凸轮轴数控磨削轮廓误差分析与补偿

摘要/Abstract

摘要： 在分析国内外磨削加工误差分析与补偿研究现状基础上，针对X轴和C轴两轴联动的凸轮轴数控磨削的轮廓误差提出一种轮廓误差分析和补偿策略，以提高凸轮磨削加工精度。基于凸轮轴数控磨削的X-C联动运动模型，推导了由凸轮升程表到磨削加工位移表的数学模型;指出凸轮升程与轮廓的误差变化规律在趋势上具有一致性。基于最小二乘多项式方法对多次磨削加工实验的凸轮升程误差进行一系列拟合处理，得到稳定的、可重复的凸轮升程预测误差;将升程预测误差按一定比例反向叠加到理论升程表中，采用最小二乘多项式法进行光顺，得到光顺的虚拟升程表;利用虚拟升程表对同类型凸轮轴进行磨削加工实验。实验结果表明，砂轮架速度和加速度在机床伺服响应范围之内，凸轮最大升程误差与最大相邻误差降低，凸轮轮廓表面粗糙度值满足加工要求，从而证明该误差分析和补偿方法是正确可行的。

关键词: 凸轮轴, 数控磨削, 轮廓误差, 最小二乘法

Abstract: Based on the current situations of grinding error analysis and compensation, a new contour error analysis and compensation method was proposed for camshaft CNC grinding in X-C axis linkage, to improve the accuracy of cam grinding. According to the camshaft grinding motion model in X-C axis linkage, the mathematical model was derived for cam lifting to grinding offset. It pointed out that the variation trends of cam lifting errors and contour errors were basically the same. Then a stable and repeatable cam lifting errors could be predicted with series fitting of cam lifting errors from multiple grinding experiments, using least square method. By inverse superposition of predicted lifting errors to theoretical lifting table in a certain proportion, the virtual lifting table could be obtained after the smoothing using least square method. Finally, the camshaft grinding experiments were applied according to the virtual table. The experimental results indicated that: the speed and acceleration of grinding carriage are basically in the response range of grinder servo, the maximum cam lifting error and the maximum adjacent error are decreased, the surface roughness satisfies with the processing requirements. It is proved that the error analysis and compensation methods are correct and feasible.

Key words: camshaft, CNC grinding, contour error, least square method

中图分类号:

TG580

杨寿智, 邓朝晖, 刘伟, 李建, 彭克立. 凸轮轴数控磨削轮廓误差分析与补偿[J]. 中国机械工程.

Yang Shouzhi, Deng Zhaohui, Liu Wei, Li Jian, Peng Keli. Contour Error Analysis and Compensation for Camshaft CNC Grinding[J]. China Mechanical Engineering.

参考文献

[1]张晓红. 凸轮轴数控磨削工艺智能专家系统的研究及软件开发[D]. 长沙: 湖南大学, 2010.

[2]余顺. 数控凸轮加工成型、质量控制及其机床设计关键理论研究[D]. 武汉: 武汉理工大学, 2006.

[3]Lei W T, Hsu Y Y. Accuracy Enhancement of Five-axis CNC Machines through Real-time Error Compensation[J]. International Journal of Machine Tools and Manufacture, 2003, 43(9): 871-877.

[4]Ibaraki S, Ota Y. A Machining Test to Evaluate Geometric Errors of Five-axis Machine Tools with Its Application to Thermal Deformation Test[J]. Procedia CIRP, 2014, 14: 323-328.

[5]李勇. 影响数控凸轮轴磨削加工精度若干因素的研究[D]. 武汉: 华中科技大学, 2004.

[6]张明伟, 沈兴全. 基于多体系统理论的三轴数控机床误差补偿模型[J]. 机械工程师, 2009 (1): 111-113.

Zhang Mingwei, Shen Xingquan.The Error Compensation Model of Three-axis Numerical Control Machine tool Based on Multi-body System[J]. Mechanical Engineer, 2009 (1): 111-113.

[7]Chen F J, Yin S H, Huang H, et al. Profile Error Compensation in Ultra-precision Grinding of Aspheric Surfaces with On-machine Measurement[J]. International Journal of Machine Tools and Manufacture, 2010, 50(5): 480-486.

[8]Mhring H C, Gümmer O, Fischer R. Active Error Compensation in Contour-controlled Grinding[J]. CIRP Annals —Manufacturing Technology, 2011, 60(1): 429-432.

[9]Zhang K, Yuen A, Altintas Y. Pre-compensation of Contour Errors in Five-axis CNC Machine Tools[J]. International Journal of Machine Tools and Manufacture, 2013, 74: 1-11.

[10]范晋伟, 关佳亮, 阎绍泽. 提高精密凸轮磨削精度的几何误差补偿技术[J]. 中国机械工程, 2004, 15(14): 1223-1226.

Fan Jinwei, Guan Jialiang, Yan Shaoze. Technology for Enhancing the Grinding Accuracy of Precision Cam by Geometric Error Compensation Method[J]. China Mechanical Engineering, 2004, 15(14): 1223-1226.

[11]陈逢军, 尹韶辉, 范玉峰, 等. 一种非球面超精密单点磨削与形状误差补偿技术[J]. 机械工程学报, 2010, 46(23): 186-191.

Chen Fengjun, Yin Shaohui, Fan Yufeng, et al. Ultra-precision Single-point Grinding Technique and Profile Error Compensation Method for Machining Aspheric Mould[J]. Journal of Mechanical Engineering, 2010, 46(23): 186-191.

[12]Chen T, Tian X. An Intelligent Self-learning Method for Dimensional Error Pre-compensation in CNC Grinding[J]. The International Journal of Advanced Manufacturing Technology, 2014, 75(9/12): 1349-1356.

[13]焦青松, 李迪, 王世勇, 等. 刀剪三轴端面磨削控制及误差补偿方法研究[J]. 机械工程学报, 2015, 51(7): 206-212.

Jiao Qingsong, Li Di, Wang Shiyong, et al. Study on Control and Error Compensation Method of 3-axis Surface Grinding for Knifes and Scissors[J]. Journal of Mechanical Engineering, 2015, 51(7): 206-212.

[14]李建. 凸轮轴数控磨削误差分析和补偿技术研究及软件设计[D]. 长沙: 湖南大学, 2009.

[15]杨寿智, 邓朝晖, 吴桂云, 等. 凸轮轴数控磨削工件主轴转速优化建模与实验研究[J]. 中国机械工程, 2016, 27(5): 652-657.

Yang Shouzhi, Deng Zhaohui, Wu Guiyun, et al. Modeling and Experimental Research on Workpiece Spindle Speed Optimization in Camshaft CNC Grinding[J]. China Mechanical Engineering, 2016, 27(5): 652-657.