WO2024124671A1 - 一种薄壁曲面构件车削加工装夹系统及适应性装夹方法 - Google Patents

一种薄壁曲面构件车削加工装夹系统及适应性装夹方法 Download PDF

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Publication number
WO2024124671A1
WO2024124671A1 PCT/CN2023/074343 CN2023074343W WO2024124671A1 WO 2024124671 A1 WO2024124671 A1 WO 2024124671A1 CN 2023074343 W CN2023074343 W CN 2023074343W WO 2024124671 A1 WO2024124671 A1 WO 2024124671A1
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Prior art keywords
vacuum
curved surface
sub
circuit
thin
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English (en)
French (fr)
Inventor
孙玉文
闫舒洋
齐书韬
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Dalian University of Technology
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Dalian University of Technology
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Priority to US18/563,542 priority Critical patent/US12370651B2/en
Publication of WO2024124671A1 publication Critical patent/WO2024124671A1/zh
Anticipated expiration legal-status Critical
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25B—TOOLS OR BENCH DEVICES NOT OTHERWISE PROVIDED FOR, FOR FASTENING, CONNECTING, DISENGAGING, OR HOLDING
    • B25B11/00—Work holders not covered by any preceding group in the subclass, e.g. magnetic work holders, vacuum work holders
    • B25B11/005—Vacuum work holders
    • 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
    • B23Q3/00—Devices holding, supporting, or positioning work or tools, of a kind normally removable from the machine
    • B23Q3/02—Devices holding, supporting, or positioning work or tools, of a kind normally removable from the machine for mounting on a work-table, tool-slide, or analogous part
    • B23Q3/06—Work-clamping means
    • B23Q3/08—Work-clamping means other than mechanically-actuated

Definitions

  • the invention belongs to the technical field of turning and clamping of thin-walled curved surface components, and in particular relates to a vacuum adsorption clamping system and an adaptive clamping method.
  • the clamping device with clamping and positioning functions not only directly affects the clamping deformation of thin-walled components, but also restricts the release of unbalanced stress during the removal of excess material, resulting in excessive processing accuracy of thin-walled curved surface components after clamping and unloading.
  • invention patent CN111702532A discloses "a thin-walled part clamping method and fixture", which realizes the adsorption clamping of the flange end face of the curved surface component by optimizing the position of the annular groove airway of the fixture, avoiding the large clamping deformation caused by direct adsorption of the rotating surface of the curved surface component.
  • Invention patent CN112676891A discloses "a high-precision machining split-type centering device and its centering method", which fixes the thin-walled curved surface component on the clamping seat of the centering device by the flange end face adsorption clamping method, and uses the optical adjustment screw to adjust the relative position between the clamping seat and the base, thereby indirectly completing the precision centering operation of the weak rigidity curved surface component.
  • the existing technical solutions mainly use the method of flange end face adsorption clamping to reduce the clamping deformation of thin-walled curved surface components, but it strengthens the constraint effect of the clamping boundary on the release of unbalanced stress, exacerbating the deformation problem of curved surface components after clamping and unloading.
  • the machining accuracy of thin-walled curved surface components is affected by residual stress and clamping stress. However, as the material removal of the component increases, the unbalanced stress generated gradually accumulates. At this time, the residual stress is gradually accumulated. The influence of machining deformation induced by residual stress on the forming accuracy of components is more significant.
  • the present invention provides a clamping system and an adaptive clamping method for turning curved surface components to solve the problem that the existing vacuum adsorption clamping device is difficult to meet the optimal clamping requirements of curved surface components in different process stages.
  • a thin-wall curved surface component turning clamping system comprising a pneumatic circuit, a vacuum adsorption fixture and an electromagnetic control circuit;
  • the pneumatic circuit includes a main circuit and five sub-circuits.
  • the main circuit includes a vacuum pump 1, an adjustable flow valve 2 and a pressure gauge 5 connected in sequence through a pneumatic hose, and an unloading valve 3 and a muffler 4 connected in sequence in parallel between the vacuum pump 1 and the adjustable flow valve 2;
  • the five sub-circuits are a first sub-circuit, a second sub-circuit, a third sub-circuit, a fourth sub-circuit and a fifth sub-circuit, which are respectively controlled by a first electromagnetic reversing valve 6, a second electromagnetic reversing valve 9, a third electromagnetic reversing valve 7, a fourth electromagnetic reversing valve 10 and a fifth electromagnetic reversing valve 8.
  • the five sub-circuits are independent of each other and connected to the main circuit through a ferrule joint.
  • the surface of the vacuum adsorption fixture 11 is provided with three vacuum annular groove belts, which are the first vacuum annular groove belt 113, the third vacuum annular groove belt 115 and the second vacuum annular groove belt 114 from the outside to the inside;
  • the inside of the vacuum adsorption fixture 11 is provided with a first vertical airway 117, a second vertical airway 118, a third vertical airway 119 and a first horizontal airway 120, a second horizontal airway 121 and a third horizontal airway 122; wherein, the axis of the second vertical airway 118 coincides with the rotation axis of the vacuum adsorption fixture 11, and the first vertical airway 117 and the third vertical airway 119 are respectively located on both sides of the second vertical airway 118; the axis of the second horizontal airway 121 intersects with the rotation axis of the vacuum adsorption fixture 11 And the position is vertical, the first horizontal airway 120 and the third horizontal airway 122 are respectively located on both sides of the second horizontal airway
  • the electromagnetic reversing valves are all normally closed two-position two-way valves.
  • the material of the ferrule joint is stainless steel.
  • the tail of the vertical airway is provided with a pipe thread, which is connected with each branch circuit through a pneumatic rotary joint.
  • the first sub-circuit and the third sub-circuit are connected together through a three-way ferrule connector.
  • the second sub-circuit and the fourth sub-circuit are connected together through a three-way ferrule connector.
  • An adaptive clamping method for thin-wall curved surface turning includes the following steps:
  • Step 1 analysis of the action of the vacuum adsorption clamping system; place the thin-walled curved surface component 12 on the upper surface of the vacuum adsorption fixture 11, adjust the vacuum negative pressure of the vacuum adsorption system to 0.02Mpa ⁇ 0.03Mpa, adjust the thin-walled curved surface component 12 to jump to the preset value under the current vacuum condition, and then increase the system vacuum negative pressure to 0.04Mpa ⁇ 0.05Mpa, and then fix the thin-walled curved surface component 12 on the vacuum adsorption fixture 11; at this time, the rubber sealing ring 13 on the auxiliary support 124 contacts the inner surface of the thin-walled curved surface component 12, and the sealed space formed by the inner surface of the thin-walled curved surface component 12 and the upper surface of the vacuum adsorption fixture 11 is separated into two mutually non-conductive vacuum sealed cavities, of which the first vacuum cavity 111 is far away from the flange, and the second vacuum cavity 112 is close to the flange; define the first vacuum cavity adsorption as
  • clamping mode 1 and clamping mode 2 are selected as the clamping schemes for the current process stage of the thin-walled curved surface component 12; when the tool cuts the outer contour of the curved surface corresponding to the second vacuum chamber 112, clamping mode 1 is activated, and the first vacuum chamber 111 is adsorbed to complete the positioning and clamping of the thin-walled curved surface component 12; similarly, when the tool cuts the outer contour of the curved surface corresponding to the first vacuum chamber 111, clamping mode 2 is activated, and the second vacuum chamber 112 is adsorbed to complete the positioning and clamping of the thin-walled curved surface component 12; according to the geometric structure of the thin-walled curved surface component 12 and the cutting parameters, the duration of tool cutting in the above two cases is calculated to be T1 and T2 respectively;
  • clamping mode 3 is selected as the clamping scheme for the current process stage of the thin-walled curved surface component 12; at this time, the excess material to be removed is small, and the machining deformation induced by the release of unbalanced stress after clamping and unloading has little effect on the forming accuracy of the curved surface component. Therefore, the flange adsorption clamping method is used to reduce the vacuum adsorption clamping deformation of the thin-walled curved surface component 12;
  • the unloading valve 3 is opened, and the air enters through the muffler 4, and finally fills the entire vacuum adsorption fixture 11 through the adjustable flow valve 2, and then the thin-walled curved surface component 12 is removed and the vacuum system is closed;
  • Step 2 the electromagnetic control circuit design of the vacuum adsorption clamping system; the electromagnetic control circuit of the vacuum adsorption clamping system consists of 8 branches connected in parallel in the 24V DC power supply; the first branch is composed of the normally closed contact C2, the electromagnetic coil Y1 and the indicator light L1 in series; the second branch is composed of the normally closed contact C4 and the delayed closing coil D1 in series; the third branch is composed of the normally closed contact C3 and the delayed closing coil D2 in series; the fourth branch is composed of the normally open contact C1, the normally closed contact C4, the electromagnetic coil Y2, the indicator light L2 and the delayed closing coil D3, among which the normally open contact C1, the normally closed contact C4, The electromagnetic coil Y2 and the indicator light L2 are in series, and the indicator light L2 and the delayed closing coil D3 are in parallel; the fifth branch is composed of the normally open contact C3, the normally closed contact C4 and the delayed closing coil D4 in series; the sixth branch is composed of the electromagnetic coil Y3 and the indicator light L3 in series; the seventh branch
  • the default state of the electromagnetic conversion switch S3 is that the second sub-control circuit is on and the first sub-control circuit is off.
  • the electromagnetic conversion switch S2 controls the on-off of the first, second and third sub-control circuits.
  • the default state of the electromagnetic conversion switch S2 is that the third sub-control circuit is off and the first and second sub-control circuits are on.
  • the electromagnetic conversion switch S2 is pressed, the first and second sub-control circuits are off and the third sub-control circuit is on.
  • the normally open key switch S1 controls the on-off of all branches.
  • the third electromagnetic reversing valve 7 and the fourth electromagnetic reversing valve 10 are switched from the normally closed state to the working state, and the correspondingly controlled third sub-circuit and the fourth sub-circuit are connected to the air pressure main circuit at the same time; the air in the first vacuum chamber 111 is gradually extracted through the second vacuum annular groove belt 114, the second horizontal airway 121 and the second vertical airway 118, and the air in the vacuum chamber is gradually drawn out.
  • the vacuum degree gradually increases until it reaches a preset value; similarly, the air in the second vacuum chamber 112 is gradually extracted through the third vacuum annular groove belt 115, the third horizontal air channel 122 and the third vertical air channel 119 to ensure that the vacuum degree in the chamber meets the requirements.
  • the thin-walled curved surface component 12 is pressed tightly on the upper surface of the fixture but can still move under the action of external force; on this basis, the balancing screws are installed in the balancing screw holes 123 to adjust the dynamic balance of the machine tool and complete the centering operation of the thin-walled curved surface component 12; then the vacuum negative pressure of the vacuum adsorption system is increased to 0.04Mpa ⁇ 0.05Mpa, and the thin-walled curved surface component 12 is fixed on the vacuum adsorption fixture 11;
  • the electromagnetic conversion switch S3 is pressed, the electromagnetic coil Y1 is turned on, and the indicator light L1 is lit; at this time, the first electromagnetic reversing valve 6 is switched from the normally closed state to the working state, and the main circuit is connected with the first branch circuit; the air in the first vacuum chamber 111 is gradually drawn out through the second vacuum annular groove belt 114, the second horizontal airway 121 and the second vertical airway 118, and the vacuum degree in the first vacuum chamber 111 increases rapidly and is finally maintained At the preset value; after the continuous action time t1, the delayed closing coil D1 is connected, the associated normally open contact C1 is closed, the electromagnetic coil Y2 is connected, the indicator light L2 is lit, and the delayed closing coils D2 and D3 start timing at the same time; at this time, the second electromagnetic reversing valve 9 is switched from the normally closed state to the working state, the main circuit is connected to the second sub-circuit, and the air in the second vacuum chamber 112 is gradually extracted through the third vacuum annul
  • the second sub-circuit is the only one connected; subsequently, after the continuous action time t3, the delayed closing coil D3 is connected, the associated The normally open contact C3 is connected, the delayed closing coil D4 starts timing, the associated normally closed contact C3 is disconnected, the delayed closing coil D2 is disconnected, the associated normally closed contact C2 is connected, and the electromagnetic coil Y1 is connected.
  • the first electromagnetic reversing valve 6 is switched from the normally closed state to the working state, and the vacuum degree of the first vacuum chamber 111 is adjusted to the predetermined value; after the first sub-circuit and the second sub-circuit act together for t4 time, the delayed closing coil D4 is connected, the associated normally closed contact C4 is disconnected, the delayed closing coil C1 is disconnected, the associated normally open contact C1 is disconnected, the electromagnetic coil Y2 is powered off, the indicator light L2 is extinguished, and the second electromagnetic reversing valve 9 is reset under the action of the spring and restored to the normally closed state.
  • the first sub-circuit is the only one connected; at the same time, the normally closed contact C4 associated with the delayed closing coil D4 is disconnected, and the delayed closing coil D4 is disconnected, so that all action controls within a cutting cycle in the semi-finishing stage are completed; the delayed closing coil D1 starts timing again, and the above action process is repeated until the vacuum clamping system action control of the next cutting cycle is completed;
  • the electromagnetic conversion switch S2 is pressed, the electromagnetic coil Y5 is turned on, and the indicator light L5 is lit.
  • the fifth electromagnetic reversing valve 8 is switched from the normally closed state to the working state, and the main circuit is connected with the fifth branch circuit; the air in the first vacuum ring groove belt 113 is extracted through the first horizontal airway 120 and the first vertical airway 117, and the upper surface of the flange of the thin-walled curved surface component 12 is subjected to the vacuum pressure, fixing the curved surface component in the vacuum state.
  • the material removal process of the curved surface component in the precision machining stage is completed.
  • the cutting time T1 is equal to the timing time t2 of the delayed closing coil D2.
  • the cutting time T2 is equal to the sum of the timing time t3 of the delayed closing coil D3 and the timing time t4 of the delayed closing coil D4.
  • the present invention designs a vacuum adsorption clamping system, and accordingly proposes an adaptive clamping method for thin-walled curved surface components.
  • the vacuum adsorption clamping system has a variety of clamping modes, which can be adaptively adjusted according to the main problems affecting the deformation of curved surface components in different process stages.
  • the system weakens the constraint effect of the clamping boundary on stress release, so that the unbalanced stress induced by material removal is released step by step, and gradually balanced during the processing of the curved surface components, which greatly reduces the stress deformation of the components after clamping and unloading.
  • the system can effectively control the clamping deformation of thin-walled curved surface components and improve the machining accuracy of the components.
  • the present invention can meet the differentiated clamping requirements of thin-walled curved surface components in different turning stages.
  • FIG. 1 is a pneumatic circuit diagram of a vacuum adsorption clamping system for thin-walled curved surface components.
  • FIG. 2 is a front view of the vacuum adsorption fixture.
  • FIG. 3 is a bottom view of the vacuum adsorption fixture.
  • FIG. 4 is an isometric view of the vacuum adsorption fixture.
  • Fig. 5 is a cross-sectional view of the vacuum adsorption fixture at section A-A.
  • Fig. 6 is a cross-sectional view of the vacuum adsorption fixture at section B-B.
  • Fig. 7 is a cross-sectional view of the vacuum adsorption fixture at section C-C.
  • FIG8( a ) is a schematic diagram of the first vacuum adsorption mode for clamping a thin-walled curved surface component
  • FIG8( b ) is a schematic diagram of the second vacuum adsorption mode for clamping a thin-walled curved surface component
  • FIG8( c ) is a schematic diagram of the third vacuum adsorption mode for clamping thin-walled curved surface components.
  • FIG. 9 is a schematic diagram of the electromagnetic control principle of the vacuum adsorption clamping system for thin-walled curved components.
  • vacuum pump 1. adjustable flow valve; 3. unloading valve; 4. muffler; 5. pressure gauge; 6. first electromagnetic reversing valve; 7. third electromagnetic reversing valve; 8. fifth electromagnetic reversing valve; 9. second electromagnetic reversing valve; 10. fourth electromagnetic reversing valve; 11. vacuum adsorption fixture; 111. first vacuum chamber; 112. second vacuum chamber; 113. first vacuum annular groove belt; 114. second vacuum annular groove belt; 115. third vacuum annular groove belt; 116. mounting hole; 117. first vertical airway; 118. second vertical airway; 119. third vertical airway; 120. first horizontal airway; 121. second horizontal airway; 122. third horizontal airway; 123. balancing screw hole; 124. auxiliary support; 12. thin-walled curved surface component; 13. rubber sealing ring.
  • a vacuum adsorption clamping system for turning thin-walled curved surface components mainly comprises three parts: an air pressure circuit, a vacuum adsorption fixture and an electromagnetic control circuit.
  • the main circuit of the pneumatic circuit shown in Figure 1 includes a vacuum pump 1, an adjustable throttle valve 2 and a pressure gauge 5, and the above-mentioned pneumatic components are connected in sequence through pneumatic hoses.
  • the first, second, third, fourth and fifth sub-circuits are respectively controlled by the first electromagnetic reversing valve 6, the second electromagnetic reversing valve 9, the third electromagnetic reversing valve 7, the fourth electromagnetic reversing valve 10 and the fifth electromagnetic reversing valve 8.
  • the above-mentioned sub-circuits are independent of each other, and one end is connected to the main circuit through a ferrule joint.
  • the surface of the vacuum adsorption fixture 11 is provided with a first vacuum annular groove belt 113, a second vacuum annular groove belt 114 and a third vacuum annular groove belt 115, and the interior is provided with a first vertical airway 117, a second vertical airway 118 and a third vertical airway 119 and a first horizontal airway 120, a second horizontal airway 121 and a third horizontal airway 122. Both ends of the horizontal airway are sealed with plugs and are respectively connected to the corresponding vacuum The annular groove belt and the vertical air channel are connected to each other, thereby forming three sealed vacuum channels inside the adsorption fixture, as shown in Figures 5, 6 and 7 respectively.
  • the tails of the first vertical air channel 117, the second vertical air channel 118 and the third vertical air channel 119 are respectively provided with the first, second and third pipe threads, which are connected to the pneumatic sub-circuit through a pneumatic rotary joint.
  • the first vertical air channel 117 is connected to the fifth sub-circuit
  • the second vertical air channel 118 is connected to the first and third sub-circuits
  • the third vertical air channel 119 is connected to the second and fourth sub-circuits.
  • an auxiliary support 124 and a mounting hole 116 are provided on the upper surface of the vacuum adsorption fixture 11, and leveling screw holes 123 are evenly distributed on the side circumferentially.
  • the height of the auxiliary support 124 is 84 mm, and a rubber sealing ring 13 is adhered to its upper surface.
  • the thin-walled curved surface component is a hemispherical surface with a flange, the flange length is 20mm, the thickness is 10mm, the inner diameter of the sphere is 120mm, and the wall thickness of the sphere is 2.8mm.
  • the thin-walled curved component 12 placed on the upper surface of the vacuum adsorption fixture 11, adjust the component jump under a small vacuum condition, then increase the vacuum adsorption force, and fix the thin-walled curved component 12 on the vacuum adsorption fixture 11.
  • the rubber sealing ring 13 on the auxiliary support 124 contacts the inner surface of the thin-walled curved component 12, and the sealed space formed by the inner surface of the curved component and the upper surface of the fixture is separated into two mutually non-conductive vacuum sealed cavities, of which the one far away from the flange is the first vacuum cavity 111, and the one close to the flange is the second vacuum cavity 112.
  • the first vacuum cavity adsorption is defined as clamping mode 1
  • the second vacuum cavity adsorption is defined as clamping mode 2
  • the flange end face adsorption is defined as clamping mode 3.
  • the clamping schematic diagrams of each mode are shown in Figure 8.
  • the spindle speed is set to 700r/min, the cutting depth is set to 10 ⁇ m, and the feed is set to 20 ⁇ m/r.
  • the wall thickness of the thin-walled curved surface component 12 is thinned to 2.45mm.
  • Clamping mode 1 and clamping mode 2 are selected as the clamping schemes for the current process stage of the thin-walled curved surface component 12.
  • clamping mode 1 is activated, and the first vacuum chamber 111 is adsorbed to complete the thin-walled curved surface. Positioning and clamping of component 12.
  • the spindle speed is set to 900r/min
  • the cutting depth is set to 5 ⁇ m
  • the feed is set to 10 ⁇ m/r
  • the wall thickness of the thin-walled curved surface component 12 is thinned to 2.4mm.
  • the clamping mode 3 is selected as the clamping scheme for the current process stage of the thin-walled curved surface component 12. At this time, the excess material to be removed is small, and the machining deformation induced by the release of unbalanced stress after clamping and unloading has little effect on the forming accuracy of the curved surface component. Therefore, the flange adsorption clamping method is used to reduce the vacuum adsorption clamping deformation of the thin-walled curved surface component 12.
  • the unloading valve 3 is opened, and the air enters along the muffler 4, and finally fills the entire vacuum adsorption fixture 11 through the adjustable flow valve 2. Then the thin-walled curved surface component 12 is removed and the vacuum system is closed.
  • the electromagnetic control circuit of the vacuum adsorption clamping system consists of 8 branches connected in parallel in the 24V DC power supply; the first branch is composed of the normally closed contact C2, the electromagnetic coil Y1 and the indicator light L1 in series; the second branch is composed of the normally closed contact C4 and the delayed closing coil D1 in series; the third branch is composed of the normally closed contact C3 and the delayed closing coil D2 in series; the fourth branch is composed of the normally open contact C1, the normally closed contact C4, the electromagnetic coil Y2, the indicator light L2 and the delayed closing coil D3, among which the normally open contact C1, the normally closed contact C4, the electromagnetic coil Y2 and the indicator light L2 are in series, and the indicator light L2 and the delayed closing coil D3 are in parallel; the fifth branch is composed of the normally open contact C3, the normally closed contact C4 and the delayed closing coil D4 in series; the sixth branch is composed of the electromagnetic coil Y3 and the indicator light L3
  • the eighth branch constitutes the second sub-control loop
  • the eighth branch constitutes the third sub-control loop.
  • the electromagnetic conversion switch S3 controls the on-off of the first sub-control loop and the second sub-control loop.
  • the default state of the electromagnetic conversion switch S3 is that the second sub-control loop is connected and the first sub-control loop is disconnected.
  • the electromagnetic conversion switch S3 is pressed, the on-off state of the above two sub-control loops is switched.
  • the electromagnetic conversion switch S2 controls the on-off of the first, second and third sub-control loops.
  • the default state of the electromagnetic conversion switch S2 is that the third sub-control loop is disconnected and the first and second sub-control loops are connected.
  • the electromagnetic conversion switch S2 is pressed, the first and second sub-control loops are disconnected and the third sub-control loop is connected.
  • the normally open key switch S1 controls the on-off of all branches.
  • the electromagnetic coil Y3 and the electromagnetic coil Y4 are connected at the same time, and the corresponding indicator lights L3 and L4 are lit together.
  • the third electromagnetic reversing valve 7 and the fourth electromagnetic reversing valve 10 are switched from the normally closed state to the working state, and the correspondingly controlled third sub-circuit and fourth sub-circuit are connected to the air pressure main circuit at the same time.
  • the air in the first vacuum chamber 111 is gradually drawn out through the second vacuum annular groove belt 114, the second horizontal airway 121 and the second vertical airway 118, and the vacuum degree in the vacuum chamber gradually increases to a preset value.
  • the air in the second vacuum chamber 112 is gradually drawn out through the third vacuum annular groove belt 115, the third horizontal airway 122 and the third vertical airway 119 to ensure that the vacuum degree in the chamber meets the requirements.
  • the thin-walled curved surface component 12 is pressed against the upper surface of the fixture but can still move under the action of external force.
  • the balancing screws are installed in the balancing screw holes 123 to adjust the dynamic balance of the machine tool and complete the centering operation of the curved surface component.
  • the vacuum degree of the vacuum pump 1 is increased to increase the vacuum adsorption force and fix the thin-walled curved surface component 12 on the vacuum adsorption fixture 11.
  • the electromagnetic conversion switch S3 is pressed, the electromagnetic coil Y1 is turned on, and the indicator light L1 is lit.
  • the first electromagnetic reversing valve 6 is switched from the normally closed state to the working state, and the main circuit is connected to the first branch circuit.
  • the air in the first vacuum chamber 111 is gradually drawn out through the second vacuum annular groove belt 114, the second horizontal airway 121 and the second vertical airway 118, and the vacuum degree in the first vacuum chamber 111 increases rapidly and is finally maintained at Near the preset value.
  • the delayed closing coil D1 is connected, the associated normally open contact C1 is closed, the electromagnetic coil Y2 is connected, the indicator light L2 is lit, and the delayed closing coils D2 and D3 start timing at the same time.
  • the second electromagnetic reversing valve 9 is switched from the normally closed state to the working state, the main circuit is connected to the second sub-circuit, and the air in the second vacuum chamber 112 is gradually drawn out through the third vacuum annular groove belt 115, the third horizontal airway 122 and the third vertical airway 119.
  • the vacuum degree of the second vacuum chamber 112 is adjusted to near the preset value.
  • the delayed closing coil D2 is connected, the associated normally closed contact C2 is disconnected, the electromagnetic coil Y1 is powered off, the indicator light L1 is off, and the first electromagnetic reversing valve 6 is reset under the action of the spring and restored to the normally closed state.
  • the second sub-circuit is the only one connected.
  • the first electromagnetic reversing valve 6 is switched from the normally closed state to the working state, and the vacuum degree of the first vacuum chamber 111 is adjusted to near the predetermined value.
  • the delayed closing coil D4 is connected, the associated normally closed contact C4 is disconnected, the delayed closing coil C1 is disconnected, the associated normally open contact C1 is disconnected, the electromagnetic coil Y2 is powered off, the indicator light L2 is extinguished, and the second electromagnetic reversing valve 9 is reset under the action of the spring and restored to the normally closed state.
  • the first sub-circuit is the only one connected.
  • the normally closed contact C4 associated with the delayed closing coil D4 is disconnected, and the delayed closing coil D4 is disconnected.
  • all action controls within a cutting cycle in the semi-finishing stage are completed.
  • the delayed closing coil D1 restarts timing and repeats the above action process until the vacuum clamping system action control of the next cutting cycle is completed.
  • the electromagnetic conversion switch S2 is pressed, the electromagnetic coil Y5 is turned on, and the indicator light L5 is lit.
  • the fifth electromagnetic reversing valve 8 is switched from the normally closed state to the working state, and the main circuit is connected to the fifth branch circuit.
  • the air in the first vacuum ring groove belt 113 is extracted through the first horizontal airway 120 and the first vertical airway 117, and the upper surface of the flange of the thin-walled curved surface component 12 is subjected to the vacuum pressure, fixing the curved surface component in the vacuum state.
  • the hollow adsorption fixture 11 is then placed on the surface of the component. Then, the material removal process of the curved surface component in the precision machining stage is completed according to the preset cutting parameters.

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Abstract

一种薄壁曲面构件车削加工装夹系统及适应性装夹方法，该装夹系统包括气压回路、真空吸附夹具（11）和电磁控制回路三部分；曲面构件定位夹紧于真空吸附夹具（11）上表面，夹具辅助支撑上的橡胶密封圈与曲面内廓形接触，将构件内的密闭空间分隔为法兰端面、第一真空腔（111）和第二真空腔（112）三个独立的吸附力作用区域；夹具内部设置三条独立的真空通道，采用气动软管将真空通道与各分回路连通，利用电磁换向阀控制上述回路的通断；该真空吸附装夹系统具有多种装夹模式，可根据曲面构件的工艺阶段适应性调整，在半精加工阶段减小构件装夹卸载后的应力变形，在精密加工阶段控制构件的真空吸附装夹变形，满足了薄壁曲面构件不同车削阶段的差异化装夹需求。

Description

一种薄壁曲面构件车削加工装夹系统及适应性装夹方法 技术领域
本发明属于薄壁曲面构件车削加工装夹技术领域，具体涉及一种真空吸附装夹系统及适应性装夹方法。
背景技术
应用于能源动力、航空航天等领域的一系列弱刚性薄壁曲面构件，由于其壁厚小且轮廓尺寸大，加工时受材料内应力、装夹应力以及加工残余应力等因素的综合影响，变形剧烈且形式复杂。其中，起夹紧与定位功能的装夹装置不仅直接影响薄壁构件的装夹变形，还会制约余量材料去除过程中的不平衡应力释放，导致装夹卸载后薄壁曲面构件加工精度超差。
为了提升薄壁曲面构件的车削加工精度，常采用真空吸附装夹方法取代传统的机械装夹方法。该方法利用夹具体内部的真空腔与大气间的压力差将薄壁曲面构件压在夹具表面，具有操作简单、装夹可靠的优点。发明专利CN111702532A公开了“一种薄壁零件夹持方法与夹具”，通过优化夹具的环槽气道位置实现了曲面构件法兰端面吸附装夹，避免了直接吸附曲面构件回转面造成的大装夹变形。发明专利CN112676891A公开了“一种高精度加工的分体式调心装置及其调心方法”，通过法兰端面吸附装夹的方法将薄壁曲面构件固定在调心装置的夹持座上，利用光学调节螺纹件调整夹持座与底座间的相对位置，进而间接完成弱刚性曲面构件的精密调心操作。
现有技术方案主要采用法兰端面吸附装夹的方法减小薄壁曲面构件的装夹变形，但却增强了装夹边界对不平衡应力释放的约束效果，加剧了装夹卸载后曲面构件的变形超差问题。薄壁曲面构件的加工精度受残余应力和装夹应力共同影响，然而随着构件材料去除的增加，产生的不平衡应力逐步累积，此时残 余应力诱导的加工变形对构件成形精度的影响更为显著。这表明在不同的加工阶段，影响薄壁曲面构件加工精度的主要问题是不同的，对装夹装置的需求也是不同的，甚至是对立的。当前装夹模式固定、功能单一的真空吸附装置无法满足薄壁曲面构件不同车削工艺阶段的差异化装夹需求。
发明内容
针对现有技术的不足，本发明提供了一种用于曲面构件车削加工的装夹系统及适应性装夹方法，以解决现有真空吸附装夹装置难以满足曲面构件不同工艺阶段最优装夹需求的问题。
本发明的技术方案：
一种薄壁曲面构件车削加工装夹系统，包括气压回路、真空吸附夹具和电磁控制回路三部分；
气压回路包括主回路和五个分回路，主回路包含通过气动软管顺次连接的真空泵1、可调节流阀2以及压力表5，以及真空泵1和可调节流阀2之间并联着依次连接的卸荷阀3和消声器4；五个分回路为第一分回路、第二分回路、第三分回路、第四分回路和第五分回路，分别由第一电磁换向阀6、第二电磁换向阀9、第三电磁换向阀7、第四电磁换向阀10和第五电磁换向阀8控制，五个分回路彼此独立，通过卡套接头与主回路相连接；
真空吸附夹具11表面设有三个真空环槽带，从外到内依次为第一真空环槽带113、第三真空环槽带115和第二真空环槽带114；真空吸附夹具11内部设有第一竖直气道117、第二竖直气道118、第三竖直气道119以及第一水平气道120、第二水平气道121、第三水平气道122；其中，第二竖直气道118轴线与真空吸附夹具11回转轴重合，第一竖直气道117与第三竖直气道119分别位于第二竖直气道118两侧；第二水平气道轴线121与真空吸附夹具11回转轴相交 且位置垂直，第一水平气道120与第三水平气道122分别位于第二水平气道121两侧；各竖直气道轴线与对应的水平气道轴线相交且位置垂直；水平气道两端均采用堵头密封，并且分别与对应的真空环槽带以及竖直气道相导通，在吸附夹具内部构成三条密封的真空通道；第一竖直气道117与第五分回路连通，第二竖直气道118分别与第一分回路、第三分回路连通，第三竖直气道119分别与第二分回路、第四分回路连通；真空吸附夹具11上表面设有辅助支撑124与安装孔116，侧面周向均布配平螺孔123，其中辅助支撑124上表面粘有橡胶密封圈13。
所述电磁换向阀均为常闭式两位两通阀。
所述卡套接头材料为不锈钢。
所述竖直气道尾部设有管螺纹，通过气动旋转接头与各分回路相连接。
所述第一分回路和第三分回路通过三通卡套接头连接在一起。
所述第二分回路和第四分回路通过三通卡套接头连接在一起。
一种用于薄壁曲面车削加工的适应性装夹方法，包括以下步骤：
步骤一、真空吸附装夹系统动作分析；将薄壁曲面构件12置于真空吸附夹具11上表面，将真空吸附系统的真空负压调整至0.02Mpa～0.03Mpa，在当前真空度条件下调整薄壁曲面构件12跳动至预设值，随后增大系统真空负压至0.04Mpa～0.05Mpa，进而将薄壁曲面构件12固定在真空吸附夹具11上；此时辅助支撑124上的橡胶密封圈13与薄壁曲面构件12内表面接触，将薄壁曲面构件12内表面与真空吸附夹具11上表面构成的密封空间分隔为两个互不导通的真空密封腔，其中远离法兰的为第一真空腔111，靠近法兰的为第二真空腔112；定义第一真空腔吸附为装夹模式1，第二真空腔吸附为装夹模式2，法兰端面吸附为装夹模式3；
在半精加工阶段，选定装夹模式1与装夹模式2作为薄壁曲面构件12当前工艺阶段的装夹方案；当刀具切削第二真空腔112对应的曲面外轮廓时，装夹模式1启动，吸附第一真空腔111完成薄壁曲面构件12的定位与夹紧；同样地，当刀具切削第一真空腔111对应的曲面外轮廓时，装夹模式2启动，吸附第二真空腔112完成薄壁曲面构件12的定位与夹紧；依据薄壁曲面构件12的几何结构以及切削参数计算上述两种情况刀具切削的持续时间分别为T1和T2；
在精密加工阶段，选定装夹模式3作为薄壁曲面构件12当前工艺阶段的装夹方案；此时，待去除的余量材料较少，装夹卸载后不平衡应力释放诱发的加工变形对曲面构件的成形精度影响较小，因此采用法兰吸附装夹的方法减小薄壁曲面构件12的真空吸附装夹变形；
加工完成后，打开卸荷阀3，空气沿消声器4进入，经可调节流阀2最终充满整个真空吸附夹具11，随后取下薄壁曲面构件12，关闭真空系统；
步骤二、真空吸附装夹系统的电磁控制回路设计；真空吸附装夹系统的电磁控制回路由并联在24V直流电源中的8条支路组成；其中第一支路由常闭触点C2、电磁线圈Y1和指示灯L1串联组成；第二支路由常闭触点C4和延时闭合线圈D1串联组成；第三支路由常闭触点C3与延时闭合线圈D2串联组成；第四支路由常开触点C1、常闭触点C4、电磁线圈Y2、指示灯L2和延时闭合线圈D3组成，其中常开触点C1、常闭触点C4、电磁线圈Y2和指示灯L2为串联关系，指示灯L2和延时闭合线圈D3为并联关系；第五支路由常开触点C3、常闭触点C4和延时闭合线圈D4串联组成；第六支路由电磁线圈Y3和指示灯L3串联组成；第七支路由电磁线圈Y4和指示灯L4串联组成；第八支路由电磁线圈Y5和指示灯L5串联组成；根据各支路的控制功能，并联的第一、第二、第三、第四和第五支路组成第一子控制回路，第六和第七支路组成第二子控制回路，第八支路 组成第三子控制回路；电磁转换开关S3控制第一子控制回路和第二子控制回路的通断，电磁转换开关S3的默认状态为第二子控制回路接通，第一子控制回路断开，按动电磁转换开关S3，上述两个子控制回路的通断状态即发生转换；电磁转换开关S2控制第一、第二子控制回路与第三子控制回路的通断，电磁转换开关S2的默认状态为第三子控制回路断开，第一和第二子控制回路接通，按动电磁转换开关S2，第一和第二子控制回路断开，第三子控制回路接通；常开按键开关S1控制所有支路的通断；
针对薄壁曲面构件12的调心过程，首先将真空吸附系统的真空负压调整至0.02Mpa～0.03Mpa，按下常开按键开关S1,电磁线圈Y3与电磁线圈Y4同时接通，对应的指示灯L3与指示灯L4一并点亮；此时第三电磁换向阀7和第四电磁换向阀10均由常闭状态切换为工作状态，对应控制的第三分回路和第四分回路同时与气压主回路连通；第一真空腔111内的空气经第二真空环槽带114、第二水平气道121以及第二竖直气道118逐渐抽出，真空腔内的真空度逐渐增大直至预设值；同样地，第二真空腔112内的空气经第三真空环槽带115、第三水平气道122以及第三竖直气道119逐渐抽出，以确保腔内真空度满足要求，此时薄壁曲面构件12压紧在夹具上表面但仍能在外力作用下移动；在此基础上，在配平螺孔123内安装配平螺钉，调整机床动平衡，并完成薄壁曲面构件12的调心操作；随后调高真空吸附系统的真空负压至0.04Mpa～0.05Mpa，进而将薄壁曲面构件12固定在真空吸附夹具11上；
在半精加工阶段，按动电磁转换开关S3，电磁线圈Y1接通，指示灯L1点亮；此时第一电磁换向阀6由常闭状态切换为工作状态，主回路与第一分回路连通；第一真空腔111内的空气经第二真空环槽带114、第二水平气道121以及第二竖直气道118逐渐抽出，第一真空腔111内的真空度快速增大并最终维持 在预设值；持续动作t1时间后，延时闭合线圈D1接通，关联的常开触点C1闭合，电磁线圈Y2接通，指示灯L2点亮，延时闭合线圈D2和D3同时开始计时；此时第二电磁换向阀9由常闭状态切换为工作状态，主回路与第二分回路接通，第二真空腔内112的空气经第三真空环槽带115、第三水平气道122以及第三竖直气道119逐渐抽出，在切削刀具到达第一真空腔111对应的曲面构件外轮廓前，将第二真空腔112的真空度调整至预设值；第一分回路和第二分回路同时动作，持续时间t2-t1后，延时闭合线圈D2接通，关联的常闭触点C2断开，电磁线圈Y1断电，指示灯L1熄灭，第一电磁换向阀6在弹簧作用下复位，恢复常闭状态，此时第二分回路唯一连通；随后，持续动作t3时间后，延时闭合线圈D3接通，关联的常开触点C3接通，延时闭合线圈D4开始计时，关联的常闭触点C3断开，延时闭合线圈D2断开，关联的常闭触点C2接通，电磁线圈Y1接通，此时第一电磁换向阀6由常闭状态切换为工作状态，调整第一真空腔111真空度至预定值；第一分回路和第二分回路共同动作t4时间后，延时闭合线圈D4接通，关联的常闭触点C4断开，延时闭合线圈C1断开，关联的常开触点C1断开，电磁线圈Y2断电，指示灯L2熄灭，第二电磁换向阀9在弹簧作用下复位，恢复常闭状态，此时第一分回路唯一连通；同时，延时闭合线圈D4关联的常闭触点C4断开，延时闭合线圈D4断开，至此完成半精加工阶段一个切削周期内的所有动作控制；延时闭合线圈D1重新开始计时，重复上述动作过程直至完成下一个切削周期的真空装夹系统动作控制；
在精密加工阶段，按动电磁转换开关S2，电磁线圈Y5接通，指示灯L5点亮，此时第五电磁换向阀8由常闭状态切换为工作状态，主回路与第五分回路连通；第一真空环槽带113内的空气经第一水平气道120和第一竖直气道117抽出，薄壁曲面构件12的法兰上表面受到真空压力作用，将曲面构件固定在真 空吸附夹具11上；随后按照预设的切削参数，完成精密加工阶段曲面构件的材料去除过程。
切削时间T1与延时闭合线圈D2的定时时间t2相等。
切削时间T2等于延时闭合线圈D3的定时时间t3和延时闭合线圈D4的定时时间t4之和。
本发明的有益效果：
本发明面向薄壁曲面构件车削过程，设计了一套真空吸附装夹系统，据此提出了一种薄壁曲面构件适应性装夹方法。该真空吸附装夹系统具有多种装夹模式，可根据不同工艺阶段影响曲面构件变形的主要问题适应性调整。在半精加工阶段，该系统弱化了装夹边界对应力释放的约束效果，使材料去除诱发的不平衡应力分步释放，并在曲面构件加工过程中逐步平衡，大大降低了构件装夹卸载后的应力变形。在精密加工阶段，该系统可有效控制薄壁曲面构件的装夹变形，提升构件的加工精度。本发明可以满足薄壁曲面构件不同车削阶段的差异化装夹需求。
附图说明
图1是薄壁曲面构件真空吸附装夹系统的气压回路图。
图2是真空吸附夹具的正面视图。
图3是真空吸附夹具的底面视图。
图4是真空吸附夹具的等轴测视图。
图5是真空吸附夹具A-A截面的剖面视图。
图6是真空吸附夹具B-B截面的剖面视图。
图7是真空吸附夹具C-C截面的剖面视图。
图8(a)是薄壁曲面构件装夹第一真空吸附模式示意图；
图8(b)是薄壁曲面构件装夹第二真空吸附模式示意图；
图8(c)是薄壁曲面构件装夹第三真空吸附模式示意图。
图9是薄壁曲面构件真空吸附装夹系统的电磁控制原理图。
图中：1.真空泵；2.可调节流阀；3.卸荷阀；4.消声器；5.压力表；6.第一电磁换向阀；7.第三电磁换向阀；8.第五电磁换向阀；9.第二电磁换向阀；10.第四电磁换向阀；11.真空吸附夹具；111.第一真空腔；112.第二真空腔；113.第一真空环槽带；114.第二真空环槽带；115.第三真空环槽带；116.安装孔；117.第一竖直气道；118.第二竖直气道；119.第三竖直气道；120.第一水平气道；121.第二水平气道；122.第三水平气道；123.配平螺孔；124.辅助支撑；12.薄壁曲面构件；13.橡胶密封圈。
具体实施方式
下面参照附图并结合具体实施方式来进一步描述本发明：
一种用于薄壁曲面构件车削加工的真空吸附装夹系统，主要包括气压回路、真空吸附夹具和电磁控制回路三部分。
图1所示的气压回路的主回路包含真空泵1、可调节流阀2以及压力表5，上述气压元件通过气动软管顺次连接。第一、第二、第三、第四和第五分回路分别由第一电磁换向阀6、第二电磁换向阀9、第三电磁换向阀7、第四电磁换向阀10和第五电磁换向阀8控制，上述分回路彼此独立，一端通过卡套接头与主回路相连接。
如图2、图3以及图4所示，真空吸附夹具11表面设有第一真空环槽带113、第二真空环槽带114和第三真空环槽带115，内部设有第一竖直气道117、第二竖直气道118和第三竖直气道119以及第一水平气道120、第二水平气道121和第三水平气道122。所述水平气道两端均采用堵头密封，并且分别与对应的真空 环槽带以及竖直气道相导通，进而在吸附夹具内部构成三条密封的真空通道，所述真空通道分别如图5、图6和图7所示。第一竖直气道117、第二竖直气道118和第三竖直气道119尾部分别设有第一、第二和第三管螺纹，通过气动旋转接头与所述气动分回路相连接。其中，第一竖直气道117与第五分回路连通，第二竖直气道118与第一和第三分回路连通，第三竖直气道119与第二和第四分回路的连通。此外，真空吸附夹具11上表面设有辅助支撑124与安装孔116，侧面周向均布配平螺孔123。其中，辅助支撑124的高度为84mm，其上表面粘有橡胶密封圈13。
针对薄壁曲面构件的车削过程，结合上述真空吸附装夹系统，提出了一种适应性装夹方法，以满足薄壁曲面构件不同工艺阶段的差异化装夹需求。其中，薄壁曲面构件为带法兰的半球面，法兰长度为20mm，厚度为10mm，球面内径为120mm，球面壁厚为2.8mm。具体如下：
将薄壁曲面构件12置于真空吸附夹具11上表面，在小真空度条件下调整构件跳动，随后增大真空吸附力，将薄壁曲面构件12固定在真空吸附夹具11上。此时辅助支撑124上的橡胶密封圈13与薄壁曲面构件12内表面接触，将曲面构件内表面与夹具上表面构成的密封空间分隔为两个互不导通的真空密封腔，其中远离法兰的为第一真空腔111，靠近法兰的为第二真空腔112。在此基础上，定义第一真空腔吸附为装夹模式1，第二真空腔吸附为装夹模式2，法兰端面吸附为装夹模式3，各模式的装夹示意图如图8所示。
在半精加工阶段，主轴转速设定为700r/min，切深设定为10μm，进给设定为20μm/r,薄壁曲面构件12的壁厚减薄至2.45mm。选定装夹模式1与装夹模式2作为薄壁曲面构件12当前工艺阶段的装夹方案。当刀具切削第二真空腔112对应的曲面外轮廓时，装夹模式1启动，吸附第一真空腔111完成薄壁曲面 构件12的定位与夹紧。同样地，当刀具切削第一真空腔111对应的曲面外轮廓时，装夹模式2启动，吸附第二真空腔112完成薄壁曲面构件12的定位与夹紧。依据曲面构件的几何结构以及切削参数计算上述两种情况刀具切削的持续时间分别为T1＝310.8s和T2＝316.1s，利用电磁控制回路实现上述两种模式的自动切换。
在精密加工阶段，主轴转速设定为900r/min，切深设定为5μm，进给设定为10μm/r,薄壁曲面构件12的壁厚减薄至2.4mm。选定装夹模式3作为薄壁曲面构件12当前工艺阶段的装夹方案。此时，待去除的余量材料较少，装夹卸载后不平衡应力释放诱发的加工变形对曲面构件的成形精度影响较小，因此采用法兰吸附装夹的方法减小薄壁曲面构件12的真空吸附装夹变形。
加工完成后，打开卸荷阀3，空气沿消声器4进入，经可调节流阀2最终充满整个真空吸附夹具11，随后取下薄壁曲面构件12，关闭真空系统。
依据上述动作过程，设计对应的真空系统电磁控制回路,具体如图9所示。真空吸附装夹系统的电磁控制回路由并联在24V直流电源中的8条支路组成；其中第一支路由常闭触点C2、电磁线圈Y1和指示灯L1串联组成；第二支路由常闭触点C4和延时闭合线圈D1串联组成；第三支路由常闭触点C3与延时闭合线圈D2串联组成；第四支路由常开触点C1、常闭触点C4、电磁线圈Y2、指示灯L2和延时闭合线圈D3组成，其中常开触点C1、常闭触点C4、电磁线圈Y2和指示灯L2为串联关系，指示灯L2和延时闭合线圈D3为并联关系；第五支路由常开触点C3、常闭触点C4和延时闭合线圈D4串联组成；第六支路由电磁线圈Y3和指示灯L3串联组成；第七支路由电磁线圈Y4和指示灯L4串联组成；第八支路由电磁线圈Y5和指示灯L5串联组成。根据各支路的控制功能，并联的第一、第二、第三、第四和第五支路组成第一子控制回路，第六和第七支路 组成第二子控制回路，第八支路组成第三子控制回路。电磁转换开关S3控制第一子控制回路和第二子控制回路的通断，电磁转换开关S3的默认状态为第二子控制回路接通，第一子控制回路断开，按动电磁转换开关S3，上述两个子控制回路的通断状态即发生转换。电磁转换开关S2控制第一、第二子控制回路与第三子控制回路的通断，电磁转换开关S2的默认状态为第三子控制回路断开，第一和第二子控制回路接通，按动电磁转换开关S2，第一和第二子控制回路断开，第三子控制回路接通。常开按键开关S1控制所有支路的通断。
针对薄壁曲面构件12的调心过程，首先将真空泵1的真空度调整至一较小值，按下电磁控制回路中的常开按键开关S1,电磁线圈Y3与电磁线圈Y4同时接通，对应的指示灯L3与指示灯L4一并点亮。此时第三电磁换向阀7和第四电磁换向阀10均由常闭状态切换为工作状态，对应控制的第三分回路和第四分回路同时与气压主回路连通。第一真空腔111内的空气经第二真空环槽带114、第二水平气道121以及第二竖直气道118逐渐抽出，真空腔内的真空度逐渐增大直至预设值。同样地，第二真空腔112内的空气经第三真空环槽带115、第三水平气道122以及第三竖直气道119逐渐抽出，以确保腔内真空度满足要求，此时薄壁曲面构件12压紧在夹具上表面但仍能在外力作用下移动。在此基础上，在配平螺孔123内安装配平螺钉，调整机床动平衡，并完成曲面构件的调心操作。随后调高真空泵1的真空度，增大真空吸附力，将薄壁曲面构件12固定在真空吸附夹具11上。
在半精加工阶段，按动电磁转换开关S3，电磁线圈Y1接通，指示灯L1点亮。此时第一电磁换向阀6由常闭状态切换为工作状态，主回路与第一分回路连通。第一真空腔111内的空气经第二真空环槽带114、第二水平气道121以及第二竖直气道118逐渐抽出，第一真空腔111内的真空度快速增大并最终维持在 预设值附近。持续动作300s后，延时闭合线圈D1接通，关联的常开触点C1闭合，电磁线圈Y2接通，指示灯L2点亮，延时闭合线圈D2和D3同时开始计时。此时第二电磁换向阀9由常闭状态切换为工作状态，主回路与第二分回路接通，第二真空腔内112的空气经第三真空环槽带115、第三水平气道122以及第三竖直气道119逐渐抽出，在切削刀具到达第一真空腔111对应的曲面构件外轮廓前，将第二真空腔112的真空度调整至预设值附近。第一分回路和第二分回路同时动作10.8s后，延时闭合线圈D2接通，关联的常闭触点C2断开，电磁线圈Y1断电，指示灯L1熄灭，第一电磁换向阀6在弹簧作用下复位，恢复常闭状态，此时第二分回路唯一连通。持续动作300s后，延时闭合线圈D3接通，关联的常开触点C3接通，延时闭合线圈D4开始计时，关联的常闭触点C3断开，延时闭合线圈D2断开，关联的常闭触点C2接通，电磁线圈Y1接通，此时第一电磁换向阀6由常闭状态切换为工作状态，调整第一真空腔111真空度至预定值附近。第一分回路和第二分回路共同动作16.1s后，延时闭合线圈D4接通，关联的常闭触点C4断开，延时闭合线圈C1断开，关联的常开触点C1断开，电磁线圈Y2断电，指示灯L2熄灭，第二电磁换向阀9在弹簧作用下复位，恢复常闭状态，此时第一分回路唯一连通。同时延时闭合线圈D4关联的常闭触点C4断开，延时闭合线圈D4断开，至此完成半精加工阶段一个切削周期内的所有动作控制。延时闭合线圈D1重新开始计时，重复上述动作过程直至完成下一个切削周期的真空装夹系统动作控制。
在精密加工阶段，按动电磁转换开关S2，电磁线圈Y5接通，指示灯L5点亮，此时第五电磁换向阀8由常闭状态切换为工作状态，主回路与第五分回路连通。第一真空环槽带113内的空气经第一水平气道120和第一竖直气道117抽出，薄壁曲面构件12的法兰上表面受到真空压力作用，将曲面构件固定在真 空吸附夹具11上。随后按照预设的切削参数，完成精密加工阶段曲面构件的材料去除过程。

Claims (9)

  1. 一种薄壁曲面构件车削加工装夹系统，其特征在于，该薄壁曲面构件车削加工装夹系统包括气压回路、真空吸附夹具和电磁控制回路三部分；
    气压回路包括主回路和五个分回路，主回路包含通过气动软管顺次连接的真空泵(1)、可调节流阀(2)以及压力表(5)，以及真空泵(1)和可调节流阀(2)之间并联着依次连接的卸荷阀(3)和消声器(4)；五个分回路为第一分回路、第二分回路、第三分回路、第四分回路和第五分回路，分别由第一电磁换向阀(6)、第二电磁换向阀(9)、第三电磁换向阀(7)、第四电磁换向阀(10)和第五电磁换向阀(8)控制，五个分回路彼此独立，通过卡套接头与主回路相连接；
    真空吸附夹具(11)表面设有三个真空环槽带，从外到内依次为第一真空环槽带(113)、第三真空环槽带(115)和第二真空环槽带(114)；真空吸附夹具(11)内部设有第一竖直气道(117)、第二竖直气道(118)、第三竖直气道(119)以及第一水平气道(120)、第二水平气道(121)、第三水平气道(122)；其中，第二竖直气道(118)轴线与真空吸附夹具(11)回转轴重合，第一竖直气道(117)与第三竖直气道(119)分别位于第二竖直气道(118)两侧；第二水平气道轴线(121)与真空吸附夹具(11)回转轴相交且位置垂直，第一水平气道(120)与第三水平气道(122)分别位于第二水平气道(121)两侧；各竖直气道轴线与对应的水平气道轴线相交且位置垂直；水平气道两端均采用堵头密封，并且分别与对应的真空环槽带以及竖直气道相导通，进而在吸附夹具内部构成三条密封的真空通道；第一竖直气道(117)与第五分回路连通，第二竖直气道(118)分别与第一分回路、第三分回路连通，第三竖直气道(119)分别与第二分回路、第四分回路连通；真空吸附夹具(11)上表面设有辅助支撑(124)与安装孔(116)，侧面周向均布配平螺孔(123)，其中辅助支撑(124) 上表面粘有橡胶密封圈(13)。
  2. 根据权利要求1所述薄壁曲面构件车削加工装夹系统，其特征在于，所述电磁换向阀均为常闭式两位两通阀。
  3. 根据权利要求1所述薄壁曲面构件车削加工装夹系统，其特征在于，所述卡套接头材料为不锈钢。
  4. 根据权利要求1所述薄壁曲面构件车削加工装夹系统，其特征在于，所述竖直气道尾部设有管螺纹，通过气动旋转接头与各分回路相连接。
  5. 根据权利要求1所述薄壁曲面构件车削加工装夹系统，其特征在于，所述第一分回路和第三分回路通过三通卡套接头连接在一起。
  6. 根据权利要求1所述用于薄壁曲面构件车削加工的真空吸附装夹系统，其特征在于，所述第二分回路和第四分回路通过三通卡套接头连接在一起。
  7. 一种用于薄壁曲面车削加工的适应性装夹方法，其特征在于，包括以下步骤：
    步骤一、真空吸附装夹系统动作分析；将薄壁曲面构件(12)置于真空吸附夹具(11)上表面，将真空吸附系统的真空负压调整至0.02Mpa～0.03Mpa，在当前真空度条件下调整薄壁曲面构件(12)跳动，随后增大系统真空负压至0.04Mpa～0.05Mpa，进而将薄壁曲面构件(12)固定在真空吸附夹具(11)上；此时辅助支撑(124)上的橡胶密封圈(13)与薄壁曲面构件(12)内表面接触，将薄壁曲面构件(12)内表面与真空吸附夹具(11)上表面构成的密封空间分隔为两个互不导通的真空密封腔，其中远离法兰的为第一真空腔(111)，靠近法兰的为第二真空腔(112)；定义第一真空腔吸附为装夹模式1，第二真空腔吸附为装夹模式2，法兰端面吸附为装夹模式3；
    在半精加工阶段，选定装夹模式1与装夹模式2作为薄壁曲面构件(12)当前工艺阶段的装夹方案；当刀具切削第二真空腔112对应的曲面外轮廓时， 装夹模式1启动，吸附第一真空腔(111)完成薄壁曲面构件(12)的定位与夹紧；同样地，当刀具切削第一真空腔(111)对应的曲面外轮廓时，装夹模式2启动，吸附第二真空腔(112)完成薄壁曲面构件(12)的定位与夹紧；依据薄壁曲面构件(12)的几何结构以及切削参数计算上述两种情况刀具切削的持续时间分别为T1和T2；
    在精密加工阶段，选定装夹模式3作为薄壁曲面构件(12)当前工艺阶段的装夹方案；此时，待去除的余量材料较少，装夹卸载后不平衡应力释放诱发的加工变形对曲面构件的成形精度影响较小，因此采用法兰吸附装夹的方法减小薄壁曲面构件(12)的真空吸附装夹变形；
    加工完成后，打开卸荷阀(3)，空气沿消声器(4)进入，经可调节流阀(2)最终充满整个真空吸附夹具(11)，随后取下薄壁曲面构件(12)，关闭真空系统；
    步骤二、真空吸附装夹系统的电磁控制回路设计；真空吸附装夹系统的电磁控制回路由并联在24V直流电源中的8条支路组成；其中第一支路由常闭触点C2、电磁线圈Y1和指示灯L1串联组成；第二支路由常闭触点C4和延时闭合线圈D1串联组成；第三支路由常闭触点C3与延时闭合线圈D2串联组成；第四支路由常开触点C1、常闭触点C4、电磁线圈Y2、指示灯L2和延时闭合线圈D3组成，其中常开触点C1、常闭触点C4、电磁线圈Y2和指示灯L2为串联关系，指示灯L2和延时闭合线圈D3为并联关系；第五支路由常开触点C3、常闭触点C4和延时闭合线圈D4串联组成；第六支路由电磁线圈Y3和指示灯L3串联组成；第七支路由电磁线圈Y4和指示灯L4串联组成；第八支路由电磁线圈Y5和指示灯L5串联组成；根据各支路的控制功能，并联的第一、第二、第三、第四和第五支路组成第一子控制回路，第六和第七支路组成第二子控制回路，第八支路 组成第三子控制回路；电磁转换开关S3控制第一子控制回路和第二子控制回路的通断，电磁转换开关S3的默认状态为第二子控制回路接通，第一子控制回路断开，按动电磁转换开关S3，上述两个子控制回路的通断状态即发生转换；电磁转换开关S2控制第一、第二子控制回路与第三子控制回路的通断，电磁转换开关S2的默认状态为第三子控制回路断开，第一和第二子控制回路接通，按动电磁转换开关S2，第一和第二子控制回路断开，第三子控制回路接通；常开按键开关S1控制所有支路的通断；
    针对薄壁曲面构件(12)的调心过程，首先将真空吸附系统的真空负压调整至0.02Mpa～0.03Mpa，按下常开按键开关S1,电磁线圈Y3与电磁线圈Y4同时接通，对应的指示灯L3与指示灯L4一并点亮；此时第三电磁换向阀(7)和第四电磁换向阀(10)均由常闭状态切换为工作状态，对应控制的第三分回路和第四分回路同时与气压主回路连通；第一真空腔(111)内的空气经第二真空环槽带(114)、第二水平气道(121)以及第二竖直气道(118)逐渐抽出，真空腔内的真空度逐渐增大直至预设值；同样地，第二真空腔(112)内的空气经第三真空环槽带(115)、第三水平气道(122)以及第三竖直气道(119)逐渐抽出，以确保腔内真空度满足要求，此时薄壁曲面构件(12)压紧在夹具上表面但仍能在外力作用下移动；在此基础上，在配平螺孔(123)内安装配平螺钉，调整机床动平衡，并完成薄壁曲面构件(12)的调心操作；随后调高真空吸附系统的真空负压至0.04Mpa～0.05Mpa，进而将薄壁曲面构件(12)固定在真空吸附夹具(11)上；
    在半精加工阶段，按动电磁转换开关S3，电磁线圈Y1接通，指示灯L1点亮；此时第一电磁换向阀(6)由常闭状态切换为工作状态，主回路与第一分回路连通；第一真空腔(111)内的空气经第二真空环槽带(114)、第二水平气道 (121)以及第二竖直气道(118)逐渐抽出，第一真空腔(111)内的真空度快速增大并最终维持在预设值；持续动作t1时间后，延时闭合线圈D1接通，关联的常开触点C1闭合，电磁线圈Y2接通，指示灯L2点亮，延时闭合线圈D2和D3同时开始计时；此时第二电磁换向阀(9)由常闭状态切换为工作状态，主回路与第二分回路接通，第二真空腔内(112)的空气经第三真空环槽带(115)、第三水平气道(122)以及第三竖直气道(119)逐渐抽出，在切削刀具到达第一真空腔(111)对应的曲面构件外轮廓前，将第二真空腔(112)的真空度调整至预设值；第一分回路和第二分回路同时动作，持续时间t2-t1后，延时闭合线圈D2接通，关联的常闭触点C2断开，电磁线圈Y1断电，指示灯L1熄灭，第一电磁换向阀(6)在弹簧作用下复位，恢复常闭状态，此时第二分回路唯一连通；随后，持续动作t3时间后，延时闭合线圈D3接通，关联的常开触点C3接通，延时闭合线圈D4开始计时，关联的常闭触点C3断开，延时闭合线圈D2断开，关联的常闭触点C2接通，电磁线圈Y1接通，此时第一电磁换向阀(6)由常闭状态切换为工作状态，调整第一真空腔(111)真空度至预定值；第一分回路和第二分回路共同动作t4时间后，延时闭合线圈D4接通，关联的常闭触点C4断开，延时闭合线圈C1断开，关联的常开触点C1断开，电磁线圈Y2断电，指示灯L2熄灭，第二电磁换向阀(9)在弹簧作用下复位，恢复常闭状态，此时第一分回路唯一连通；同时，延时闭合线圈D4关联的常闭触点C4断开，延时闭合线圈D4断开，至此完成半精加工阶段一个切削周期内的所有动作控制；延时闭合线圈D1重新开始计时，重复上述动作过程直至完成下一个切削周期的真空装夹系统动作控制；
    在精密加工阶段，按动电磁转换开关S2，电磁线圈Y5接通，指示灯L5点亮，此时第五电磁换向阀(8)由常闭状态切换为工作状态，主回路与第五分回 路连通；第一真空环槽带(113)内的空气经第一水平气道(120)和第一竖直气道(117)抽出，薄壁曲面构件(12)的法兰上表面受到真空压力作用，将曲面构件固定在真空吸附夹具(11)上；随后按照预设的切削参数，完成精密加工阶段曲面构件的材料去除过程。
  8. 根据权利要求7所述的薄壁曲面构件适应性装夹方法，其特征在于，切削时间T1与延时闭合线圈D2的定时时间t2相等。
  9. 根据权利要求7所述的薄壁曲面构件适应性装夹方法，其特征在于，切削时间T2等于延时闭合线圈D3的定时时间t3和延时闭合线圈D4的定时时间t4之和。
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