• CN:11-2187/TH
  • ISSN:0577-6686

机械工程学报 ›› 2025, Vol. 61 ›› Issue (3): 259-271.doi: 10.3901/JME.2025.03.259

• 机械动力学 • 上一篇    

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高转速效应下空气静压主轴微铣削加工表面形貌预测研究

史江海1,2, 冯鑫1,2, 曹宏瑞1,2   

  1. 1. 西安交通大学装备运行安全保障与智能监控国家地方联合工程研究中心 西安 710049;
    2. 西安交通大学机械工程学院 西安 710049
  • 收稿日期:2024-02-13 修回日期:2024-06-03 发布日期:2025-03-12
  • 作者简介:史江海,男,1991年出生,博士,助理教授。主要研究方向为空气静压主轴动力学建模及其微铣削加工稳定性。E-mail:shijiang@xjtu.edu.cn;曹宏瑞(通信作者),男,1982年出生,博士,教授,博士研究生导师。主要研究方向为智能主轴动态监测与控制、航空发动机数字孪生建模及故障智能诊断。E-mail:chr@mail.xjtu.edu.cn
  • 基金资助:
    国家自然科学基金资助项目(52205125)。

Surface Topography Prediction in Micro-milling Processing of Aerostatic Spindle under High-speed Effects

SHI Jianghai1,2, FENG Xin1,2, CAO Hongrui1,2   

  1. 1. National and Local Joint Engineering Research Center of Equipment Operation Safety and Intelligent Monitoring, Xi'an Jiaotong University, Xi'an 710049;
    2. School of Mechanical Engineering, Xi'an Jiaotong University, Xi'an 710049
  • Received:2024-02-13 Revised:2024-06-03 Published:2025-03-12

摘要: 空气静压主轴是超精密加工机床的核心部件,其动态特性直接影响着超精密机床的加工性能。在高速旋转工况下,转子的离心力、陀螺力矩以及空气轴承的动态参数(刚度和阻尼)随着转速发生变化,进而影响空气静压主轴的动力学特性。由于主轴动力学特性与微铣削加工过程之间的耦合效应,在不同切削工况下,切削力会发生波动以及非连续性变化,往往会导致主轴发生较大的振动响应。如果主轴振动响应过大,会引起颤振现象发生,直接导致工件表面加工失效。因此,基于Timoshenko梁单元建立考虑转速效应的空气静压主轴动力学模型及微铣削加工三维表面形貌预测模型,定量分析转速和每齿进给量对工件表面形貌的影响。结果表明:在主轴稳态切削过程中,工件表面相邻切痕之间的距离随着每齿进给量的增大逐渐增加,导致表面粗糙度呈线性增大;当切削速度和每齿进给量很小时,转速可以影响主轴加工效率,但对加工表面的粗糙度影响不大。

关键词: 空气静压主轴, 高转速效应, 动力学建模, 表面形貌预测

Abstract: Aerostatic spindle is the core component of ultra-precision machine tool, and its dynamic characteristics directly affect the machining performance of machine tool. Under high-speed conditions, the centrifugal force and gyroscopic torque of the rotor, and the dynamic parameters (stiffness and damping) of the air bearings vary with the speed, which in turn affects the dynamic characteristics of the aerostatic spindle. Due to the coupling effect between the dynamic characteristics of the spindle and the micro-milling process, the cutting force will fluctuate and change discontinuously under different cutting conditions. As a result, it often leads to a large vibration response of the spindle. If the vibration response is too large, it will cause the chatter phenomenon, which directly leading to workpiece surface processing failure. Therefore, based on Timoshenko beam element, an aerostatic spindle dynamic model considering speed effect and a 3D surface topography prediction model for micro-milling are established. And the influence of rotational speed and feed per tooth on the surface topography of the workpiece is quantitatively analyzed. The results show that during the steady cutting process, the distance between adjacent cutting marks on the workpiece surface increases gradually with the increase of the feed per tooth, causing the surface roughness increases linearly. When rotational speed and feed per tooth reach a small amount, the rotational speed can affect the machining efficiency, but has little effect on the roughness of the machined surface.

Key words: aerostatic spindle, high-speed effect, dynamic modelling, surface topography prediction

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