时的切削深度，所述刀具的切削刃上任意点(x,y,z)的回转半径为
Figure PCTCN2019090334-appb-000004
请参考图7，图7为本申请实施方式中刀具存在中心刀低误差时刀具坐标系与主轴坐标系的示意图。刀具的切削刃边界位于面x'o'z'上，将切削刃(L 1)绕z轴逆时针旋转α角后所得切削刃曲线(L 2)，同 时，这也为中心圆台的母线方程。因刀具坐标系o'-x'y'z'相对于主轴坐标系o-xyz在x方向和y方向上分别具有偏移量s和h，又因刀具的z'轴与主轴z的水平距离与竖直距离分别为s和h，如图7所示，则可得曲线L 1与L 2的旋转角α为：
Figure PCTCN2019090334-appb-000005
通过曲线L 1与L 2之间的角度变换，可得切削刃曲线(L 2)在主轴坐标系o-xyz下表示为：
Figure PCTCN2019090334-appb-000006
前面的讨论已知，本申请所研究的模拟切削力的分力F′的方向与主轴坐标系o-xyz中z轴方向一致，故将切削刃曲线(L 2)在面xoy上的投影，其投影方程为：
Figure PCTCN2019090334-appb-000007
最后，建立所述刀具的切削刃在切削所述工件后形成的中心圆台侧面的母线在面xoy上的投影长度在所述主轴坐标系中的轨迹方程：
Figure PCTCN2019090334-appb-000008
本申请实施方式中，所述模拟切削力模型的表达式为:
Figure PCTCN2019090334-appb-000009
其中，F′为模拟切削力的分力，且所述模拟切削力的分力与所述主轴坐标系o-xyz中z轴的正方向平行，即F′垂直于工件的表面向外。F为切削力，z为所述刀具的切削刃轨迹上任意点(x,y,z)中z在所述主轴坐标系o-xyz中的坐标，R为所述刀具的刀尖圆弧半径，a p为所述刀具切削时的切削深度，s为所述刀具的切削刃中心与所述y轴之间的水平距离，h为所述刀具的切削刃中心与所述x轴之间的垂直距离。
请一并参考图8，图8为本申请一实施方式图6中S330所包括的流程图示意图。本申请实施方式中，S330包括S331和S332，其中S331为根据切削力和所述中心圆台侧面的母线在所述工件背离所述机床的表面上的投影长度在所述主轴坐标系中的轨迹方程，建立模拟切削力模型。S332为根据所述模拟切削力模型，得到中心刀低误差的值，所述中心刀低误差的值即为所述误差值。请一并参考图9，图9为本申请实施方式图8中S332所包括的流程图示意图。所述“根据所述模拟切削力模型，得到中心刀低误差的值”，即S332包括S333。S333的详细介绍如下。
S333，根据所述模拟切削力模型、及列文伯格-马夸尔特算法，得到所述中心刀低误差的值。
在得到模拟切削力模型后，需要通过利用数据点与模型之间的非线性最小二乘法拟合来求得实际刀低误差值。从图4中可以很明显地看出实际切削力随时间变化图像会经历一个拐点。而对于在实际的车削中，刀具的水平误差是不可控的，因此，在本研究中选取刀具行进到拐点位置之前的数据点(t i,y i)来作分析拟合。确定拟合刀具行进到拐点之前的切削力曲线，将模拟切削力模型进行变形，则拟合模型曲线为下式所示：
Figure PCTCN2019090334-appb-000010
其中k为
Figure PCTCN2019090334-appb-000011
f r为刀具的进给速率，S t为模拟过程中刀具运动到主轴中心的时间。
根据上式刀具切削力随时间变化的关系式，可取总模拟时间为6秒，则所需拟合段时间变量t取值范围为(0，4.687)。当t＝4.687秒时，刀具刚好行进到拐点处，与此同时，在实际切削力图像中选取拐点前4.687秒段切削力随时间变化的数据点(t i,y i)。在上式中，仅有刀低误差h为未知量，通过优化模型曲线使其与数据点(t i,y i)之间的残差平方和最小，如下式所示：
Figure PCTCN2019090334-appb-000012
再对模型进行最小二乘法拟合，数据点(t i,y i)与模型曲线之间的拟合可使用多种算法，如高斯牛顿迭代法、列文伯格-马夸尔特等。本申请中以采用列文伯格-马夸尔特算法做实施例，在任意给定变量h的初始值条件下，设J为函数f(t i，h)的雅可比矩阵，如下式所示为：
Figure PCTCN2019090334-appb-000013
在每个迭代步骤中，参数向量h被h+△h替换，△h由函数通过线性化近似后可得：
f(t i，h+Δh)≈f(t i，h)+J iΔh。
对于当前迭代，列文伯格-马夸尔特算法的搜索方向为:
(J TJ+λI)Δh＝J T[y i-f(t i，h)]。
式中，λ为正参数，I为单位矩阵。
取h的初始值为0，利用列文伯格-马夸尔特算法的最小二乘法非线性拟合后，如表1所示，可得刀低误差的拟合值与实际值的差值基本稳定在1μm左右。
表1刀低误差拟合值与实际值
Figure PCTCN2019090334-appb-000014
利用表1中所求刀具在竖直方向上h的拟合值，将值代入到模拟切削力模型中，拟合刀具到达主轴中心前6秒内切削力随时间变化的曲线。请一并参考图10、图11、图12、图13。图10为本申请实施方式中中心刀低误差值为0.36μm时刀具到达主轴中心前6秒内切削力随时间变化的曲线。图11为本申请实施方式中中心刀低误差值为19.92μm时刀具到达主轴中心前6秒内切削力随时间变化的曲线。 图12为本申请实施方式中中心刀低误差值为41.21μm时刀具到达主轴中心前6秒内切削力随时间变化的曲线。图13为本申请实施方式中中心刀低误差值为58.65μm时刀具到达主轴中心前6秒内切削力随时间变化的曲线。并且此时的切削参量为刀具半径R为1.0mm，刀具后角为10°，切削深度为6μm。如图12-图15所示，模拟切削力拟合曲线与实际曲线吻合程度很好，证明模拟切削力模型的准确性。
请一并参考图14，图14为本申请另一实施方式图6中S330所包括的流程图示意图。本申请实施方式中，所述“根据所述模拟切削力模型，得到中心刀低误差的值”，即S332包括S334。S334的详细介绍如下。
S334，根据所述模拟切削力模型，得到模拟切削力曲线图，当所述模拟切削力曲线图和所述切削力曲线图拟合时，得到中心刀低误差的值。
请一并参考图15，图15为本申请实施方式图14中S334所包括的流程示意图。本申请实施方式中，所述“当所述模拟切削力曲线图和所述切削力曲线图拟合时，得到中心刀低误差的值”，即S334包括S335。S335的详细介绍如下。
S335，调整所述模拟切削力模型的表达式中的所述h，当所述模拟切削力曲线图和所述切削力曲线图拟合时，此时所述h的值为所述中心刀低误差的值。
当得到所述模拟切削力模型的表达式和模拟切削力曲线图后，调整所述模拟切削力模型的表达式中的所述h，当所述模拟切削力曲线图和所述切削力曲线图拟合时，此时所述h为所述中心刀低误差。可选地，当所述模拟切削力曲线图和所述切削力曲线图完全拟合时，此时所述h的准确度和精度更高。
请一并参考图16，图16为本申请另一实施方式中刀具存在中心刀高误差时刀具的对准方法的工艺流程图。本申请实施方式中，所述“根据所述刀具在所述主轴中心的竖直方向上存在的误差形式，得到所述刀具在所述主轴中心的竖直方向上存在的误差值”，即S300包括S340，S350，S360。S340，S350，S360的详细介绍如下。
S340，若所述刀具存在的所述误差形式为所述中心刀高误差时，根据所述切削力曲线图，得到干涉力幅值。
当刀具存在的所述误差形式为所述中心刀高误差时，可根据切削力曲线图，得到干涉力幅值。而干涉力幅值对后面得到中心刀高误差的值具有重大的作用。本申请所提供的干涉力幅值为在切削行程末端出现拐点后的切削力达到最大时与拐点前段切削力平均值的差值。
S350，根据所述工件的力学性能、以及切削参量，建立干涉力幅值模型。
工件的力学性能、以及工件的切削参量，会影响中心刀高误差的值，因此根据所述工件的力学性能、以及切削参量可建立横坐标为中心刀高误差的值，纵坐标为干涉力幅值的干涉力幅值模型。
S360，根据所述干涉力幅值、及所述干涉力幅值模型，得到中心刀高误差的值，所述中心刀高误差的值即为所述误差值。
根据S340中得到的干涉力幅值，便可在干涉力幅值模型中得到此时的中心刀高误差的值。因此本申请提供的对准方法，方法简单，可准确地计算出中心刀高误差的值，具有很强的实用性。
本申请实施方式中，所述工件的力学性能包括所述工件的材质、所述工件的硬度、及所述工件的弹性模量；所述切削参量包括所述刀具的刀尖圆弧半径、所述刀具的后角、所述刀具切削时的切削深度、及所述刀具的进给速率。
请一并参考图17，图17为本申请一实施方式图3中S300所包括的流程示意图。本申请实施方式中，所述“根据所述刀具在所述主轴中心的竖直方向上存在的误差形式，得到所述刀具在所述主轴中心的竖直方向上存在的误差值”，即S300包括S370。S370的详细介绍如下。
S370，若所述误差形式为所述中心刀高误差，则控制所述刀具在所述主轴中心的竖直方向上的高度，使所述误差形式更改为所述中心刀低误差，再得到所述刀具在所述主轴中心的竖直方向上存在的误差值。
若所述误差形式为所述中心刀高误差，可通过切削力曲线图得到切削力形态，此时的拐点后的切削力的幅值应大于拐点前段切削力平均值。然后把刀具沿竖直方向向下移动一段距离，再对工件表面切削 一次，根据得到切削力曲线图，得到切削力形态。判断此时的拐点后的切削力的幅值是否小于拐点前段切削力平均值。如果小于拐点前段切削力平均值，则说明此时的误差形式已更改为中心刀低误差。如果不小于拐点前段切削力平均值，则继续将刀具沿竖直方向向下移动一段距离，然后进行重复操作。
请一并参考图18，图18为本申请另一实施方式图3中S300所包括的流程示意图。本申请实施方式中，所述“根据所述刀具在所述主轴中心的竖直方向上存在的误差形式，得到所述刀具在所述主轴中心的竖直方向上存在的误差值”，即S300包括S380。S380的详细介绍如下。
S380，若所述误差形式为所述中心刀低误差，则控制所述刀具在所述主轴中心的竖直方向上的高度，使所述误差形式更改为所述中心刀高误差，再得到所述刀具在所述主轴中心的竖直方向上存在的误差值。
若所述误差形式为所述中心刀低误差，可通过切削力曲线图得到切削力形态，此时的拐点后的切削力的幅值应小于拐点前段切削力平均值。然后把刀具沿竖直方向向上移动一段距离，再对工件表面切削一次，根据得到切削力曲线图，得到切削力形态。判断此时的拐点后的切削力的幅值是否小于拐点前段切削力平均值。如果大于拐点前段切削力平均值，则说明此时的误差形式已更改为中心刀高误差。如果不大于拐点前段切削力平均值，则继续将刀具沿竖直方向向上移动一段距离，然后进行重复操作。
本申请由于中心刀高误差与中心刀低误差的计算方法不同，中心刀高误差的计算方法较简单，而中心刀低误差的计算方法更为准确。因此如果误差形式为所述中心刀高误差时，本申请可以先将其变成中心刀低误差，然后采用中心刀低误差的方法进行更准确的计算。如果误差形式为所述中心刀低误差时，本申请可以先将其变成中心刀高误差，然后采用中心刀高误差的方法进行更快捷的计算。
本申请实施方式中还给出了两种具体的中心刀高误差的经验公式，此经验公式中所包含的参数将随着刀具的磨损情况等会发生变化。本申请第一实施例为工件为6061铝合金的中心刀高误差的经验公式。本申请第二实施例为工件为黄铜的中心刀高误差的经验公式。通过计算得到具体的公式为：
Figure PCTCN2019090334-appb-000015
式中
Figure PCTCN2019090334-appb-000016
对干涉力幅值的影响系数K 1、K 2、K 3、K 4与G 1、G 2、G 3、G 4分别为6061铝合金和黄铜的刀具半径、刀具后角、切削深度、进给速率。通过上述公式，可快速地计算出6061铝合金以及黄铜的中心刀高误差的值。
本申请又一实施方式提供的对准方法中，还可以首先进行中心刀低误差时的计算，得到中心刀低误差的值。然后将刀具沿竖直方向向上移动一段距离后变成中心刀高误差，然后再使用中心刀高误差的计算方法，计算中心刀高误差的值。然后将两者进行比较，综合判断刀具在竖直方向上的误差值。本申请又一实施方式提供的对准方法，虽然步骤会增多，但它可计算出两个值，然后可以通过对比两个值，综合判断刀具在竖直方向上的误差值，可进一步提高刀具在竖直方向上误差值的辨识精度。
本申请再一实施方式提供的对准方法中，还可以进行多次预切削，然后将每次计算得到的值进行平均值计算。通过多次切削取平均值的方法，可极大地提高刀具在竖直方向上误差值的辨识精度。
从上述内容可知，刀具不仅会在竖直方向上存在竖直误差，刀具在进给方向上也会存在水平误差。下面将具体介绍水平误差的消除方法。本申请实施方式中，所述“根据所述刀具在所述主轴中心的竖直方向上存在的误差形式，得到所述刀具在进给方向上存在的中心偏差值”，包括：
根据所述刀具在所述主轴中心的竖直方向上存在的误差形式，建立所述切削力曲线图建立中心偏差 模型；
根据所述中心偏差模型，得到所述刀具在进给方向上存在的中心偏差值，所述中心偏差模型为：s＝(t-T)f r，其中，s为中心偏移误差，t为所述切削力曲线图中从开始出现拐点到切削力为零时的第一干涉时间，T为所述切削力曲线图中从开始出现拐点到刀具行进至所述主轴中心时的第二干涉时间，f r为所述刀具的进给速率。
本申请使用刀具存在中心刀低误差时切削力曲线图进行举例说明。本申请请一并参考图19、图20、图21。图19为刀具存在中心刀低误差和刀具欠中心偏差时的切削力曲线图，图20为刀具仅存在中心刀低误差时的切削力曲线图，图21为刀具存在中心刀低误差和刀具过中心偏差时的切削力曲线图。干涉初始点即为图中第一次出现拐点所对应的位置。其中刀具的进给速率f r是已知的。从图中也可以看出第一干涉时间t是已知的，其值可通过测量切削力曲线图中拐点至切削力为零时的时间来得到。而第二干涉时间T是未知的，并且针对刀具在竖直方向上的误差的情况不同，第二干涉时间T也并不完全相同。
因此结合刀具在主轴中心的竖直方向上存在的误差形式和在刀具的进给方向上存在的所述中心偏差，可知本申请在主轴坐标系的xoy面中刀具共存在三种误差情况：第一种情况，刀具存在所述中心刀低误差，且所述刀具在进给方向上存在所述中心偏差。第二种情况，刀具在所述主轴中心的竖直方向上不存在误差形式，但所述刀具在进给方向上存在中心偏差。第三种情况，刀具存在所述中心刀高误差，且所述刀具在进给方向上存在中心偏差。这三种误差情况的第二干涉时间T并不是完全相同的。同时，如果刀具存在中心刀高误差与刀具在竖直方向上不存在误差时，对于中心偏差的内容同样适用，在此不做重复说明。
本申请实施方式中，若所述误差形式为所述中心刀低误差时，则所述第二干涉时间的表达式为
Figure PCTCN2019090334-appb-000017
其中，R为所述刀具的刀尖圆弧半径，a p为所述刀具切削时的切削深度。
本申请实施方式中，若所述刀具在所述主轴中心的竖直方向上不存在误差形式时，则所述第二干涉时间的表达式为
Figure PCTCN2019090334-appb-000018
其中，R为所述刀具的刀尖圆弧半径，a p为所述刀具切削时的切削深度。
本申请实施方式中，若所述误差形式为所述中心刀高误差时，则所述第二干涉时间的表达式为
Figure PCTCN2019090334-appb-000019
其中，R为所述刀具的刀尖圆弧半径，a p为所述刀具切削时的切削深度，δ为所述刀具的后角，h 高为所述刀具的所述中心刀高误差。
以上为本申请提供的车削加工中刀具的对准方法的详细内容，下面本申请将继续提供一种使用本申请提供的车削加工中刀具的在线对准方法的智能刀架。
请参考图22及图23，图22为本申请实施方式中智能刀架的结构示意图。图23为图22的爆炸图。本申请实施方式提供了一种智能刀架，所述智能刀架1包括：
刀台10，所述刀台10用于安装所述刀具100。刀台10主要用于安装并固定刀具100。并且可将采集模块40也装设于刀台10上。
粗调模块20、及微调模块30，所述粗调模块20和所述微调模块30用于控制所述刀具100在竖直方向上进行移动。
采集模块40，所述采集模块40用于采集所述刀具100在车削时的切削力信号。
处理模块50，所述处理模块50用于接收所述切削力信号，并根据本申请第一方面提供的刀具100的对准方法来对所述切削力信号进行处理，使所述刀具100进行在线对准。
本申请实施方式提供的智能刀架1，通过使用处理模块50采用本申请实施方式提供的对准方法，当本申请实施方式的提供的对准方法准确计算出误差值和中心偏差值后，对于刀具在主轴中心的竖直方向上的误差值，则需控制所述处理模块50控制粗调模块20和微调模块30进行工作，进而控制刀具100在竖直方向上的移动；而对于刀具在进给方向上的中心偏差值，则只需控制所述处理模块50直接修改机床中刀具坐标在x轴上的坐标值即可，最终使刀具100与机床的主轴中心进行在线对准，提高刀具100车削的效率与工件表面的质量，具有很强的实用性。
本申请中智能刀架1是与机床通常是配套使用的，机床可沿主轴坐标系中的x轴方向移动，对刀装置可整体沿z轴的方向移动，或者机床可沿主轴坐标系中的x轴和z轴方向移动，或者智能刀架1可整体沿主轴坐标系中的x轴和z轴方向移动。上述的移动方法从本质上来说也就相当于刀具100可沿x轴和z轴方向进行移动，但刀具100无法沿y轴方向进行移动。
请一并参考图24，图24为本申请实施方式中刀台的结构示意图。本申请实施方式中，所述刀台10包括刀具100、夹板101、刀具紧固螺栓102，所述刀具100、夹板101通过刀具紧固螺栓102固定在所述刀台10上。
请一并参考图25，图25为本申请实施方式中粗调模块的结构示意图。所述粗调模块20包括联轴器200、固定板紧固螺钉201、上挡板202、孔用弹性挡圈203、第一滚珠轴承204、导轨205、键207、下挡板210、第二滚珠轴承211、固定板212、丝杆208和滑块209，所述伺服电机700通过联轴器200与所述丝杆208连接，所述丝杆208过丝杆螺母206与所述滑块209连接，所述滑块209与所述刀台10连接，丝杆208优选为滚珠丝杆208。本申请中伺服电机700可带动丝杆208进行旋转，然后丝杆208的旋转可带动滑块209沿竖直方向上进行移动，而滑块209的移动会带动刀台10的移动。而刀具100是安装在刀台10上的。所以通过伺服电机700控制粗调模块20的移动进而控制刀具100在竖直方向上的移动。该模块主要用于刀具100在竖直高度方向上的快速调节，量程分辨率在5μm左右。其实现原理是在伺服电机700控制下的滑块209的微动。伺服电机700可以实现运动控制的闭环，能够精准实现滑块209位置的到达。
请一并参考图26及图27，图26为本申请实施方式中微调模块的结构示意图。图27为图26的爆炸图。所述微调模块30包括刀座300、刀架固定螺钉301，电容位移传感器303、压电陶瓷驱动器302、压电陶瓷驱动器紧固螺钉304和柔性铰链305，所述柔性铰链305设置在所述刀座300上，所述压电陶瓷驱动器302与所述柔性铰链305连接，所述电容位移传感器303设置在所述柔性铰链305上，所述固定板212通过定板紧固螺钉设置在所述柔性铰链305上。可选地，柔性铰链305为平行四边形柔性铰链305。微调模块30主要用于刀具100在竖直高度方向上的细微调整，量程分辨率在1μm以下。其实现原理是基于压电陶瓷驱动器302、电容位移传感器30324控制下的柔性铰链305的微动。压电陶瓷驱动器302、电容位移传感可以实现运动控制的闭环，能够精准控制刀台10位置的微动。
请一并参考图28，图28为本申请实施方式中制动模块的结构示意图。本申请实施方式中，所述智能刀架1还包括制动模块60，所述制动模块60用于控制所述刀台10和所述微调模块30的连接与断开。所述制动模块60包括电磁铁600和电磁铁紧固螺钉601，所述电磁铁600通过电磁铁紧固螺钉601固定在所述刀台10上。该模块主要用于实现微调模块30与刀台10的抱死，即刀台10与刀座300的紧密连接与断开。其实现原理是基于电磁铁600通电时的有磁性与断电时的无磁性。当电磁铁600通电时，由于磁性的作用，刀台10与微调模块30紧密连接，此时刀台10即与刀座300紧密连接。避免刀台10在经过粗调后再次位移，从而影响刀具的位置精度，同时便于微调模块30对刀台10进行微调。而当电磁铁600断电时，由于电磁铁600没了磁性，因此刀台10与微调模块30之间断开连接，即刀台10与刀座300断开了连接。
请再参考图22-23，所述力信号采集模块40包括传感器400，所述传感器400安装在所述刀具100上方，用于对刀具100进行实时采集切削力信号或定时采集切削力信号。该模块主要用于检测刀具100的各种情况。例如检测刀具100的位置、刀具100的切削力信号、刀具100表面的磨损与崩刃情况，对刀具100在车削工件时进行全方位的信号采集。而采集后的信号便可发送给处理模块50进行相应的处 理。其实现原理是传感器400实时采集车削的力信号并发送给模块50分析异常。而所述处理模块50则可设于刀座300内，并与所述采集模块40电连接。所述处理模块50用于接收采集模块40发送来的各种信号，并对相关信号进行处理，然后再根据处理后的结果对驱动模块70、粗调模块20、微调模块30进行相应的控制，同时所述处理模块50可直接将计算出误差值和中心偏差值传递给机床，进而控制机床的刀具坐标位置。本申请的处理过程就是利用上述提到的对准方法进行处理。
请再参考图22-图23，本申请实施方式中，所述智能刀架1还包括驱动模块70，所述驱动模块70用于控制所述粗调模块20和所述微调模块30以使所述刀具100在竖直方向上进行移动。本申请的驱动模块70可以但不限于伺服电机700。
请一并参考图29，图29为本申请实施方式中对刀方法的流程示意图。本申请实施方式提供了一种智能刀架1的对刀方法，所述对刀方法包括S600、S700、S800。其中，S600、S700、S800的详细介绍如下。
S600，提供智能刀架1，所述智能刀架1包括刀台10，所述刀台10用于安装所述刀具100，粗调模块20、及微调模块30，所述粗调模块20和所述微调模块30用于控制所述刀具100在竖直方向上进行移动，采集模块40，所述采集模块40用于采集所述刀具100在车削时的切削力信号，处理模块50，所述处理模块50用于接收所述切削力信号，并根据本申请第一方面提供的刀具100的对准方法来对所述切削力信号进行处理。
S700，使用所述刀具100对工件表面进行预切削，同时使用所述采集模块40采集所述刀具100在车削时的切削力信号。
S800，所述处理模块50接收所述切削力信号，并对所述切削力信号进行处理，再通过所述粗调模块20和所述微调模块30使所述刀具100在竖直方向上进行移动，以使所述刀具100进行在线对准。
本申请实施方式提供的智能刀架1的对刀方法，通过使用处理模块50采用本申请实施方式提供的对准方法，当本申请实施方式的提供的对准方法准确计算出误差值和中心偏差值后，对于刀具在主轴中心的竖直方向上的误差值，则需控制所述处理模块50控制粗调模块20和微调模块30进行工作，进而控制刀具100在竖直方向上的移动；而对于刀具在进给方向上的中心偏差值，则只需控制所述处理模块50直接修改机床中刀具坐标在x轴上的坐标值即可，最终使刀具100与机床的主轴中心进行在线对准，提高刀具100车削的效率与工件表面的质量，具有很强的实用性。
结合本申请实施方式提供的智能刀架1，本申请提供的对刀方法的具体步骤可以为：
接收对刀信号，电磁铁600断电，解除刀台10与刀座300的抱死状态。
控制伺服电机700旋转，通过联轴器200带动丝杆208同步旋转，而丝杆螺母206固定在滑块209内，刀台10与滑块209通过螺钉链接，同时丝杆208旋转带动丝杆螺母206、滑块209和刀台10一起沿刀座300的竖直方向上做直线运动，实现刀台10的上下移动，完成刀具100对刀的粗调。
控制电磁铁600通电，刀台10通过电磁铁600抱死在刀座300上，使刀台10粗调完之后不会出现窜动，保证位置精度。再通过给压电陶瓷驱动器302输入电压以控制压电陶瓷驱动器302伸缩(如图27所示)，电容位移传感器303反馈伸缩量，进而使刀座300上的柔性铰链305竖直方向上做微小的平行四边形运动，实现微调，实现刀具100对准机床的主轴中心。从而实现远程控制，在线对刀，最终实现超精密智能制造，无人工厂，达到《中国制造2025》的要求。
以上对本申请实施方式所提供的内容进行了详细介绍，本文对本申请的原理及实施方式进行了阐述与说明，以上说明只是用于帮助理解本申请的方法及其核心思想；同时，对于本领域的一般技术人员，依据本申请的思想，在具体实施方式及应用范围上均会有改变之处，综上所述，本说明书内容不应理解为对本申请的限制。

Claims (20)

  1. 一种车削加工中刀具的对准方法，其中，包括：
    安装刀具和工件，将所述刀具与安装所述工件的机床的主轴中心进行预对准，再进行预切削，得到切削力曲线图；
    根据所述切削力曲线图判断所述刀具在所述主轴中心的竖直方向上存在的误差形式、所述误差形式包括中心刀高误差和中心刀低误差；
    根据所述刀具在所述主轴中心的竖直方向上存在的误差形式，得到所述刀具在所述主轴中心的竖直方向上存在的误差值；
    根据所述刀具在所述主轴中心的竖直方向上存在的误差形式，得到所述刀具在进给方向上存在的中心偏差值；
    根据所述误差值和所述中心偏差值，将所述刀具进行在线对准。
  2. 如权利要求1所述的对准方法，其中，所述“根据所述刀具在所述主轴中心的竖直方向上存在的误差形式，得到所述刀具在所述主轴中心的竖直方向上存在的误差值”，包括：
    若所述刀具存在的所述误差形式为所述中心刀低误差时，建立所述刀具的切削刃在主轴坐标系中的轨迹方程；
    根据所述刀具的切削刃在主轴坐标系中的轨迹方程和所述刀具的切削刃的回转半径，建立所述刀具的切削刃在切削所述工件后形成的中心圆台侧面的母线在所述工件背离所述机床的表面上的投影长度在所述主轴坐标系中的轨迹方程；
    根据切削力和所述中心圆台侧面的母线在所述工件背离所述机床的表面上的投影长度在所述主轴坐标系中的轨迹方程，建立模拟切削力模型，根据所述模拟切削力模型，得到中心刀低误差的值，所述中心刀低误差的值即为所述误差值。
  3. 如权利要求2所述的对准方法，其中，所述“所述建立所述刀具的切削刃在主轴坐标系中的轨迹方程”，包括：
    以所述主轴中心为原点建立所述主轴坐标系o-xyz，其中，x轴的正方向与所述刀具的进给方向相反，z轴的正方向垂直于所述工件表面向外，y轴的正方向竖直向上，所述x轴，所述y轴和所述z轴两两互相垂直；
    根据所述主轴坐标系o-xyz确定所述刀具的切削刃在所述主轴坐标系中的轨迹方程为：
    Figure PCTCN2019090334-appb-100001
    其中，x,y和z为所述刀具的切削刃轨迹上任意点(x,y,z)在所述主轴坐标系o-xyz中的坐标，R为所述刀具的刀尖圆弧半径，a p为所述刀具切削时的切削深度，s为所述刀具的切削刃中心与所述y轴之间的水平距离，h为所述刀具的切削刃中心与所述x轴之间的垂直距离。
  4. 如权利要求2所述的对准方法，其中，所述“根据所述刀具的切削刃在主轴坐标系中的轨迹方程和所述刀具的切削刃的回转半径，建立所述刀具的切削刃在切削所述工件后形成的中心圆台侧面的母线在所述工件背离所述机床的表面上的投影长度在所述主轴坐标系中的轨迹方程”，包括：
    根据所述刀具的切削刃在主轴坐标系中的轨迹方程和所述刀具的切削刃的回转半径，建立所述刀具的切削刃在切削所述工件后形成的中心圆台的侧面在所述主轴坐标系中的轨迹方程：
    Figure PCTCN2019090334-appb-100002
    其中，x,y和z为所述刀具的切削刃轨迹上任意点(x,y,z)在所述主轴坐标系o-xyz中的坐标，h为所述刀具的切削刃中心与所述x轴之间的垂直距离，s为所述刀具的切削刃中心与所述y轴之间的水平距离，R为所述刀具的刀尖圆弧半径，a p为所述刀具切削时的切削深度，所述刀具的切削刃上任意点(x,y,z)的回转半径为
    Figure PCTCN2019090334-appb-100003
    再将所述刀具的切削刃在切削所述工件后形成的中心圆台侧面在所述主轴坐标系中的轨迹方程进行变化，建立所述刀具的切削刃在切削所述工件后形成的中心圆台侧面的母线在所述工件背离所述机床的表面上的投影长度在所述主轴坐标系中的轨迹方程：
    Figure PCTCN2019090334-appb-100004
  5. 如权利要求2所述的对准方法，其中，所述模拟切削力模型的表达式为:
    Figure PCTCN2019090334-appb-100005
    其中，F′为模拟切削力的分力，且所述模拟切削力的分力与所述主轴坐标系o-xyz中z轴的正方向平行，F为切削力，R为所述刀具的刀尖圆弧半径，a p为所述刀具切削时的切削深度，s为所述刀具的切削刃中心与所述y轴之间的水平距离，h为所述刀具的切削刃中心与所述x轴之间的垂直距离。
  6. 如权利要求5所述的对准方法，其中，所述“根据所述模拟切削力模型，得到中心刀低误差的值”，包括：
    根据所述模拟切削力模型、及列文伯格-马夸尔特算法，得到所述中心刀低误差的值。
  7. 如权利要求5所述的对准方法，其中，所述“根据所述模拟切削力模型，得到中心刀低误差的值”，包括：
    根据所述模拟切削力模型，得到模拟切削力曲线图，当所述模拟切削力曲线图和所述切削力曲线图拟合时，得到中心刀低误差的值。
  8. 如权利要求7所述的对准方法，其中，所述“当所述模拟切削力曲线图和所述切削力曲线图拟合时，得到中心刀低误差的值”，包括：
    调整所述模拟切削力模型的表达式中的所述h，当所述模拟切削力曲线图和所述切削力曲线图拟合时，此时所述h的值为所述中心刀低误差的值。
  9. 如权利要求1所述的对准方法，其中，所述“根据所述刀具在所述主轴中心的竖直方向上存在的误差形式，得到所述刀具在所述主轴中心的竖直方向上存在的误差值”，包括：
    若所述刀具存在的所述误差形式为所述中心刀高误差时，根据所述切削力曲线图，得到干涉力幅值；
    根据所述工件的力学性能、以及切削参量，建立干涉力幅值模型；
    根据所述干涉力幅值、及所述干涉力幅值模型，得到中心刀高误差的值，所述中心刀高误差的值即为所述误差值。
  10. 如权利要求9所述的对准方法，其中，所述工件的力学性能包括所述工件的材质、所述工件的硬度、及所述工件的弹性模量；所述切削参量包括所述刀具的刀尖圆弧半径、所述刀具的后角、所述刀具切削时的切削深度、及所述刀具的进给速率。
  11. 如权利要求1所述的对准方法，其中，所述“根据所述刀具在所述主轴中心的竖直方向上存在的误差形式，得到所述刀具在所述主轴中心的竖直方向上存在的误差值”，包括：
    若所述误差形式为所述中心刀高误差，则控制所述刀具在所述主轴中心的竖直方向上的高度，使所述误差形式更改为所述中心刀低误差，再得到所述刀具在所述主轴中心的竖直方向上存在的误差值。
  12. 如权利要求1所述的对准方法，其中，所述“根据所述刀具在所述主轴中心的竖直方向上存在的误差形式，得到所述刀具在所述主轴中心的竖直方向上存在的误差值”，包括：
    若所述误差形式为所述中心刀低误差，则控制所述刀具在所述主轴中心的竖直方向上的高度，使所述误差形式更改为所述中心刀高误差，再得到所述刀具在所述主轴中心的竖直方向上存在的误差值。
  13. 如权利要求1所述的对准方法，其中，所述“根据所述刀具在所述主轴中心的竖直方向上存在的误差形式，得到所述刀具在进给方向上存在的中心偏差值”，包括：
    根据所述刀具在所述主轴中心的竖直方向上存在的误差形式，建立所述切削力曲线图建立中心偏差模型；
    根据所述中心偏差模型，得到所述刀具在进给方向上存在的中心偏差值，所述中心偏差模型为：s＝(t-T)f r，其中，s为中心偏移误差，t为所述切削力曲线图中从开始出现拐点到切削力为零时的第一干涉时间，T为所述切削力曲线图中从开始出现拐点到刀具行进至所述主轴中心时的第二干涉时间，f r为所述刀具的进给速率。
  14. 如权利要求13所述的对准方法，其中，若所述误差形式为所述中心刀低误差时，则所述第二干涉时间的表达式为
    Figure PCTCN2019090334-appb-100006
    其中，R为所述刀具的刀尖圆弧半径，a p为所述刀具切削时的切削深度。
  15. 如权利要求13所述的对准方法，其中，若所述刀具在所述主轴中心的竖直方向上不存在误差形式时，则所述第二干涉时间的表达式为
    Figure PCTCN2019090334-appb-100007
    其中，R为所述刀具的刀尖圆弧半径，a p为所述刀具切削时的切削深度。
  16. 如权利要求13所述的对准方法，其中，若所述误差形式为所述中心刀高误差时，则所述第二干涉时间的表达式为
    Figure PCTCN2019090334-appb-100008
    其中，R为所述刀具的刀尖圆弧半径，a p为所述刀具切削时的切削深度，δ为所述刀具的后角，h 高为所述刀具的所述中心刀高误差。
  17. 一种智能刀架，其中，所述智能刀架包括：
    刀台，所述刀台用于安装所述刀具；
    粗调模块、及微调模块，所述粗调模块和所述微调模块用于控制所述刀具在竖直方向上进行移动；
    采集模块，所述采集模块用于采集所述刀具在车削时的切削力信号；
    处理模块，所述处理模块用于接收所述切削力信号，并根据如权利要求1-16任一项所述的刀具的对准方法来对所述切削力信号进行处理，使所述刀具进行在线对准。
  18. 如权利要求17所述的车削装置，其中，所述智能刀架还包括制动模块，所述制动模块用于控制所述刀台和所述微调模块的连接与断开。
  19. 如权利要求17所述的车削装置，其中，所述智能刀架还包括驱动模块，所述驱动模块用于控制所述粗调模块和所述微调模块以使所述刀具在竖直方向上进行移动。
  20. 一种智能刀架的对刀方法，其中，所述对刀方法包括：
    提供智能刀架，所述智能刀架包括刀台，所述刀台用于安装所述刀具，粗调模块、及微调模块，所述粗调模块和所述微调模块用于控制所述刀具在竖直方向上进行移动，采集模块，所述采集模块用于采集所述刀具在车削时的切削力信号，处理模块，所述处理模块用于接收所述切削力信号，并根据如权利要求1-16任一项所述的刀具的对准方法来对所述切削力信号进行处理；
    使用所述刀具对工件表面进行预切削，同时所述采集模块采集所述刀具在车削时的切削力信号；
    所述处理模块接收所述切削力信号，并对所述切削力信号进行处理，再通过所述粗调模块和所述微调模块使所述刀具在竖直方向上进行移动，以使所述刀具进行在线对准。
PCT/CN2019/090334 2018-11-27 2019-06-06 一种车削加工中刀具的对准方法、智能刀架及对刀方法 WO2020107854A1 (zh)

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