Research on Key Technology of Grinding for Screw Rotor Profile

双螺杆压缩机具有工作可靠、适应性强、易于操作维护和多相混输等优点，被广泛应用于汽车、压缩机、制冷机、矿山机械、动力机械等工业领域。双螺杆压缩机的核心部件是一对相互啮合的螺杆转子，螺杆转子加工质量是保证双螺杆压缩机性能及能效的关键，提高转子加工精度有利于降低其能耗，对节能减排具有非常重要的意义。随着现代机械设计制造技术的发展，出现了一批专用的数控螺杆转子加工设备及其配套软件，但其核心技术仍由国外掌握。我国在这一研究领域还处在刚起步阶段，与世界领先技术相比还有很大差距，且由于欧美等发达国家的技术封锁，目前我国螺杆压缩机设计制造过程中在型线设计、加工设备、加工与装配工艺等关键技术领域仍然落后于国外。...The advantages of twin-screw compressor include high reliability, good adaptability, ease of operation and maintenance, the ability to transport various mixed liquids. Thereby, the twin-screw compressor has been widely used in automotive, compression, refrigeration, metallurgy, buildings and other industrial field. A pair of conjugate screw rotors is the most crucial component of the twin-screw co...学位：工学博士院系专业：物理与机电工程学院_机械制造及其自动化学号：1992012015388

Method of error compensation for precise grinding the helical rotor tooth profile

针对成形法精密磨削加工螺杆转子螺旋面的问题,研究了螺杆转子加工过程中由工艺系统误差产生的齿廓加工误差的补偿方法。提出了一种基于首件转子磨削后的齿; 廓测量误差,进行预处理再修整砂轮的新算法。使用处理后的补偿数据对砂轮修整后,加工误差明显减小与收敛,大大提高了磨削转子的齿廓制造精度。Aiming at the process of the machining screw rotor helical surface by; forming precision grinding, the compensation method of tooth profile; error caused by the process system error in the process of screw rotor; machining is researched. A new pretreatment and refinish grinding wheel; algorithm is proposed which based on the measurement error of the tooth; profile after the first rotor grinding. After the grinding wheel was; dressed base on the compensated data, machining error is obviously; reduced and convergence, the machining precision of root is improved; obviously.陕西省地方重大资助项

The Design of Self-Adaptive Control System for Grinding Force

可转位刀片的传统磨削加工大多采用恒进给量控制法,若工件的余量不均、材质不均、磨削速度较高、砂轮的切削性能较差时,在进给速度较大时,将对工件的加工表面质量产生不良影响,如表面粗糙度增大,工件表面烧伤和产生微裂纹,砂轮磨损加剧,砂轮轴变形,甚至砂轮崩裂。若降低进给速度势必会影响加工效率。自适应加工技术是解决上述问题的重要途径,论文讨论了应用该技术对影响加工效率和精度的切削力、转矩、功率、刀具磨损、尺寸精度、和表面粗糙度等物理量进行检测、建模、提取特征,对进给速度、主轴转速等工艺参数进行实时控制,使机床的工艺系统在高效加工中处于最佳状态。Mostly,the traditional method of grinding indexable insert is to keep constant feed rate.If the allowance of workpiece was uneven,the material was nonuniform,the speed of grinding was high and cutting performance of grinding wheel was poor,a large feed rate would exert a bad effect on the quality of manufacturing.For example,surface roughness would increase,surface would burn and emerge tiny fissures,grind wheel wear would exacerbate,shaft would distort,even crack.However,if you reduce the feed rate,efficiency will certainly be low.Self-adaptive manufacturing technology is an important way to solve those problems above.The technology detects,builds up models and extracts characteristics of physical quantities,such as force,torque,power,tool wear,dimensional accuracy and surface roughness which affect processing efficiency and precision.Then,it keeps feed rate,spindle speed and other parameters in real-time control to ensure the best condition.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

Analysis and compensation of the springback of metal wire bending

回弹对于线材折弯加工的精度影响非常明显,为探索线材回弹规律,建立了线材折弯过程的数学模型,以材质45钢的线材为研究对象,进行有限元分析与试验研究。验证了有限元分析与试验方法获得回弹角度数据的一致性,考虑折弯角度和线材直径两个主要参数对回弹的影响,建立了线材折弯回弹角度的双参数数学模型。将回弹角度双参数数学模型应用于弯丝机的补偿模块,进行线材折弯试验,取得明显的折弯补偿效果,使线材折弯加工精度达到了1°,实现了对任意折弯角度和线材直径的线材折弯回弹补偿。It is evidently shown that the springback has an influence on the accuracy of wire bending process.In order to explain the law of springback,a mathematical model of wire bending process was built for 45 steel wire,and finite element analysis and experimental research were carried out.The consistence of springback angle was attained through the finite element simulation and experiments.Considering the influence of the two main parameters of bending angle and wire diameter,a double-parameter mathematical model of springback angle was established.When the double-parameter mathematical model was applied to the compensation module of wire-bending machine for the test of wire bending,a prominent compensation effect was achieved,the processing precision was up to 1° with the springback compensation of arbitrary bending angle and wire diameter realized.厦门市产业技术攻关资助项目(3502Z20131007

普通圆柱蜗杆的参数化设计与制造研究

为提高普通圆柱蜗杆的参数化设计和制造水平，基于普通圆柱蜗杆数学模型、齿轮啮合原理、蜗杆磨床结构、蜗杆加工工艺等开发一款普通圆柱蜗杆的参数化设计、制造软件。以法向直廓圆柱蜗杆（ZN型蜗杆）为例，建立法向直廓圆柱蜗杆几何数学模型，并根据蜗杆与砂轮的空间位姿关系和齿轮啮合原理推导了磨削蜗杆用成形砂轮廓形的数学模型；基于Visual C++6.0开发了包含有产品管理模块、蜗杆参数输入模块、蜗杆线形过渡模块、蜗杆线形调整模块、砂轮廓形计算模块以及加工代码生成模块的蜗杆设计、制造软件。为验证所开发软件的正确性，采用SK6505数控蜗杆磨床对法向直廓圆柱蜗杆进行磨削加工，磨削后的测量结果验证了该软件的正确性

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

Modeling of Virtual Grinding Wheel Based on Random Distribution of Multi Abrasive Grains and Prediction of Grinding Force

利用VHX-600E型超景深显微镜测量了金刚石砂轮表面的磨粒分布情况,计算得到了砂轮表面的磨粒密度、真实接触弧长以及砂轮总的磨粒数和有效磨粒数。基于磨粒间隔分布假设和虚拟格子方法在虚拟砂轮端面随机分布等磨粒密度的多颗正六面体磨粒,并随机分配磨粒的位姿以模拟砂轮的真实形貌。将1/4虚拟砂轮模型导入dEfOrM-3d软件中,建立三维虚拟磨削仿真模型,采用lAgrAngIAn InCrEMEnTAl算法获得多颗磨粒的仿真磨削力值,并建立了基于多颗磨粒磨削仿真的磨削力预测模型。通过金刚石砂轮端面磨削硬质合金刀片的实验,比较了实测磨削力与预测磨削力;仿真与实验结果具有一致性,证明了采用本方法建立的多颗磨粒虚拟磨削仿真模型可以用于磨削力预测,为多颗磨粒共同磨削的磨削力研究提供了新的思路。The distribution of abrasive grains existing in diamond grinding wheel surface is firstly measured by a VHX-600 Eoptic microscope.The density of abrasive grains,the actual contact length and the effective number of abrasive grains are then calculated.Based on the assumption of interval distribution of abrasive grains and virtual grid method,the surface of virtual grinding wheel is randomly distributed with multi hexahedron abrasive grains which are equal in density.Besides,the posture of abrasive grains is randomly allocated to simulate the real topography of grinding wheel.The 3Dsimulated model of virtual grinding is built by importing a 1/4virtual grinding wheel model into Deform-3Dsoftware and the simulated grinding force value of multi grains is obtained by Lagrangian Incremental algorithm.The multi-grain grinding force predictive model is then built with the simulated model.A carbide blade grinding experiment is performed to validate the predictive model by comparing the measured grinding force with the predictive force.The test verifies the accuracy and effectiveness of the proposed model in the paper.This paper provides a new method to investigate the grinding force which is co-grinded by multigrains.厦门市科技计划项目(3502Z20131007)~

Formation of helix angle of milling cutter and its effect on cutting performance

首先通过铣刀螺旋槽和铣刀前角的数学模型,研究了铣刀螺旋角的形成原理及其对铣刀切削性能的影响。其次用3组不同螺旋角的成形单刃铣刀做切削试验,并记录试验结果。对所得的试验结果进行分析,通过分析可知,铣刀的螺旋角越大,其排屑效果越好,切削纹路越细,最后验证所提理论的正确性。Firstly,this paper studies the helix angle of milling cutter in its forming principle and influence on cutting performance by building up the equation of helical groove and rake angle.Then,it carries out a cutting experiment with three single cutters of different helix angles and records the results.Lastly,it analyzes the results,draws a conclusion that the bigger the helix angle is,the better its effect of chip removal and the thinner its chip can be achieved and proves the theory proposed to be true.国家科技重大专项资助项目(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