变激励变约束工况下螺纹旋铣系统加工特性及形性协同优化

High-quality screw transmission components are the bottleneck of limiting development of precision CNC machine tool industry. Screw whirling with the merits of high-efficiency and good-quality is the frontier cutting process for mass production of high-quality screws. Since screw whirling has the complex cutting condition with time-varying interrupted impact and variable multi-point constraints, the existing metal hard-cutting theories cannot be directly applied into the dynamic modeling of screw whirling system and analysis of "geometry" (geometric accuracy, surface roughness, et al.) and "performance" (residual stress, micro-hardness, accuracy preservation, reliability, lifetime, et al.) for screws. Aiming at the problem, this project will construct the dynamic model of whirling system integrating "machine-tool-part" in order to analyze macro/micro machining characteristics of whirling system. The failure evolution mechanism and relations with machining characteristics will be studied based on the small-sample accelerated life test of screw service performance. Furthermore, forecasting models of screw service performance will be constructed based on the machining performance of whirling system. Following these, the synthetically representing model for macro/micro machining performance and service performance of screws will be established to synergistically optimize "geometry" and "performance" for hard whirling screws. The above researches will improve the fundamental theories of high-speed hard cutting, and also can be applied in domestic machine tools for hard whirling screws to greatly enhance production efficiency and machining performance.

以高品质滚珠丝杠为代表的螺纹传动件是制约我国精密机床等行业发展的瓶颈，高效优质的螺纹旋铣技术是解决高品质丝杠批量生产的核心前沿工艺。螺纹旋铣具有变激励变约束的特殊工况，现有的金属硬切削理论难以直接解决其系统动力学建模，以及"形"（几何精度及表面粗糙度等）"性"（残余应力、显微硬度、精度保持性、可靠性及寿命等）基础理论问题。本项目以螺纹旋铣技术为研究对象，建立螺纹旋铣"机床－刀具－工件"工艺系统的动力学模型，进而研究该旋铣系统的宏/微观加工特性；同时结合螺纹服役性能小子样加速试验，研究螺纹服役过程的失效演化机理及其与加工特性间的关联性，构建基于加工特性的螺纹服役性能预测模型；在此基础上，建立螺纹宏/微观加工特性及服役性能的综合表征模型，实现螺纹加工"形"和"性"两方面的协同优化。研究成果将进一步完善高速硬切削加工的基础理论，同时应用于国产螺纹旋风铣削加工装备，以显著提高其产能和加工特性。

高品质滚珠丝杠是制约我国精密机床等发展的瓶颈，丝杠旋铣工艺不使用冷却液，通过安装在刀盘上高速旋转的多把刀具实现多刃渐进一次成形，具有加工效率高和绿色环保等特点，是高品质丝杠批量生产的核心前沿技术，在高档精密数控机床乃至大型装备制造业的高品质丝杠成形加工中有着广阔的应用前景。. 本项目针对螺纹旋铣加工变激励、变约束的特殊工况，开展了螺纹旋铣工艺系统动力学建模及加工特性、螺纹服役性能小子样加速试验方法与评价、螺纹服役过程失效演化机理及服役性能预测、以及高品质螺纹硬态旋风铣削形性协同优化等方面的研究，具体包括：. 1）建立了旋铣大型螺纹丝杠的系统动力学模型，进而基于再生切削颤振理论建立了螺纹硬切削再生切厚的理论模型；结合二次切削有限元仿真模型揭示了螺纹旋铣“机床-刀具-工件”工艺系统的切削稳定性和宏/微观加工特性；. 2）提出了“基于全周期分段步加策略的极小子样加速实验方法”和“A+A加速试验方法”两种服役性能小子样加速试验方法，制定了螺纹丝杠副加速寿命试验方案，构建了其服役性能评价体系；. 3）揭示了螺纹丝杠副在服役过程中常见失效形式与服役多源信号间的映射关系，进而分析了其在服役过程中的失效演变机理与退化规律，修正了丝杠副精度衰退模型和额定寿命计算公式，实现了丝杠副服役性能预测；. 4）构建了基于熵权和专家权重的螺纹丝杠副综合性能评价模型，实现了工艺能耗和工艺性能的协同优化；进而拓展研究了旋铣丝杠表面的研磨工艺，实现了丝杠“形”（行程误差、表面粗糙度等）和“性”（残余应力、精度保持性等）的协同优化。.依托本项目共发表论文12篇（SCI/EI 7篇），出版专著手册1本，授权发明专利1项，公开2项，制定行业标准1项，培养硕士6名，博士3名。主持人获江苏省“青蓝工程”中青年学术带头人，以及教育部自然科学二等奖。主要研究成果进一步完善了金属高速硬切削加工的基础理论，并应用于国产丝杠旋铣加工装备，显著提高其产能和加工特性。