超高速精密微主轴刀具动态误差分析及其控制方法研究

采用微机床的微细切削磨削加工技术在复杂形状三维微小零件加工方面具有无可比拟的优势。但是目前研制的微主轴在超高速回转时刀具的跳动误差很大，严重影响了微机床的加工质量和效率。本项目提出结合静动态误差预估方法与刀具跳动误差在位补偿技术的超高速精密微主轴刀具动态误差控制方法及理论，突破微主轴超高转速下刀具亚微米跳动的技术瓶颈，有效解决微主轴超高转速时加工质量低的问题。研究微主轴系统刚度传递规律及动力学特性，建立系统刚度链模型及切削参数与刀尖位移量之间的关系模型，为静态与动态下误差的预估提供理论依据；研究超高转速下刀具跳动误差的各种影响因素，揭示刀具跳动误差随转速、载荷、时间的变化规律，为在位补偿其跳动误差提供技术支持；在上述研究基础上，最终建立超高速精密微主轴刀具动态误差的控制方法及理论，为我国微细切削加工装备及工艺研究提供理论依据并打下坚实的基础。本研究具有很强的理论意义和实用价值。

Micro-cutting and micro-grinding technologies with micro-machine tools have incomparable advantage in the production of geometrically complex 3D miniature components in a wide range of engineering materials. But the tool motion error of micro-spindles currently developed is quite large at ultra-high speeds, which seriously affects machining quality and machining efficiency of micro-machine tools. This project proposes the control methods including advance error evaluation with the combination of static and dynamic states and on-line compensation, and corresponding theory for dynamic error of the tool of ultra-high speed and precision micro-spindle, in order to break the technological bottleneck of submicron error motion of the micro-spindle at ultra-high speeds and effectively resolve the problem of its poor machining quality at ultra-high speeds. It will study stiffness transfer rule and dynamic characteristics of the micro-spindle system and establish stiffness chain model and relation model between cutting parameters and tool tip displacement, which can provide a basis for error evaluation of the micro-spindle at static and dynamic states. It will study various factors that influence the error motion of the tool at ultra-high speeds and reveal the variation laws of motion error with rotational speed, load and time, which can provide technical support for on-line tool dynamic error compensation. Based on above study, it will establish the control methods and corresponding theory for dynamic error of the tool of ultra-high speed and precision micro-spindle, so as to provide theoretical basis and lay solid foundation for the research of micro-cutting equipment and process of our country. This project has strong theoretic significance and practical value.