基于随动支撑头的薄壁件加工优化

Optimisation of Thin-Walled Parts Machining Based on A Follow-Up Support Head

针对航空航天大型薄壁零件加工过程易发生变形和颤振的特点,设计开发了基于音圈电机驱动的刚柔多点随动支撑头,该支撑头在抑振的同时可以保证壁厚误差。首先,采用ANSYS对薄壁件进行了模态分析与动力学分析并确定最佳预推位移;其次,通过模态实验以及铣削加工试验对最佳预推位移及其抑振效果进行验证;同时,采用自抗扰控制器(ADRC)控制音圈电机实时轴向伸缩调节使得加工过程中的轴向切深始终保持一致。结果表明,该支撑头可以有效降低薄壁件的振动且最佳预推位移为1 mm;同时,该支撑头可以控制轴向切深在加工过程中始终保持一致,同时可以将振动抑制在±5μm范围内。

A rigid-flexible multi-point support head driven by voice coil motors is designed and developed in response to the characteristics of aerospace large thin-walled parts that are prone to deformation and chattering during machining.The support head can ensure the wall thickness error while suppressing vibration.Firstly,ANSYS was used to carry out modal analysis and dynamics analysis on the thin-walled part and determine the optimal pre-push displacement,and then the optimal pre-push displacement and the vibration suppression effect was verified through the modal experiments as well as the milling experiments.Meanwhile,the active disturbance rejection controller(ADRC)was employed in the milling tests to control the real-time axial displacements of the two motors,ensuring consistent axial cutting depth throughout the machining process.The results indicate that the support head effectively suppresses vibration in thin-walled parts with an optimal pre-push displacement of 1 mm.The support head demonstrates excellent control effect over maintaining consistent axial cutting depth throughout the machining process,while also suppressing the vibration within the range of±5μm.