智能主轴高速高效加工早期微弱颤振辨识与主动控制研究

Smart spindle has been a research hotspot in machine tool manufacturing area, leading the trend of next generation of spindle. Aiming at the demand of aerospace industry, this project will focus on the chatter problem arising from high-speed and high-efficiency machining process and study the basic theories and key technologies in terms of incipient weak chatter identification and active control of smart spindle. Firstly, an integrated dynamic model of smart spindle–cutting process is proposed to explore the interactive mechanism of spindle time-varying dynamic characteristics with time-varying cutting process, and the chatter instability mechanism of smart spindle is clarified. Secondly, the energy aggregation and enhancement method of the synchrosqueezing time-frequency representation with respect to the incipient weak chatter signal is studied. With the extraction of chatter features, incipient weak chatter identification of smart spindle under the strong excitation of time-varying cutting forces is implemented. Eventually, a gain-scheduling adaptive robust control algorithm is developed and a chatter closed-loop control system is designed to realize active control of smart spindle chatter under the influence of time-varying dynamic properties. A test rig is set up for chatter identification and active control of smart spindle, and high-speed and high-efficiency milling tests will be carried out to complete experimental and engineering validation of theoretical methods.. This project is expected to achieve innovations in the weak chatter feature extraction, chatter adaptive control and other aspects. The research achievements with academic significance and application value will provide new theories and techniques for incipient weak chatter identification and active control of smart spindle in high-speed and high-efficiency machining.

智能主轴是下一代主轴的发展方向，正在成为机床制造领域的研究热点。针对航空、航天等领域需求，本项目聚焦于高速高效加工过程中的颤振问题，研究智能主轴早期微弱颤振辨识与主动控制的基础理论和关键技术。首先建立智能主轴-切削过程集成动力学模型，探索主轴时变动态特性与时变切削过程的交互机制，阐明智能主轴颤振失稳机理。其次研究早期微弱颤振信号时频域同步压缩的能量聚集与增强方法，提取颤振特征，实现时变切削力强激励下智能主轴早期微弱颤振辨识。最后，研究变增益自适应鲁棒控制算法，建立颤振闭环控制系统，实现时变动态特性影响下智能主轴颤振的主动控制。搭建智能主轴颤振辨识与主动控制试验平台，开展高速高效铣削试验，完成理论方法的试验与工程原理验证。. 本项目预期在微弱颤振特征提取、颤振自适应控制等方面有所创新，获得有学术意义和应用价值的成果，为智能主轴高速高效加工早期微弱颤振辨识与主动控制提供新的理论与技术。

智能主轴是下一代主轴的发展方向，正在成为机床制造领域的研究热点。针对航空、航天等领域需求，本项目聚焦于高速高效加工过程中的颤振问题，研究智能主轴早期微弱颤振辨识与主动控制的基础理论和关键技术。在“智能主轴高速高效加工颤振机理分析”方面，提出了转子与轴承动力学模型耦合的刚体单元法，建立了主轴转子-轴承系统动力学模型；提出了主轴与高速切削过程动力学耦合分析方法，突破主轴动态特性时不变的假设，揭示高速切削状态下主轴自激颤振发生机理及振动响应规律。在“时变切削力强激励下智能主轴早期微弱颤振辨识”方面，提出了“移频细化”和“时间重排”同步压缩方法，实现谐波类、冲击类快变信号时频特征的高精度提取。在信号特征提取的基础上，提出了基于3σ准则的铣削颤振自动报警阈值设定方法、基于C0复杂度与相关系数的铣削颤振检测等方法，实现了时变切削力强激励下智能主轴早期微弱颤振辨识。在“时变动态特性影响下智能主轴颤振主动控制”方面，提出基于自适应鲁棒控制算法的智能主轴颤振主动控制方法、智能主轴颤振的非对称刚度控制方法、智能主轴颤振的模型预测主动控制方法和智能主轴颤振的模糊控制方法，实现了智能主轴颤振的有效控制，提高了加工效率。首次提出了智能主轴的完整概念和“工业4.0”时代下智能主轴工作新模式，开发了智能主轴原理样机进行示范应用。. 基于本项研究成果在Int J Mach Tool Manu，ASME Transactions等领域顶级期刊发表论文27篇，其中SCI 检索26篇，ESI高被引论文3 篇（领域前1%），出版“机械专业卓越工程师培养精品教材系列”教材1 部；授权国家发明专利10项，软件著作权1项；获得机械制造领域权威期刊Int J Mach Tool Manu最佳论文奖，2篇代表论文连续被著名工程科学领域评论机构遴选为Key Scientific Articles进行报道（入选率0.1%）。在本项目的基础上，项目负责人获批优秀青年科学基金，入选德国洪堡学者、国际生产工程科学院（CIRP）Research Affiliate等。