A non-contact calibration method for cutter runout with spindle speed dependent effect and analysis of its influence on milling process
A non-contact calibration method for cutter runout with spindle speed dependent effect and analysis of its influence on milling process
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主轴转速相关刀具跳动非接触标定方法及其对铣削加工的影响分析
DOI：
10.1016/j.precisioneng.2017.08.020
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发表时间：
2018
期刊：
影响因子：
--
通讯作者：
Zhao Wanhua
中科院分区：
文献类型：
--
作者：
Zhang Xing;Zhang Jun;Zhang Wei;Li Jianhui;Zhao Wanhua
在传统的铣削力学和动力学研究中，刀具跳动通常被假定为一个定值。实际上，主轴系统的动态特性和振动响应在不同的主轴转速下会发生变化，从而导致主轴转速对刀具跳动的影响。提出了一种考虑主轴转速影响的刀具跳动非接触标定方法，并进一步分析了刀具跳动对铣削力学和动力学的影响。基于电涡流传感器测量系统测得的轮齿相对变化量，提出了一种识别刀具跳动参数的数值优化方法。该方法的主要优点是简单方便，特别适用于研究不同主轴转速下的刀具跳动。在此基础上，建立了考虑跳动效应的刀-工件啮合过程中的瞬时未切屑厚度模型，并提出了一种改进的SDM铣削稳定性预测方法。理论和实验结果表明，考虑主轴转速影响的刀具跳动的铣削力、稳定性和SLE预测方法与以往的其他方法相比具有更高的预测精度。最后，分析了刀具跳动对铣削力、铣削稳定性和系统稳定性的影响，结果表明，刀具跳动可以提高铣削稳定性，但会恶化铣削力的激励特性和系统稳定性。
The Cutter runout in traditional studies about milling mechanics and dynamics are always assumed as a constant value. Actually, the dynamic characteristics and vibration response of spindle system will change under different spindle speeds, which would result in a spindle speed dependent effect for cutter runout. A non-contact calibration method for cutter runout with consideration of spindle speed dependent effect is proposed in the paper, and the influence of cutter runout on milling mechanics and dynamics is further analyzed. Based on the measured relative variation of tooth by the eddy current sensor measurement system, a numerical optimization method for identifying cutter runout parameters is presented. The main advantage of the method is simple and convenient, especially for studying the cutter runout under different spindle speeds. Then, the paper gives out an instantaneous uncut chip thickness model during cutter/workpiece engagement with runout effect, and puts forward an enhanced SDM for milling stability prediction. Theoretical and experimental results show that milling force, stability and SLE prediction considering the cutter runout with spindle speed dependent effect have a higher prediction accuracy compared with other previous methods. Lastly, the studies analyze the influence of cutter runout on milling force, milling stability and SLE, and the results indicate that cutter runout can improve the milling stability, but deteriorate the milling force excitation characteristics and SLE.