基于冲击阻尼的深孔车削减振车刀设计

Design of Damped Turning Cutter for Deep Hole Turning Based on Impact Damper

针对内圆车削过程中特别是大长径比内孔车削时,径向力造成工件振动或变形,影响加工精度和表面质量的问题,开展基于冲击阻尼器的减振车刀研究。首先基于欧拉–伯努利梁理论,通过建模仿真开展冲击阻尼机理研究;其次对不同的切削参数与阻尼参数,运用模拟退火算法,优化单侧间隙、恢复力系数等变量,使减振车刀主模态负实部最大化,提升车削稳定性;最后基于冲击阻尼原理设计减振车刀并进行切削试验。试验结果表明,当转速n=400r/min,进给量f=0.1mm/r,切削深度ap=0.4mm时,内置冲击阻尼器可使长径比为7的内圆车刀径向振动加速度由46.5m/s^2下降到4.0m/s^2;工件表面粗糙度Ra由4.62μm下降到1.95μm。

Radial force can cause vibration or deformation of workpiece in internal turning process, especially for deep hole turning, which have a negative effect on machining accuracy and surface quality. In this paper, the impact damper theory is investigated and the damped turning cutter is designed. Firstly, the impact damper theory is investigated via modeling and simulation based on Euler–Bernoulli beam theory. Then, the clearance and restitution coefficient are optimized via simulated annealing algorithm with different cutting parameters. The negative real part of the main mode of the damped turning cutter is maximized, which can achieve the stability of cutting process. Finally, the damped turning tool is designed based on impact damper theory and the cutting test is carried out. When n=400r/min, f=0.1mm/ r, ap=0.4 mm, the experimental results show that the vibration acceleration amplitude can be decreased from 46.5m/s^2 to 4.0m/s^2 and the roughness can be decreased from 4.62μm to 1.95μm.