考虑双向弱刚性的机器人铣削加工空间刚度辨识与位姿优化分析

doi:10.3901/JME.2025.23.308

摘要/Abstract

摘要： 复杂轻合金薄壁舱体铸件的机器人内腔铣削加工是一种舱体类零件内腔减薄加工的新工艺。由于薄壁舱体零件和机器人系统刚性较弱，铣削减薄过程的等效刚度呈现空间分布特性，导致工件加工成形尺寸精度一致性较差。建立准确的机器人铣削加工系统空间刚度辨识方法与表征模型是其精度控制的关键。基于改进的丹纳维特-哈滕伯格(Denavit-Hartenberg，D-H)方法和铣削过程离散仿真建立了工件-刀具-主轴-机器人系统的空间刚度的数学表征模型，可综合考虑铣削加工系统-工件在铣削力作用下的双向变形影响。在此基础上，通过建立机器人铣削系统高保真有限元仿真模型，提出多位姿载荷输入下的机器人系统关节刚度辨识方法，由此实现多轴机器人系统空间刚度的准确表征；考虑铣削系统刚度随运动空间分布特性，在高保仿真模型的基础上，针对筒形舱体内腔铣削特点，开展机器人铣削加工系统位姿分析及实验验证。结果表明：通过建立工件-刀具-主轴-机器人系统的高保真有限元仿真模型，在提升机器人系统关节刚度辨识精度的基础上，可实现铣削加工系统-工件在加工过程中的空间刚度解析，有效提升机器人铣削系统空间加工精度和工件轮廓精度。

关键词: 机器人铣削, 双向弱刚度, 刚度辨识, 位姿优化, 孪生仿真

Abstract: Robotic internal cavity milling of complex light alloy thin-walled cabin castings is a new method for thinning cabin parts. The weak stiffness of both the thin-walled parts and the robotic system results in spatial distribution characteristics of the equivalent stiffness during milling. This leads to poor consistency in the dimensional accuracy of the processed workpieces. Establishing an accurate spatial stiffness identification method and characterization model for the robotic milling system is crucial for precision control. A mathematical characterization model for the spatial stiffness of the workpiece-tool-spindle-robot system is introduced. The model is based on the improved Denavit-Hartenberg (D-H) method and the discrete simulation of the milling process, which can comprehensively consider the bidirectional deformation effects of the milling system-workpiece under the action of milling forces. Additionally, a high-fidelity finite element simulation model of the robotic milling system is established. Using this model, a joint stiffness identification method for the robotic system under multiple pose loading inputs is proposed, achieving accurate characterization of the spatial stiffness of the multi-axis robotic system. Considering the stiffness distribution characteristics within themotion space, pose analysis and experimental verification of the robotic milling processing system are conducted. These are based on the milling characteristics of the inner cavity of the cylindrical cabin. The results demonstrate that the high-fidelity finite element simulation model of the workpiece-tool-spindle-robot system enables spatial stiffness analysis of the milling system-workpiece during machining. This improves the joint stiffness identification accuracy of the robotic system, thereby enhancing the spatial machining accuracy of the robotic milling system and the accuracy of the workpiece contour.

Key words: robotic milling, bidirectional weak-stiffness, stiffness identification, pose optimization, digital twin

中图分类号:

TP242

顾群飞, 刘顺, 金隼. 考虑双向弱刚性的机器人铣削加工空间刚度辨识与位姿优化分析[J]. 机械工程学报, 2025, 61(23): 308-320.

GU Qunfei, LIU Shun, JIN Sun. Spatial Stiffness Identification and Pose Optimization Analysis of Robotic Milling Process Considering Bidirectional Weak-stiffnesses Characteristic[J]. Journal of Mechanical Engineering, 2025, 61(23): 308-320.

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