机床精度的机构弹性误差运动学与动力学理论基础研究

A rigorous and systematic approach for modelling dynamic inaccuracies of machine tools during various processes is proposed in this project. The structural components and kinematic joints of a machine tool are hypothesized to behave like an actual mechanism having deformable links, and deformable and erroneous kinematic pairs. This novel treatment turns finding dynamic inaccuracies in analysis and design of a machine tool into solving forward and inverse problems of an actual mechanism. The erroneous motions of the actual kinematic pairs are investigated with the help of the inaccuracy models to be developed on the basis of deformable multibody dynamics. The so-developed models can be employed in confidence to reveal the quantitative relationships among the erroneous motions of the kinematic pairs, the geometric and physical parameters of the components and the assembly parameters. The discrete kinematic geometry, developed for analyses and syntheses of mechanisms, is used in design of inaccuracy tests and identification errors in connection with a closed-loop kinematic chain with multiple kinematic pairs. The influences of manufacturing parameters of components and assembly on the erroneous motion of the kinematic pairs are subsequently studied. According to the inaccuracy models of the kinematic pairs, the designed pre-assembly process parameters and the tested kinematic parameters, a new method for configuring assembly parameters is developed. The proposed research realizes the kinematic inaccuracy design, assembly, test and evaluation of machine tools by means of solving kinematics and dynamics of elastic--erroneous mechanisms.

本项目研究机床动态精度的理论基础，将机床支承件和运动轴分别等效为弹性构件和弹性误差运动副，机床整机运动精度分析和设计转化为机构弹性误差运动学与动力学的正解与反解。研究机床运动副的误差运动机理，建立运动副精度模型，揭示实际运动副的误差运动与其零件几何物理参数、装配工艺参数的定量关系；讨论机床/运动副的运动精度检测的运动几何原理，把被测要素与测量传感器等效为闭环刚柔复合测试机构，建立运动精度测量模型，将机床整机/运动副精度测试、评价与误差辨识转化为测试机构的离散运动几何学问题求解；研究零件制造参数与装配工艺参数对运动副输出误差运动的影响，通过预装配工艺参数设置和相应运动参数测量，基于运动副精度模型探讨装配工艺参数的配置方法。据此将机床运动精度设计、装配、检测与评价等问题转化为机构弹性误差运动几何学与动力学问题研究，既丰富和发展了机构运动几何学理论体系，又为精密机床动态精度设计提供理论基础。

本项目建立了机床运动副的精度模型，探讨了运动副误差运动的形成机理与影响因素；研究了机床支撑组件、运动轴的弹性误差运动函数，形成了精密机床运动精度的分析与设计方法；首次发现了机床误差运动的全局不变量，其反映了误差运动的整体性质，建立了机床运动精度的不变量理论；首次提出了机床运动精度测量的运动几何学原理，建立了被测试件几何要素、测量运动参数与测量感知数据间的内在联系；首次提出了机床多轴运动精度测量的可重构刚柔复合机构方法，将球杆仪测量机床多轴联动运动精度的相关问题转化为机构模型的正反解，揭示了多轴联动中影响球杆仪测量数据的因素及其相互关系；并建立了机床运动轴的装配工艺优化模型，通过预装配工艺参数的设置和相应运动参数测量，探讨了装配工艺参数的配置方法与调整手段。项目实施期间，培养博士6名，硕士52名，培训工程师30余名，在国内外顶级期刊及会议发表论文20篇，申请专利4项，研究成果已经在辽宁省相关企业产品研发、关键部件设计与制造、单轴/整机精度检测与误差补偿等领域得到良好应用。.本项目为精密机床的动态精度分析与设计提供了机构弹性误差运动几何学与动力学的理论基础；突破了阿贝原则和布莱恩准则中测量仪器与功能点选择的局限性，将其发展到整体误差运动的不变量精度理论；形成了误差运动测量、试件几何尺度与形状测量、传感器标定等测量问题的运动几何学理论基础；并将经典刚体机构拓展到刚柔复合机构，为机床多轴运动精度测量提供测量参数配置与精度评价方法。.通过本项目的研究，提升了机床运动精度设计、装配、检测与评价能力，丰富运动几何学研究内容，发展了机构学的内涵并拓展了机构学理论与方法的应用领域。