基于广义动力学空间的高进给切削刀具振动磨损机理

High feed cutting is widely used in large equipment key parts with high precision long pitch screw as the representative. During the cutting process of high feed and long stroke in multiple directions alternately, the dynamics and tribology system of cutters and workpieces has chaotic characteristics. The variable characteristics of cutting vibration and serious tool wear have become the bottlenecks of improving high feed cutting efficiency, and the evolution rule and scientific essence of high feed cutting tool vibration wear behavior remain to be revealed in the effect of multi strong-field coupling.. The machine tool, cutter and workpiece of high feed cutting process system have different dynamical space scales, and the friction between the cutter and workpiece has complex interaction in different dynamical space scale evolution, which has controlling influence on the process of cutter wear. The generalized dynamical space of process system and the dynamical constitutive relation between system composition are the key to study the cutter vibration wear.. This application based on the existing efficient cutter vibration reduction mechanism and the friction wear properties, builds high feed machining generalized dynamic space, reveals the dynamic constitutive relation and the time-varying characteristic of vibration, researches the cutting tool vibration and abrasion coupling effect based on generalized dynamic space, proves the cutting edge performance deterioration motivation and the model parameters controlling mechanism, and provides the basis for studying a new type cutting tool of high efficiency.

高进给切削在以高精度大螺距螺杆为代表的大型装备关键零部件加工中应用广泛。沿多个方向交替进行的高进给、长行程切削过程中，刀具与工件的动力学和摩擦学系统具有混沌特性，切削振动特性多变，刀具磨损严重，已成为高进给切削效能大幅度提高的瓶颈，多强场耦合作用下高进给切削刀具振动磨损行为的演变规律和科学实质有待揭示。高进给切削工艺系统的机床、刀具与工件具有不同的动力学空间尺度，刀具与工件的摩擦在不同动力学空间尺度上的演变过程存在复杂交互作用，对刀具磨损过程产生了控制性影响，工艺系统的广义动力学空间及系统组成之间的动力学本构关系，是研究刀具振动磨损的关键。本申请拟在已有的高效切削刀具减振机理和摩擦磨损特性研究基础上，构建高进给切削广义动力学空间，揭示其动力学本构关系和振动的时变特性，研究基于广义动力学空间的刀具振动与磨损的耦合效应，探明切削刃性能劣化动因与模型参数控制机制，为研制新型高效切削刀具提供依据。

为揭示多强场耦合作用下高进给切削刀具振动磨损行为的演变规律和科学实质，实现大螺距螺纹件高效、高品质加工。本项目以构建广义动力学空间为切入点，结合大螺距螺纹件加工特点，通过系统动力学特性分析，探明刀具振动磨损耦合机制，进行基于广义动力学空间的刀具振动与磨损的耦合效应研究。同时进行刃口稳定性设计和工艺稳定性设计，为研制新型高效切削刀具和稳定工艺设计提供依据。. 研究高进给切削工艺系统的机床、刀具和工件三个子系统动力学行为，构建描述机床、刀具和工件动力学行为的广义动力学空间，并表征各子系统之间的关联特性和高进给切削系统动力学行为；研究时变切削力引起的工艺系统振动变化规律，通过半实验法建立机床、刀具和工件时变振动交互作用关系，阐述子系统之间的相互作用机理；构建车削外螺纹件的应变能和动能方程，结合考虑“再生颤振效应”瞬时切削力和边界条件，根据虚功原理构建工件时变振动方程；构建高进给切削系统颤振模型，基于遗传算法对切削参数进行优化，提出高进给切削振动抑制条件；构建车削大螺距螺纹刀具表面热力学动态演变方程，并建立大螺距螺纹刀具振动磨损模型；阐述高进给切削刀具刃口刃形控制机制，并揭示了切削参数和刀具结构是控制刃口稳定性的主要因素；设计减振刀杆和开发适用于车削大螺距螺纹工件加工条件的减振刀具；研究高进给切削工艺系统稳定性设计方法，进行高进给切削工艺系统稳定性影响因素分析，提出车削大螺距螺杆工艺系统的稳定性设计方法。. 项目资助已发表论文7篇，待发表2篇，其中SCIE和EI双检3篇，EI检索2篇，核心期刊4篇。获专利授权9项，其中发明专利3项，实用新型专利6项。申请发明专利7项。培养博士研究生1名，在读。培养硕士生17名，其中9名已经取得硕士学位，2名完成毕业论文撰写预计2020年3月参加毕业答辩，6名在读。项目投入经费62万元，累计支出52.4896万元，结余9.5104万元，各项支出基本与预算相符。剩余经费将用于本项目研究后续支出。