大型深孔精密加工的刀具工件交互效应与加工精度控制方法

大型深孔零件广泛应用于核电、兵器、航空、冶金、石油等国家重点行业。由于孔深径比大、加工过程封闭、刀杆悬伸量大、冷却排屑不畅、工况复杂恶劣、加工容易失稳，深孔加工过程的刀具工件交互效应显著，严重影响其效率、精度和动态特性。项目以中大口径身管内膛浮动镗和小孔径轧辊深孔枪镗为加工对象，（1）从刀具工件动态交互效应与加工稳定性行为、表面微观形貌与圆度误差控制、表面位置误差与直线度误差控制、刀具动态特性与耐磨性能适配设计等4个方面开展深孔精密加工的基础研究；（2）拟阐明变激励与弱刚度条件下加工过程非线性动态响应特征、加工稳定性行为影响机制与稳定性极限映射关系、加工表面位置误差累积效应与时间空间演变规律等影响深孔精密加工的关键科学问题；（3）将提出刀具工件交互效应建模、表征与加工精度控制方法，为提升大型深孔零件数字化加工效率、精度和稳定性，实现关键制造工艺与切削刀具自主可控提供理论指导和实验依据。

Large scale deep hole parts are widely used in many key industries such as nuclear power, armament, aviation, metallurgy and petroleum. Due to the high aspect ratio, closed machining process, large hanging of boring bar, poor cooling and chip removal, complex and severe machining conditions, easy to chatter during boring process, which lead to the significant of cutting tool & process interaction effect, as well as the poor efficiency, accuracy and dynamic characteristics. In this project, floating boring and gun boring of deep hole in roller were selected as the machining process, the fundamental research on precision machining of large scale deep hole will be carried out from the dynamic interaction effect of cutting tool & workpiece and machining stability behavior, surface morphology characteristics and roundness error control, surface location error characteristics and straightness error control, adaptive design of tool dynamic characteristic and wear resistance property respectively. The fundamental scientific problems will be deeply clarified which restricting machining accuracy and cutting tool design for large scale deep hole such as nonlinear dynamic response characteristics under the variable excitation and weak process system stiffness, influence mechanism of machining stability behavior and stability limit mapping, cumulative effect of surface location error and time & space evolution law. As a result, the modeling and characterization of cutting tool & workpiece interaction effect and machining accuracy control method will be presented, which will act as the theoretical and experimental basis to improve the digital machining efficiency, accuracy and stability for large deep hole, as well as for the implementing autonomous controllability of key technologies of precision machining and cutting tool systems.