曲面侧铣过程动力学建模与稳定性分析

To achieve high-performance flank milling of complex surfaces, this project aims to establish a comprehensive tool-workpiece dynamic model for flank milling of surfaces in the framework of flexible multibody dynamics, propose a process damping model characterizing the flank milling process with viscoelastic material, and quantitatively analyze milling stability and machining errors under various operating conditions. This project will provide a theoretical basis with an analytical tool for machining parameter optimization for flank milling of aero-engine impellers. This project contains four research issues as follows. (1) The geometric simulation and cutting force modeling for flank milling of surfaces will be investigated firstly. (2) In the framework of flexible multibody dynamics, taking the convolution model based process damping for flank milling of viscoelastic material into account, the dynamic equation describing the coupling of rigid motions and vibrations will be established, as opposed to the traditional modeling method neglecting this coupling effect. (3) In the discrete time domain, the stability analysis method and algorithm for prediction of machining errors will be exploited. (4) At last, the software prototype for modeling, analysis and optimization of the flank milling processes will be developed, and experimental tests will be conducted to validate the proposed models and the proposed methods will be applied for flank milling of aero-engine impellers.

以实现复杂曲面高性能侧铣为研究目标，建立柔性多体系统动力学体系下的曲面侧铣动力学模型，提出基于动力学模型的曲面侧铣过程稳定性分析和动态加工误差计算方法，为航空发动机叶轮类零件侧铣工艺参数优化提供理论支撑。研究内容包括：(1) 曲面侧铣过程几何仿真与静态切削力建模；(2) 建立综合考虑黏弹性工件材料铣削卷积型过程阻尼的曲面侧铣过程"刀具-工件"系统大范围运动-振动耦合动力学模型，突破基于结构动力学理论忽略运动-振动耦合效应的传统模型的局限性；(3) 在离散时域中提出基于动力学模型的稳定性分析和动态加工误差预测方法；(4) 开发曲面侧铣过程动力学建模、仿真与工艺优化软件系统，完成曲面侧铣动力学实验验证工作，并应用于航空发动机叶轮类零件侧铣加工。

项目围绕曲面侧铣动力学核心问题，开展了动力学建模、稳定性分析和工艺参数优化等工作。具体成果包括：在变转速加工方面，提出了周期时变时滞铣削过程稳定性高精度分析及广义变转速调制方法；对于多刀加工过程，提出了基于微分求积的多时滞系统稳定性分析方法；在过程阻尼方面，提出了基于铣削过程动态响应构造优化模型来辨识阻尼系数的方法；在侧铣加工工艺参数优化方面，提出了考虑机床旋转轴运动光顺的五轴侧铣加工刀具路径规划方法，以及基于加工过程稳定性和动态加工误差约束的工艺参数和铣刀刀具参数优化模型。项目研究结果共计发表和录用SCI源刊论文8篇（包括美国机械工程师协会汇刊Transactions of the ASME论文6篇），申请发明专利5项（其中已授权1项）。项目实施期间，培养博士生2名。