Feed Drives for High-Accuracy, High-Speed Milling Machines

高速铣削（HSM）被认为是近年来机械加工领域最重要的创新之一。HSM进一步发展的主要障碍之一是设计能够达到所需的高速和高加速度，同时保持瞬态路径跟踪精度的进给驱动器的挑战。这是由于要移动的重质量，以及由运动激发的结构的振动模式。为了充分利用当前一代的高速主轴，需要1g到2g的轴加速度，速度高达1米每秒。为了达到这种水平的性能，需要有100hz或更高的位置伺服带宽。该项目将专注于高速铣床的进给驱动和控制策略，以实现更高的速度和加速度，并提高高速运动时的轮廓精度。利用该大学开发的高速铣床，将开发并验证传统的滚珠丝杠/旋转伺服电机驱动、直接线性伺服电机驱动和静压丝杠/旋转伺服电机驱动的适当控制策略。该项目有望显著推进高速加工技术。该技术的实际应用可能包括，例如，飞机的生产，其中用实心块铣削的薄片结构部件取代铆接的金属板组件，以及在锻造、压铸和注塑模具的生产中，高速铣削大规模地取代电火花加工。

High speed milling (HSM) is recognized as one of the most significant recent innovations in machining. One of the main obstacles to further advancement of HSM is the challenge of designing feed drives capable of reaching the required high speeds and high accelerations while maintaining transient path following accuracy. This is due to the heavy masses to be moved, and the vibration modes of the structure that are excited by the motion. In order to fully utilize the current generation of high speed spindles, axis accelerations of 1g to 2g are required with speeds up to 1 meter per second. In order to achieve this level of performance, it is desirable to have positional servo bandwidths of 100 Hz or more. This project will focus on the feed drives and control strategies of high speed milling machines, to enable higher speeds and accelerations and also to enhance contouring accuracy during high speed motions. Using the high speed milling machines developed at the university, appropriate control strategies will be developed and verified for traditional ballscrew/rotary servomotor drives, direct linear servomotor drives, and hydrostatic leadscrew/rotary servomotor drives. This project is expected to significantly advance high speed machining technology. Practical implementation of this technology may include, for example, the production of aircraft, where structural parts with thin sections milled from solid blocks are replacing riveted sheet metal assemblies, and in the production of forging, die casting, and injection molding dies where high speed milling is replacing electrical discharge machining on a large scale.