螺旋锥齿轮差曲面模型的建立与仿真

根据六轴五联动数控螺旋锥齿轮磨床结构,应用多体系统理论、齿轮啮合理论建立了螺旋锥齿轮的差曲面,仿真了砂轮在沿X、Y轴平移和绕C轴转动时的差曲面,并由此分析了磨床主轴各运动副误差对螺旋锥齿轮齿面生成的影响.结果表明,砂轮绕C轴旋转对齿面误差影响较大.此研究对提高螺旋锥齿轮的加工精度和误差补偿提供了理论依据.     

滚刀刀齿运动轨迹精确建模与仿真研究

针对仿真中由于模型简化而带来的仿真精度问题,提出了基于实体造型的滚齿加工仿真方法。重点解决了滚刀刀齿空间运动轨迹精确建模问题,提出了基于时间驱动的滚齿加工运动矢量建模方法,获得了刀齿运动轨迹点位置矢量与速度矢量;指定速度矢量为一阶导矢、位置矢量为节点坐标进行样条曲线插值,得到刀齿运动轨迹曲线。分析轨迹曲线在不同数量插值轨迹点下的插值精度,优选出最佳插值轨迹点数量。将插值轨迹曲线应用于所开发的滚齿加工仿真系统,齿轮端面仿真齿廓与理论渐开线齿廓比较,验证了所提出方法的合理性与准确性。     

一种环形结构的耦合振荡器阵列及其在有源天线阵中的应用

基于耦合振荡器阵列的有源相控阵天线由于不采用移相器,利于集成,因而是相控阵天线实现低成本和小型化的有效途径之一.提出了一种环形结构的二维耦合振荡器阵列,这种阵列的阵元按照环形排列,阵元之间的耦合通过径向的耦合网络实现.推导了环形结构耦合振荡器阵列的平面相位分布控制方法,只需要控制边界阵元即可实现阵列的平面相位分布控制.同时,对基于环形结构耦合振荡器阵列的有源天线阵的相位控制误差和波束扫描范围进行了分析,理论和仿真结果表明,阵列的相位控制误差具有积累特性.当阵元径向间距为半波长时,可以实现偏离阵面法线30度范围内的波束扫描.     

笛卡尔空间机械手间接轮廓运动控制

针对笛卡尔空间机械手的轮廓运动控制问题,提出了一种具有双闭环结构的间接轮廓运动控制方法。外环为笛卡尔空间运动学控制策略,首先将期望轮廓的Frenet标架定义为任务坐标系,然后机械手运动学的误差动态方程被转换到该任务坐标系内,跟踪误差向量被解耦为切向误差向量和法向误差向量,设计外环控制器,分别配置切向误差和法向误差动态特性,为内环提供速度给定信号;而内环为关节空间的速度伺服环。数值仿真显示这种控制结构具有良好的性能。     

一类不确定执行器非线性系统的自适应控制

针对一类带不确定执行器非线性的控制系统,提出了一种自适应神经网络控制方法。建立了包括死区、齿隙和“类齿隙”磁滞特征的非线性执行器模型。通过结合所建立的模型和Nussbaum增益技术,解决了当执行器非线性不确定时的控制问题。所设计的方案不需知道非线性特征参数边界,并且当非线性特征为死区时,其坡度可以为时变的。引入了自适应补偿项消除建模误差和干扰的影响。仿真结果验证了该方法的有效性。     

捷联惯导算法中螺旋理论的应用

算法定义了推力速度坐标系、重力速度坐标系、位置坐标系,以螺旋理论为数学工具,提出了一种新的捷联惯导算法。算法利用螺旋矢量描述空间中的旋转和平移,推导出对偶四元数表示的导航运动学方程,同时对载体的姿态、速度进行更新。设计的螺旋补偿算法包括了传统的圆锥补偿和划船补偿,有效地减小了刚体转动的不可交换性误差。仿真结果表明:在高动态环境中,采用高精度的惯性传感器时,新算法的性能优于传统算法。     

侧风状况下轿车气动特性的仿真与实验研究

以获得适合计算侧风气动特性的湍流模型为目的,应用计算流体动力学方法对比了标准k模型、RNG k模型、Realizable k模型以及SST模型对不同横摆角状态下轿车气动特性仿真结果的影响。结果表明,当0时,采用Realizable k湍流模型仿真得出的阻力系数与实验结果最为吻合,误差仅为1.53%,侧力系数的仿真结果与理论分析更为吻合;当3～1 5时,采用Realizable k湍流模型仿真得出的阻力系数与实验结果相比误差最大为0.96%,侧力系数的仿真结果与实验结果趋势一致,误差最大也仅为4.9%。总之,Realizable k湍流模型能够很好的模拟侧风状态下车辆的气动特性,仿真结果为进一步分析车辆的侧风稳定性提供了参考数据。     

加权平均法在GFSINS角速度解算中的应用

针对积分法带来快速误差积累以及开方法存在大量开方运算和符号误判等问题,提出了将加权平均法应用到无陀螺捷联惯导系统(gyro free strapdown inertial navigation system, GFSINS)角速度解算中的新方法。基于一种改进的九加速度计配置方式,推导了两种传统角速度解算方法;采用基于多元统计理论的加权平均法,将积分法和开方法得到的两组角速度通过选择最优权数进行有效数据融合,得到一组误差更小的角速度。仿真结果表明,此方法不仅能消除迭代误差,而且其角速度解算精度比开方法提高了大约1.5倍。     

基于ANSYS的曲轴—滑动轴承系统动力学模型的研究

在考虑滑动轴承油膜刚度和阻尼的基础上,利用ANSYS建立了大功率低速船用柴油机曲轴转子-轴承系统的动力学模型.研究了转速变化时系统固有频率的影响规律,计算了系统的前6阶振型,用ANSYS谐响应分析法,研究了系统的不平衡响应.研究发现不平衡质量可以激起轴向振动;系统的振动多以耦合振动方式出现;此类曲轴固有频率很低,只能在低速条件下工作和加工.通过对曲轴转子振动规律的研究,为曲轴精加工时切削用量的选择提供理论依据.     

基于分集技术的射频仿真角度精度提高

研究了提高射频仿真系统的角度精度的方法。提出了三元组分集技术,该技术通过使用多个三元组同时对同一个点目标进行模拟来提高仿真角度精度。不同三元组具有相互独立的角度误差的电磁能流在空中汇集,称之为空间合并。当各三元组的能流配以合适的权重时,空间合并会给出最佳的角度精度。该文依据最大比率合并算法,给出了各三元组的最佳权重。当5个三元组进行分集时,仿真角度误差的方差可以减小到原来的60%以下。参与分集的三元组数目越大,仿真角度精度越高。这对于进一步提高三元组射频仿真精度具有理论意义和实用价值。     

Generation method for five-axis NC spiral tool path based on parametric surface mapping

A new spiral tool path generation algorithm for 5-axis high speed machining is proposed in this paper. Firstly, the voltage contours are calculated to satisfy the machining parameters in the mapping parametric domain by means of the electrostatic field model of partial differential equations. Secondly, the mapping rules are constructed and the machining trajectory is planned out in the standard parametric domain in order to map and generate the spiral trajectory in the corresponding parametric domain. Finally, this trajectory is mapped onto the parametric surface for the obtainment of the spiral tool path. This spiral tool path can realize the machining of complicated parametric surface and trimmed surface without tool retractions. The above-mentioned algorithm has been implemented in several simulations and validated successfully through the actual machining of a complicated cavity. The results indicate that this method is superior to the existing machining methods to realize the high speed machining of the complicate-shaped cavity based on parametric surface and trimmed surface.     

High Speed Machining for Linear Paths Blended with G3 Continuous Pythagorean-Hodograph Curves

Previously, many studies have illustrated corner blend problem with different parameter curves. Only a few of them take a Pythagorean-hodograph (PH) curve as the transition arc, let alone corresponding real-time interpolation methods. In this paper, an integrated corner-transition mixing-interpolation-based scheme (ICMS) is proposed, considering transition error and machine tool kinematics. Firstly, the ICMS smooths the sharp corners in a linear path through blending the linear path with G3 continuous PH transition curves. To obtain optimal PH transition curves globally, the problem of corner smoothing is formulated as an optimization problem with constraints. In order to improve optimization efficiency, the transition error constraint is deduced analytically, so is the curvature extreme of each transition curve. After being blended with PH transition curves, a linear path has become a blend curve. Secondly, the ICMS adopts a novel mixed interpolator to process this kind of blend curves by considering machine tool kinematics. The mixed interpolator can not only implement jerk-limited feedrate scheduling with critical points detection, but also realize self-switching of two interpolation modes. Finally, two patterns are machined with a carving platform based on ICMS. Experimental results show the effectiveness of ICMS.

     

Tool Orientation Optimization and Path Planning for 5-Axis Machining

Tool path generation is a fundamental problem in 5-axis CNC machining, which consists of tool orientation planning and cutter-contact(CC) point planning. The planning strategy highly depends on the type of tool cutters. For ball-end cutters, the tool orientation and CC point location can be planned separately;while for flat end cutters, the two are highly dependent on each other. This paper generates a smooth tool path of workpiece surfaces for flat end mills from two stages: Computing smooth tool orientations on the surface without gouging and collisions and then designing the CC point path. By solving the tool posture optimization problem the authors achieve both the path smoothness and the machining efficiency. Experimental results are provided to show the effectiveness of the method.     

Time-optimal interpolation for CNC machining along curved tool pathes with confined chord error

In this paper, two new interpolation algorithms lot CNC machining along curve~l tom pathes are proposed： a time-optimal interpolation algorithm under chord error, feedrate, and tangential acceleration bounds, and a greedy interpolation algorithm under the chord error and tangential jerk bounds. The key idea is to reduce the chord error bound to a centripetal acceleration bound which leads to a velocity limit curve, called the chord error velocity limit curve. Then, the velocity planning is to find the proper velocity curve governed by the acceleration or jerk bounds ＇~under＂ the chord error velocity limit curve. For two types of simple tool pathes, explicit formulas for the velocity curve are given and the methods are implemented in commercial CNC controllers.     

计算机仿真技术在超硬材料抛光技术中的应用

计算机仿真技术在机械工程、自动化控制工程、国防建设等领域得到广泛的应用，已成为研究、设计和分析复杂问题的重要工具。文中首次将计算机仿真技术引入超硬材料加工技术，从运动学和几何学原理出发，建立了双摇杆机构的数学模型，得出了双摇杆机构中工件中心点的运动轨迹方程，并用Visual Basic语言编制了相应的计算机仿真软件，以图形的形式显示出了运动轨迹曲线。并对各杆的长度及相角度等设计参数进行了优化，并将其成功地应用于立方氮化硼等超硬材料的抛光技术。     

Variable feedrate interpolation of NURBS Toolpath with geometric and kinematical constraints for five-axis CNC machining

Variable feedrate interpolation algorithms for five-axis parametric toolpath are very promis- ing but still rather limited currently. In this paper, an off-line feedrate scheduling method of dual NURBS curve is presented with geometric and kinematical constraints. For a given dual parametric curve, the feedrates of sampling points are first scheduled sequent with confined feedrate of cutter tip and machine pivot, chord error, normal acceleration and angular feedrate. Then, the feedrate profiles of angular feed acceleration sensitive regions of the path are adjusted using a bi-directional scanning algorithm. After that, a linear programming method is used to adjust the feedrate profiles of linear feed acceleration sensitive regions and control the linear feed acceleration of both cutter tip and machine pivot within preset values. Further, a NURBS curve is used to fit the feedrates of sampling points. Finally, illustrative examples are carried out to validate the feasibility of the proposed feedrate schedul- ing method. The results show that the proposed method has the ability of effectively controlling the angular feed characters of cutter axis as well as the chord error and linear feed characters of cutter tip and machine pivot, and it has potential to be used in high accuracy and high quality five-axis machining.     

A HEURISTIC PATH-PLANNING METHOD FOR ENHANCING MACHINE-TOOL CONTOUR-FOLLOWING

Nomenclature ki integral action coefficient[s-1]kp speed proportional gain[s-1]kv position proportional gain[s-1]kf feed forward factor of the speed loop[%]M axis mass[kg]V speed[m/s]F driving effort[N]Rc radius of curvature[m]d distance to the apex[m]o lateral offset[m]εcontouring error[m]ωm lowest mechanical resonant frequency[s-1]ζdamping coefficient[-]r inertia ratio[-]μmembership function[-]αcorner angle[rad]x,y horizontal and vertical coordinates[m]?angle to the normal line[rad]1.I…     

基于CATIA V5的圆柱齿轮虚拟加工研究

以共轭齿面包络原理为理论基础,布尔运算为方法,商用三维实体软件为工具,研究了磨前滚刀加工圆柱齿轮的计算机虚拟加工问题,利用CATIA V5的二次开发功能构建出磨前滚刀加工圆柱齿轮的虚拟仿真加工系统.对仿真系统虚拟加工的齿轮齿廓进行了曲面重构,得到了精确齿轮实体模型,通过分析模型的公法线误差,验证了该方法的正确性.为基于包络制造原理的曲面零件的数字化制造提供了一种有效方法.     

A tool path correction and compression algorithm for five-axis CNC machining

A novel approach is proposed for correcting command points and compressing discrete axis commands into a C2 continuous curve. The relationship between values of rotation angles and tool posture errors is firstly analyzed. A segmentation method based on values of rotation angles and lengths of adjacent points is then used to subdivide these command points into accuracy regions and smoothness regions. Since tool center points generated by CAD~CAM system are usually lying in the space that is apart from the desired curve within a tolerance distance, and the corresponding tool orientation vector may change a lot while the trajectory length of the tool center point is quite small, directly machining with such points will lead to problems of coarse working shape and long machining time. A correction method for command points is implemented so that good processing effectiveness can be achieved. Also, the quintic spline is used for compressing discrete command points into a C2 continuous smooth curve. The machining experiment is finally conducted to demonstrate the effectiveness of the proposed algorithm.     

硬态切削过程建模技术研究发展

硬态切削以加工柔性好、经济性和环保性好等特点，在汽车行业、轴承行业、液压行业等被广泛采用。而针对于预测硬态切削加工性能和优化加工参数等方面，仿真建模技术不仅起到了重要作用，还能更好地反映切削加工本质，对实际生产加工具有一定的理论指导作用。对国内外硬态切削仿真建模方法进行了介绍，综述了切屑形成、切削力、切削温度、刀具磨损和已加工表面质量的仿真建模方法，并对其今后的发展方向进行了初步的展望。