高速重载静压转台服役性能分析与健康运行理论研究

Heavy-duty hydrostatic rotary table is regarded as the key component of heavy-duty CNC machine tools. With the increase of load and rotary speed, several factors, such as the structure optimization design, integral dynamic characteristic, component manufacturing, assembly quality, inappropriate using and maintaining will influence the machine tools’ working performance. In this project, dynamic model which takes manufacturing errors, offset load and the supply flow rate fluctuation into consideration is established to analyze the dynamic variation of rotary tables, and then identify main factors of vibration. Fluid-structure coupling model is carried out to analyze the wear damage of the oil pad. Based on the dynamic model, the impact of wear damage of the oil pad on hydrostatic rotary tables is determined. Then a health assessment and monitoring method for Heavy-duty hydrostatic rotary table is built to make sure the running state of Heavy-duty hydrostatic rotary table is observable and predictable. Eventually, theories and methods of Heavy-duty hydrostatic rotary table are set up according to micro and dynamic hydrostatic model with minimum wear damage taken into consideration. Health service of systematic theory and method is also included to improve the application of rotary table. The launch of this project will bring users a lot of benefits for further guidance to use hydrostatic tables better and contributes to the Heavy-duty CNC machine tools industry in our country.

重载静压转台是重型机床支承超大零件的关键功能部件，随着其自重、载重和转速的增加，其结构的优化设计、整体动力学特性、部件的制造和装配质量以及符合工程规律的使用和维护严重影响着转台健康服役性能。本项目通过构建转台整体动力学模型，剖析运行过程中转台的加工装配误差及偏置载荷对转台动特性的影响规律，确定诱发转台运行振动的主要因素，形成转台健康工作理论，建立油垫与导轨面接触的流固耦合模型，分析油垫损伤成因及对承载影响阈值；进而结合转台整体动力学模型，研究油垫损伤对转台整体服役行为的影响；然后，建立重载静压转台运行监控及健康评估方法，使得转台的运行状况和健康状况得到有效的监控、预测和评估；最终形成高速重载静压转台从微观流体静压承载到中观包含损伤分析的整体动力学，再到健康服役的系统化理论和方法。本项目的展开将为重载静压转台的长期、可靠、稳定使用提供技术和理论指导，为我国重型高档数控机床性能的提升做出贡献。

重载静压转台是重型机床支承超大零件的关键功能部件，随着其自重、载重和转速的增加，其结构的优化设计、整体动力学特性、部件的制造和装配质量以及符合工程规律的使用和维护严重影响着转台健康服役性能。本项目通过构建转台整体动力学模型，剖析了运行过程中转台的加工装配误差及偏置载荷对转台动特性的影响规律，提出加工装配误差与静压转台的倾斜度和油垫油膜厚度呈正相关关系，要保证油垫加工装配误差幅值在2×10-5m以内，且偏载可使转台的最小油膜厚度减少多达50%，增加了油垫损伤的概率；建立了油垫与导轨面接触的流固耦合模型，分析了油垫损伤成因及对承载影响阈值，进而结合转台整体动力学模型，研究了油垫损伤对转台整体服役行为的影响，提出了因单个油垫损伤造成的承载性能下降会引发转台倾斜，工件加载在油垫损坏侧时转台倾斜加剧，反之工件加载在另一侧时，偏载工件的外弯矩会与油垫损伤产生的弯矩相抵消，转台的倾斜会得到修正；然后，建立了重载静压转台运行监控及健康评估方法，使得转台的运行状况和健康状况得到有效的监控、预测和评估；最终形成了高速重载静压转台从微观流体静压承载到中观包含损伤分析的整体动力学，再到健康服役的系统化理论和方法。研究成果共发表18篇SCI论文，申请了13项发明专利，其中授权 5 项发明专利，获得9项软件著作权，培养了博士研究生2名，硕士研究生8名。本项目的展开将为重载静压转台的长期、可靠、稳定使用提供技术和理论指导，为我国重型高档数控机床性能的提升做出贡献。