基于力感知的超精密车削刀高设置误差在线辨识与补偿系统构建

doi:10.3901/JME.2025.19.397

机械工程学报 ›› 2025, Vol. 61 ›› Issue (19): 397-406.doi: 10.3901/JME.2025.19.397

• 制造工艺和装备 • 上一篇

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基于力感知的超精密车削刀高设置误差在线辨识与补偿系统构建

张稳祺^1,2,3, 张国庆^1,2,3, 马帅^1,2,3

1. 深圳大学机电与控制工程学院深圳 518060;
2. 深圳大学广东省微纳光机电工程技术重点实验室深圳 518060;
3. 深圳大学深圳市高性能特种制造重点实验室深圳 518060

收稿日期:2024-10-25 修回日期:2025-05-18 发布日期:2025-11-24
作者简介:张稳祺，男，2000年出生。主要研究方向为超精密加工工艺与装备。E-mail：2210295086@email.szu.edu.cn
张国庆(通信作者)，男，1982年出生，博士，教授，博士研究生导师。主要研究方向为超精密加工工艺与装备、机器人与智能装备。E-mail：zhanggq@szu.edu.cn
基金资助:
国家自然科学基金(52275454, U2013603, 51827901)和深圳自然科学基金(JCYJ20220531103614032, JCYJ20220818102409021)资助项目。

Construction of Online Identification and Compensation System for Ultra-precision Turning Tool-above-centre Error Based on Force Sensing

ZHANG Wenqi^1,2,3, ZHANG Guoqing^1,2,3, MA Shuai^1,2,3

1. College of Mechatronics and Control Engineering, Shenzhen University, Shenzhen 518060;
2. Guangdong Provincial Key Laboratory of Micro/Nano Optomechatronics Engineering, Shenzhen University, Shenzhen 518060;
3. Shenzhen Key Laboratory of High Performance Nontraditional Manufacturing, Shenzhen University, Shenzhen 518060

Received:2024-10-25 Revised:2025-05-18 Published:2025-11-24

摘要/Abstract

摘要： 提出一种基于力感知的超精密车削刀高设置误差在线辨识及补偿系统，旨在解决离线辨识刀高设置误差时加工连续性破坏和加工效率影响的问题。首先，研究了刀高设置误差存在时刀具后刀面与工件中心残余干涉所形成的表面形貌，及其对应的切削力特征，并建立了刀高设置误差与切削力之间的映射关系模型。其次，设计了基于该映射关系的刀高设置误差自动辨识算法，并利用LabVIEW软件开发执行程序和界面。最后，在加工实验中利用在线辨识系统对切削过程中的力信号进行特征识别，输出刀高设置误差，并借助实验平台集成的精密微调机构对误差进行在线补偿。实验结果表明，通过切削力辨识得到的刀高设置误差与机床反馈误差之间的平均差值在8 μm以内，并通过精密微调机构迅速补偿辨识出的误差，偏差在1%内，整个辨识与补偿过程仅耗时约1 min，验证了刀高设置误差在线辨识及补偿系统的可靠性和快速性。该研究将为超精密加工刀具设置误差自动辨识与补偿提供新的方案参考。

关键词: 超精密车削, 切削力, 刀高设置误差, 在线辨识与补偿

Abstract: An online identification and compensation system for ultra-precision turning tool-above-centre error based on force sensing is proposed, aiming to solve the problems of machining continuity disruption and machining efficiency impact during offline identification of tool-above-centre error. Firstly, the surface morphology formed by the residual interference between the tool back face and the workpiece center when the tool-above-centre error exists, and its corresponding cutting force characteristics are studied, and the mapping relationship model between the tool-above-centre error and the cutting force is established. Secondly, the automatic identification algorithm of tool-above-centre error based on this mapping relationship is designed, and the execution program and interface are developed using LabVIEW software. Finally, the online recognition system is used in the machining experiments to identify the features of the force signals during the cutting process, output the tool-above-centre error, and compensate for the error online with the precision fine-tuning mechanism integrated into the experimental platform. Experimental results show the average difference between the tool-above-centre error identified by cutting force recognition and the machine tool feedback error is within 8 μm. The identified error is quickly compensated by a precision micro-adjustment mechanism, with a deviation within 1%. The entire identification and compensation process takes only about one minute, demonstrating the reliability and rapidity of the online tool- above-centre error identification and compensation system. This study will provide a new reference for the automatic identification and compensation of tool setting errors in ultra-precision machining.

Key words: ultra-precision turning, cutting force, tool-above-centre error, online recognition and compensation

中图分类号:

TH161

张稳祺, 张国庆, 马帅. 基于力感知的超精密车削刀高设置误差在线辨识与补偿系统构建[J]. 机械工程学报, 2025, 61(19): 397-406.

ZHANG Wenqi, ZHANG Guoqing, MA Shuai. Construction of Online Identification and Compensation System for Ultra-precision Turning Tool-above-centre Error Based on Force Sensing[J]. Journal of Mechanical Engineering, 2025, 61(19): 397-406.

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基于力感知的超精密车削刀高设置误差在线辨识与补偿系统构建

Construction of Online Identification and Compensation System for Ultra-precision Turning Tool-above-centre Error Based on Force Sensing

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