变曲率复杂零件高进给速度加工动态误差溯源与补偿

As the key parts in high-end equipments, the variable curvature complex parts is rather difficult to machine due to the adopting of difficult-to-machine material and the characteristics like complex surface, low rigidity, etc. The contradiction between the increasing demand and the low processing efficiency becomes significant, and the high feed speed machining method provides an effective way for processing the variable curvature complex parts with high quality and high efficiency. In view of the big dynamic error which restricts the improvement of machining efficiency in processing of the variable curvature complex parts with high feed speed, it is one of the key technologies to study the technology of dynamic error tracing and compensation, so as to realize the high efficiency machining for such kind of parts. Dominated by the high feed speed machining and based on the deep analysis about geometric characteristics and processing technology of the variable curvature complex parts, the vibration suppression method for variable curvature complex parts in high feed speed machining will be explored and the precise model of irregular machining deformation error based on the dynamic cutting force will be established. Subsequently, it will also be studied that the methods for contour error tracing and precise estimate of the variable curvature complex parts and for dynamic error compensation based on the processing code with multiple error factors coupling, so as to develop the dynamic error compensation simulation system and finally provide new methods and new technologies of dynamic error tracing and compensation in high feed speed processing for the variable curvature complex parts. The study achievements will provide theoretical and technical support for the processing of variable curvature complex parts with high quality and high efficiency, improve the manufacturing ability and level of key parts in high-end equipments and enrich the manufacturing theory for complex parts.

变曲率复杂零件作为高端装备中的关键件，采用难加工材料，兼具形面复杂、刚度低等特点，加工难度大，需求量增加与加工效率不高间矛盾日益凸显，高进给速度加工方法为该类零件高质高效加工提供了一种有效途径。鉴于变曲率复杂零件高进给速度加工存在大动态误差，制约加工效率的提升，研究动态误差溯源与补偿技术是实现该类零件高质高效加工的关键技术之一。以高进给速度加工为主导，深入分析变曲率复杂零件几何特征与加工工艺的基础上，探索变曲率复杂零件高进给速度加工振动抑制方法，建立基于动态切削力的非规则加工变形误差模型，提出变曲率复杂零件轮廓误差溯源与精确估计及多误差因素耦合作用下基于加工代码的动态误差补偿方法，开发动态误差补偿仿真系统，最终形成变曲率复杂零件高进给速度加工动态误差溯源与补偿新方法、新技术。研究成果为变曲率复杂零件高质高效加工提供理论与技术支撑，提升高端装备关键件制造能力和水平，丰富复杂零件加工制造理论。

变曲率复杂零件作为高端装备中的关键件，往往采用难加工材料，兼具形面复杂、刚度低等特点，加工难度大，高进给速度加工方法为该类零件高质高效加工提供了一种有效途径。面向变曲率复杂零件高质高效加工需求，针对变曲率复杂零件在高进给速度加工中易振动、加工变形不规则、出现大轮廓误差等问题，开展了变曲率复杂零件高进给速度加工动态误差溯源与补偿相关技术研究。针对切削颤振问题，在建立变曲率复杂曲面高速切削力模型基础上，通过对不同轴向切深下薄壁曲面刚度求解，建立了轴向切深与变曲率薄壁曲面零件刚度间关联模型，获得稳定轴向切深与实际轴向切深间对应关系，形成了适用于变曲率曲面零件的加工稳定域通用求解方法；针对加工变形不均问题，建立了加工过程瞬时切削量与加工变形的对应关系，创新提出规划进给速度以实现瞬时切削量再规划方法，实现变曲率薄壁曲面加工变形均匀化，为薄壁曲面加工变形一次高效补偿开辟了新途径；复杂曲面加工刀轨高精插补是抑制动态误差的基础，在建立刀轨动态轮廓误差与进给轴伺服参数、加工进给速度、刀轨几何特征之间关联模型基础上，提出刀轨动态轮廓误差约束下的插补点处最大许用进给速度求解方法，据此发明了三轴/五轴数控机床的NURBS曲线插补技术，确保了进给轴运动高阶连续；面向刀轨动态轮廓误差因随进给速度、刀轨轮廓等因素变化而实时改变导致难以准确预估难题，发明了一种基于等效平面构建与初值再生Newton法的轮廓误差高精实时快速算法，估计精度较国际同期方法提高1个数量级；在刀轨轮廓误差精确估计的基础上，发明了一种五轴加工轨迹轮廓误差双闭环实时补偿方法，加工试件轮廓表明，刀轴方向和刀尖点轮廓误差均降低60%以上，实现了复杂曲面加工轮廓误差的稳健抑制；最终开发了变曲率复杂零件高进给速度加工动态误差补偿仿真系统，形成变曲率复杂零件高进给速度加工动态误差溯源与补偿新方法、新技术，并进行了验证。研究成果为变曲率复杂零件高质高效加工提供理论与技术支撑，提升高端装备关键件制造能力和水平，丰富复杂零件加工制造理论。通过项目实施，发表学术论文34篇(其中SCI检索27篇、EI检索32篇)，申请发明专利24项、授权21项，授批软件著作权2项；2篇学术论文分别获辽宁省自然科学学术成果奖(学术论文类)三等奖，2篇学术论文分别获大连市自然科学优秀学术论文三等奖；参加国际学术会议(ICDMM2017、IMECE2017)2次。