MECHANICS, DYNAMICS AND CONTROL OF MACHINING SYSTEMS

机械加工系统的力学、动力学和控制

• 批准号: RGPIN-2016-03702
• 负责人: Altintas, Yusuf
• 金额: $ 3.35万
• 依托单位: University of British Columbia
• 依托单位国家: 加拿大
• 项目类别: Discovery Grants Program - Individual
• 财政年份: 2019
• 资助国家: 加拿大
• 起止时间: 2019-01-01 至 2020-12-31
• 项目状态: 已结题
• 来源: https://www.nserc-crsng.gc.ca/ase-oro/Details-Detailles_eng.asp?id=689315
• 关键词: MECHANICS; DYNAMICS; CONTROL; MACHINING; SYSTEMS

Machining is the most widely used operation in manufacturing mechanical parts. Costly aerospace parts are machined from solid blocks by removing 90% of the material. Prototyping costs of mass production lines in the automotive industry can reach a few million dollars in order to shorten the machining time while avoiding scrap rates. The physical trial and prototyping of Computer Numerical Control (CNC) machine tools for targeted machining applications are costly and time consuming. The industry needs productive machining strategies to stay competitive by predicting the physical performance of manufacturing steps ahead of costly physical trials. This research contributes to the mathematical modeling of multi-axis machining operations and their interaction with machine tool structures, kinematics, and control systems. The mathematical models will be used to predict the outcome of the machine design and manufacturing scenarios, which will enable the engineer to optimize manufacturing operations. ***The kinematics and control research will be based on a novel, 9 axis, high speed high precision CNC Micro Machine developed in our laboratory. The machine has three linear motor driven axes with a magnetically levitated rotary table placed on a translational table. The machine's kinematics will be modeled, and 5 degrees of freedom motion will be delivered accurately while controlling 9 drives simultaneously. The machine will be tested in 5 axis micro-milling of dies and molds, as well as in 3D printing of plastics. The kinematics knowledge will be applied in modeling 5-axis CNC mill-turn machines which are widely used in the industry. The research in machining dynamics will focus on the prediction of cutting forces, torque, power and vibrations to simulate and optimize mill-turning and thin walled part machining operations in a digital environment. The thin walled parts experience severe chatter vibrations during machining which leads to poor surface quality and tolerance violations, hence limiting the productivity. As the material is removed during the machining, the mass and stiffness of the parts change continuously. Numerical modeling of part dynamics at each material removal step requires the solution of an eigenvalue problem from large stiffness and mass matrixes of the structure. Therefore, it is time prohibitive for use in production. This research will investigate the analytical and rapid updating of the structural dynamic models of the parts at tool workpiece contact zones along the tool path. The proposed method will be applied in 5 axis ball end milling of jet engine blades and thread turning of oil-gas transportation pipes. ***The proposed research will enrich the current knowledge in machining to achieve complete, science and physics based digital machining technology.

加工是制造机械零件中最广泛使用的操作。昂贵的航空航天零件是通过删除90％的材料来加工的。汽车行业中质量生产线的原型成本可以达到几百万美元，以便缩短加工时间，同时避免废料率。针对目标加工应用程序的计算机数值控制（CNC）机床的物理试验和原型制作是昂贵且耗时的。该行业需要生产的加工策略来保持竞争力，通过预测制造步骤的身体性能在昂贵的物理试验之前。这项研究有助于多轴加工操作的数学建模及其与机床结​​构，运动学和控制系统的相互作用。数学模型将用于预测机器设计和制造场景的结果，这将使工程师能够优化制造运营。 ***运动学和控制研究将基于我们实验室中开发的小说，9轴，高速高精度高精度的高精度CNC微机器。该机器具有三个线性电动机驱动轴，并在翻译表上放置了磁性悬浮的旋转桌。机器的运动学将进行建模，同时控制9个驱动器时，将准确传递5度的自由运动。该机器将以5轴模具和模具以及塑料印刷的3D打印进行测试。运动知识将用于建模5轴CNC磨机机器，这些机器在行业中广泛使用。加工动力学的研究将集中于切割力，扭矩，功率和振动的预测，以模拟和优化数字环境中的磨坊和薄壁的零件加工操作。薄壁零件在加工过程中经历了严重的颤动振动，从而导致表面质量差和耐受性侵蚀，从而限制了生产力。当加工过程中除去材料时，零件的质量和刚度不断变化。在每个材料拆卸步骤中零件动力学的数值建模需要解决结构的较大刚度和质量矩阵的特征值问题。因此，在生产中使用的时间是过时的。这项研究将研究沿刀具路径上刀具工件接触区域零件的结构动态模型的分析和快速更新。所提出的方法将应用于喷气发动机叶片的5轴球端铣削和油气运输管道的螺纹转动。 ***拟议的研究将丰富当前的加工知识，以实现基于科学和物理的数字加工技术。