Design of CNC System for Wire Bending Robot Based on GTS Motion Controller

为了解决三维复杂金属线材和弹簧类零件的快速制造与生产问题,设计了一台具有X、z两个移动轴和y、A、b三个回转轴的五自由度弯丝机器人。采用PC+运动控制卡的开放式数控结构完成了系统硬件平台的搭建,利用MfC与控制卡提供的动态链接库完成了数控系统软件的编写,实现了系统的绝大部分功能,并应用于课题组设计的弯丝机器人系统中。In order to solve rapid manufacturing and processing problem of workpieces with 3D complex surface and springs w hich w ere made of metal w ire or such other materials,a five degreed of freedom CNC w ire bending robot w hich had X,Z tw o parallel movement axes and Y,A,B three rotary movement axes w as designed.The system hardw are platform w as build through an open-architecture NC system based on IPC and motion control card,the softw are w as programmed by Microsoft Foundation Class and the dynamic link library w hich provide by Googol GTS card that achieved mostly system functions.The CNC system has been used to the w ire bending robot w hich designed by research team.国家科技重大专项(2010ZX04001-162

Structure Analysis and Optimization for 5-axis CNC Grinder Bed

在AnSyS软件平台上建立五轴数控磨床有限元模型,对其床身结构进行静、动态特性分析与优化,通过对比提出两种优化方案,分析结果表明:综合改进后的床身相比原床身在静态特性上得到极大提高,且动态特性也有相应的增强。Finite element model of 5-axis CNC grinder bed was built on ANSYS software platform.The two optimal schemes for the bed structure were extracted on the basis of static and dynamic analyses and optimization.Comprehensive analysis shows that the static performance of the improved bed has been greatly enhanced and the dynamic performance has been correspondingly strengthened than original bed.国家科技重大专项资助项目(2010ZX04001-162

Spindle Thermal Error Comprehensive Prediction Model Based on Information Granulation and SVM

主轴热变形是影响数控机床加工精度的主要因素。为提高主轴热误差的预测精度,提出了基于信息粒化支持向量机（SVM）的主轴热误差综合预测模型。使用信息粒化方法对采样温度数据与主轴热误差数据进行预处理,分别建立基于SVM的主轴热误差的回归预测模型和时间序列模型,通过计算两个模型权重系数,最终建立主轴热误差综合预测模型。以2MZK7150五轴数控可转位刀片工具磨床为研究对象,实验表明,较之于单一模型该模型具有良好的泛化能力和较高建模精度。Spindle thermal deformation has an extraordinary influence on the NC machining precise. Aiming to the im- provement of the spindle thermal deformation predict ability, the spindle thermal error comprehensive predict model is pro- posed on the basis of the information granulation and support vector machine（SVM）. Information granulation method is em- ployed to pretreat the sampling temperature and spindle thermal error. The regression prediction model and time series mod- el of spindle thermal error are also carried out based on the SVM. Finally, the spindle thermal error comprehensive predict model is established using the weight coefficients of the two models. The 2MZK7150 five-axis NC indexable insert tool grinding lathe machining experiment shows that the established model has better generalization ability and higher modeling precision compared with the unitary model.陕西省科技统筹创新工程计划（2014KTD201-04-03

Deform Analysis on Fixture for Peripheral Grinding of Indexable Inserts

在高速精密磨削可转位刀片周边时,由于采用双顶尖油压夹紧刀片,再通过在刀片上产生的摩擦力和油压力来约束刀片的6个运动自由度,造成夹具结构刚性相对薄弱。为此,针对极限夹紧工况时夹具的受力变形进行了分析,通过结构改进与误差补偿,提高了夹具定位精度和磨削加工的可靠性。In high speed precision grinding the peripheral of indexable inserts,due to the double chucks clamping the blade by the oil pressure,and through the friction and the oil pressure produced in the blade to restrain the insert'six movement degrees,all these w ill make the fixture structure rigid become relatively w eak.Therefore,the paper analyses the fixture deformation in the limit w orking condition,and improves the accuracy of the fixture location and the reliability of the grinding process through the structure improvement and error compesation.国家国家科技重大专项(2010ZX04001-162

Structural analysis and lightweight study for the five-axis grinder bed

以五轴联动工具磨床的床身为研究对象,分析了磨床在极限位置使用情况下床身的静态特性,找到了床身变形最大区域。通过自由模态分析和约束模态分析,得到床身各阶模态的振动特点,并从最大变形区域中选取一点进行谐响应分析,预测床身的持续动力特性。根据分析结果,找出薄弱环节,在保证床身动静态特性不降低的基础上对床身进行轻量化研究,最终减重7.73%,节省了材料与成本。With the five-axis grinding machine tool bed as the research object, the maximum deformation region can be found after analyzing the static characteristics in the use of the grinder limit positions.Through free modal and constraint modal analysis, the vibration characteristics of each order of the bed can be seen and a point in the maximum deformation region is selected to carry out the harmonic response analysis to predict the sustainable dynamic characteristic.According to the results of analysis, find out the weak areas in the bed and conduct the lightweight optimization on the condition of no reduction of static and dynamic characteristic of the bed.And finally, it reduces 7.73% of materials and prime costs.数控国家科技重大专项(2010ZX04001-162

Research on Virtual Inspection and Grinding Simulation Technology of Five-axis CNC Tool Grinder

给出了可转位刀片在线测量的数学模型,建立了五轴数控工具磨床虚拟检测及虚拟磨削环境,对可转位刀片磨削前和磨削后的测量过程进行了虚拟仿真。最后以带修光刃正方形刀片为例,借助虚拟检测和磨削仿真技术对其进行生产制造的前期验证工作,检验了自动生成数控加工程序的正确性,同时完成了机床干涉判断。整个研究对测量规划可行性及数控程序可靠性的评估分析有较高的参考意义。The mathematical model of on-line inspection of indexable inserts is given.This paper established a virtual inspection environment and a virtual machining environment for five-axis CNC tool grinder,and conducted the inspection simulation of the indexable inserts.Taking the squre inserts as an example,this virtual inspection technology and grinding simulation technology is very adapt to the early verification of manufacturing.The correc-tness of NC processing commands can be checked and the result can judged the mutual interference of machine tool.The research provides highly reference significance for estimating ang analyzing the feasibility of measurement and the reliability of NC commands.国家科技重大专项(2010ZX04001-162

Research on Virtual Five-axis CNC Tool Grinder Machining Simulation Technology

通过计算机辅助设计与虚拟样机技术,建立了五轴数控工具磨床虚拟加工环境。借助这个平台对回转面刀具进行了设计制造的前期验证,检验加工指令的准确与否。最后以两刃立铣刀为例,利用生成的数控加工程序对其进行了虚拟仿真磨削,结果证明了研究理论的可行性和准确性。同时,加工仿真可有效判断机床工艺系统的相互干涉问题,提高了数控指令的可靠性。The design process of a virtual machining environment for five-axis CNC tool grinder based on the research of the computer aided design and virtual prototype technology has been presented in this paper.This simulation platform is very adapt to the early verification of helical cutter design and manufacturing.And the correctness of NC processing commands can also checked on this simulation platform.Taking the end mill as an example,the manufacturing process was simulated.The simulation results show that the virtual modeling method is feasible and the result can effectively judge the mutual interference of machine tool system.This method also can improve the reliability of NC commands.国家科技重大专项资助项目(2010ZX04001-162

Theoretical studies on forming arc transition edge surface of indexable inserts

为了提高切削性能和加工质量,可转位刀片一般带有圆弧形过渡刃,圆弧过渡刃曲面的精密成形是制造圆弧过渡刃可转位刀片的关键技术之一,通过对常用的圆弧过渡刃曲面的分析,归纳了4种曲面形式,建立了统一的数学模型和成形方法,利用曲面造型理论和可转位刀片的三维实体数控成形仿真技术,验证了圆弧过渡刃曲面构建模型理论推导的正确性。In order to improve the cutting performance and processing quality,the indexable insert generally works with an arc transition edge,the precision forming of the arc transition edge surface is one of the key technologies for fabricating the indexable inserts.By analyzing the commonly used arc transition edge surface,four kinds of surfaces are obtained and the unified mathematical model and forming methods are established.By applying the surface forming theory and 3D solid NC forming simulation technology of the indexable insert,the validity of the theoretical derivation for arc transition edge surface configuration is verified.国家科技重大专项资助项目(2010ZX04001-162

Research of CNC Grinding Forming Technology for Extrusion Tap

研究了挤压丝锥的成形方法,根据机床的结构运动关系建立了五轴数控工具磨床的虚拟样机,对磨削工艺技术进行了虚拟仿真,确保实际加工形状的准确性和可靠性。针对小型挤压丝锥加工磨削过程存在刚性差、让刀严重、砂轮钝化等问题,设计了顶尖和砂轮修整器的相应工装。通过磨削试验,证明所用成形技术可以满足5μM以内的挤压丝锥制造精度。This paper studies the method of forming extrusion tap.A virtual prototype of the five-axis CNC tool grinder is established according to the structure movement relationship of the machine for the virtual simulation of grinding technology to ensure the Accuracy and reliability of the actual machining shape.The Top and Dresser corresponding tooling are also designed to solve the problems of poor rigidity,tool recession and wheel dull of small extrusion tap.The result of processing test has proved the presented forming technology can achieve the machining accuracy of 5μm.国家“高档数控机床与基础制造装备”科技重大专项资助(2010ZX04001-162

Calculation of Grinding Wheel Profile and 3D Simulation for Grinding Screw Rotor Flute

【中文摘要】 介绍了螺杆转子成型磨削原理,并给出成形砂轮截形计算的基本流程.再利用啮合原理推导建立了螺杆转子螺旋面与砂轮回转面的接触线方程式,从而计算得到成型砂轮截形曲线.详细论述了用分段累加弦长参数的数值计算方法,对砂轮截形进行计算,避开对转子截形曲线各离散点直接求导的困难,提高了计算效率.最后以某非对称型线螺杆阴转子为例,对砂轮截形进行计算绘制,并通过仿真加工检验计算的正确性,同时进行干涉判断.该方法也为螺杆转子后续的有限元分析和虚拟测试实验提供了精确的实体模型. 【英文摘要】 In order to describe the forming grinding principle of screw rotor,the design process of the forming grinding wheel is given.The contact line equation of screw rotor′s helical groove and forming grinding wheel′s rotation surface is established by engagement principle.To optimize the traditional method of calculating forming grinding wheel by known rotor end section profile,a numerical analysis method(accumulated chord length parameter method) has been presented in detail.This method can improve the efficien...国家科技重大专项项目(2010ZX04001-162