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CN105956303B - It is a kind of to be fitted to each other face design method as the lathe of target to offset distortion inaccuracy - Google Patents

It is a kind of to be fitted to each other face design method as the lathe of target to offset distortion inaccuracy Download PDF

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CN105956303B
CN105956303B CN201610307344.6A CN201610307344A CN105956303B CN 105956303 B CN105956303 B CN 105956303B CN 201610307344 A CN201610307344 A CN 201610307344A CN 105956303 B CN105956303 B CN 105956303B
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joint surface
machine tool
assembly
deformation
point
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CN105956303A (en
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刘志刚
洪军
刘鹏
郭俊康
赵强强
陈以磊
荆冲
周强
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Xian Jiaotong University
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    • G06FELECTRIC DIGITAL DATA PROCESSING
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Abstract

本发明公开了一种以抵消变形误差为目标的机床装配结合面设计方法,在CAD软件中根据静力学分析要求和机床结构特点进行结构简化,然后参数化装配机床实体模型;将经过简化和参数化装配的实体模型导入到有限元分析软件Ansys Workbench中;利用该软件创建自动分析与提取变形的容器,并正交化加工空间位置、网格划分,同时完成静力学分析与结果保存;然后通过数据学习获得机床装配名义结合面的在考虑整个加工空间变形情况下的实际变形量;对获得的实际变形量取反,并将取反后的量与名义结合面相加作为主动设计的机床装配结合面;基于蒙特卡洛方法以及最小二乘法,联合数据回归技术,完成装配结合面的轮廓度公差设计。

The invention discloses a method for designing the joint surface of a machine tool assembly aiming at offsetting deformation errors. In CAD software, the structure is simplified according to the requirements of static analysis and the structural characteristics of the machine tool, and then the entity model of the machine tool is parametrically assembled; the simplification and parameter Import the solid model of the assembly into the finite element analysis software Ansys Workbench; use this software to create a container for automatic analysis and extraction of deformation, and orthogonalize the processing space position and grid division, and complete the static analysis and result preservation at the same time; then through Data learning obtains the actual deformation amount of the nominal joint surface of the machine tool assembly considering the deformation of the entire processing space; inverts the obtained actual deformation amount, and adds the inverted amount to the nominal joint surface as the actively designed machine tool assembly Joint surface: Based on the Monte Carlo method and the least square method, combined with data regression technology, the contour tolerance design of the assembly joint surface is completed.

Description

一种以抵消变形误差为目标的机床装配结合面设计方法A Design Method of Machine Tool Assembly Joint Surface Aiming at Counteracting Deformation Error

技术领域technical field

本发明属于机械制造与设计领域,涉及一种基于数据学习的机床装配结合面设计方法,包含了Workbench自动分析与提取变形技术、结合面主动设计技术以及结合面轮廓度公差设计技术,具体涉及一种以抵消变形误差为目标的机床装配结合面设计方法。The invention belongs to the field of mechanical manufacturing and design, and relates to a data learning-based method for designing a joint surface of a machine tool assembly, including Workbench automatic analysis and extraction deformation technology, joint surface active design technology and joint surface profile tolerance design technology, and specifically relates to a A design method for the joint surface of machine tool assembly aiming at offsetting the deformation error.

背景技术Background technique

数控机床在切削力、夹紧力、重力和惯性力等作用下会产生明显附加几何变形,从而破坏机床各组成部分原有的相互位置关系,产生附加加工误差,这被称作变形(力)误差。研究指出变形误差占到机床所有误差的12%,是导致机床空间误差的第三大误差源。世界顶级机床制造厂三井精机生产的超过精密机床7CN定位精度达到0.5um,在其官网上指出通过刮研装配结合面有效降低了变形误差;国际著名机床厂DIXI指出其最高精度产品DIXI270通过超过500小时的刮研也有效降低了变形误,保证了单轴精度以及轴与轴之间的误差;我国著名机床主机厂,昆明机床、秦川机床等,在机床零件图纸上都会标注(-)或(+)作为直线度、平面度的附加要求来降低变形误差对加工误差的影响。Under the action of cutting force, clamping force, gravity and inertial force, CNC machine tools will produce obvious additional geometric deformation, thereby destroying the original mutual positional relationship of each component of the machine tool and generating additional processing errors, which is called deformation (force) error. Studies have pointed out that deformation errors account for 12% of all machine tool errors, and are the third largest error source leading to machine tool space errors. The world's top machine tool manufacturer Mitsui Seiki produced a precision machine tool 7CN with a positioning accuracy of 0.5um. It pointed out on its official website that the deformation error was effectively reduced by scraping and grinding the assembly joint surface; the internationally renowned machine tool manufacturer DIXI pointed out that its highest precision product DIXI270 passed more than The 500 hours of scraping and grinding also effectively reduced the deformation error and ensured the accuracy of the single axis and the error between the axes; my country's famous machine tool manufacturers, Kunming Machine Tool, Qinchuan Machine Tool, etc., will mark (-) on the machine tool parts drawings Or (+) as an additional requirement for straightness and flatness to reduce the influence of deformation errors on machining errors.

通过刮研削装配结合面来抵消几何变形对加工精度的破坏是机床制造企业的重要手段,然而将机床装配结合面刮研削为何种形状,即在何处刮研,刮研多少等问题上,严重依赖经验,缺乏科学合理定量化的技术方案。本质上讲是缺乏在考虑零件变形情况下的零件轮廓形状设计方法。It is an important means for machine tool manufacturers to counteract the damage of geometric deformation to machining accuracy by scraping and grinding the assembly joint surface. Rely on experience, lack of scientific and reasonable quantitative technical solutions. Essentially, there is a lack of a design method for the contour shape of the part considering the deformation of the part.

在对机床结合面主动设计为数不多的研究中,大连理工的Sun等利用多形式拟合方法,对导轨结合面进行了“预变形”设计来抵消进给系统因为塑形变形导致的误差,但没有从机床整机角度进行装配结合面主动设计;同时该方法是针对机床滑动结合面,对机床固定结合面不适用;并且用多项式拟合方法只适用于构建二维轮廓,对于常见的机床三维装配结合面轮廓不具有可行性。In one of the few studies on the active design of the joint surface of the machine tool, Sun et al. of Dalian University of Technology used a multi-form fitting method to carry out a "pre-deformation" design on the joint surface of the guide rail to offset the error caused by the plastic deformation of the feed system. However, there is no active design of the assembly joint surface from the perspective of the whole machine tool; at the same time, this method is aimed at the sliding joint surface of the machine tool, and is not applicable to the fixed joint surface of the machine tool; and the polynomial fitting method is only suitable for building two-dimensional contours. 3D assembly joint surface contours are not feasible.

发明内容Contents of the invention

本发明的目的在于针对当前机床制造主机厂缺乏科学合理、定量化的机床装配结合面轮廓设计方法,严重依赖钳工经验,以及针对当前结合面设计仅能针对二维形状的缺陷的现状,提出一种以抵消变形误差为目标的机床装配结合面设计方法,该方法基于数据学习方式,考虑整个加工空间变形的结合面轮廓及其轮廓度公差,能够大大降低变形误差。The purpose of the present invention is to propose a method for the lack of scientific, reasonable and quantitative method for designing the profile of the joint surface of the machine tool assembly in the current machine tool manufacturers, relying heavily on the experience of the fitter, and for the current situation that the current design of the joint surface can only address the defects of two-dimensional shapes. A method for designing the joint surface of machine tool assembly with the goal of offsetting deformation errors is provided. Based on the data learning method, the method considers the contour of the joint surface deformed in the entire machining space and its contour tolerance, which can greatly reduce the deformation error.

为达到上述目的,本发明采用的技术方案为:In order to achieve the above object, the technical scheme adopted in the present invention is:

一种以抵消变形误差为目标的机床装配结合面设计方法,包括以下步骤:A method for designing a joint surface of a machine tool assembly with the goal of offsetting deformation errors, comprising the following steps:

1)在CAD软件中根据静力学分析要求和机床结构特点进行机床实体模型简化;1) Simplify the solid model of the machine tool in the CAD software according to the static analysis requirements and the structural characteristics of the machine tool;

2)在CAD软件中参数化装配机床实体模型,得到参数化的装配体模型;2) Parametrically assemble the solid model of the machine tool in the CAD software to obtain a parametric assembly model;

3)利用Ansys Workbench软件将机床加工空间正交化,得到正交化的加工空间点;3) Use Ansys Workbench software to orthogonalize the machining space of the machine tool to obtain the orthogonalized machining space points;

4)将参数化的装配体模型和正交化的加工空间点导入到Ansys Workbench容器中;4) Import the parametric assembly model and the orthogonal processing space point into the Ansys Workbench container;

5)基于Ansys Workbench容器中得到的加工空间变形数据,利用数据学习方式,完成装配结合面的设计;5) Based on the processing space deformation data obtained in the Ansys Workbench container, use the data learning method to complete the design of the assembly joint surface;

6)基于蒙特卡洛方法以及最小二乘法,联合数据回归方法,完成装配结合面轮廓度公差设计。6) Based on the Monte Carlo method and the least square method, combined with the data regression method, the tolerance design of the assembly joint surface profile is completed.

所述步骤1)中机床实体模型简化包括以下步骤:The simplification of the machine tool entity model in the step 1) includes the following steps:

(1)删除尺寸<20mm的圆角和倒角;(1) Delete fillets and chamfers with dimensions <20mm;

(2)删除不影响分析计算的特征,包括螺钉孔、螺栓孔和注油孔;(2) Delete the features that do not affect the analysis and calculation, including screw holes, bolt holes and oil injection holes;

(3)传动系统简化,包括:减速箱内部使用等效质量代替进行结构简化,丝杠结构使用简单圆柱代替;(3) Simplification of the transmission system, including: the equivalent mass is used inside the reduction box to simplify the structure, and the screw structure is replaced by a simple cylinder;

(4)主轴结构简化,进行整机分析时,主轴作为整体结构考虑,使用等效实体模型和等效质量代替主轴;(4) The structure of the main shaft is simplified. When analyzing the whole machine, the main shaft is considered as the overall structure, and the equivalent solid model and equivalent mass are used instead of the main shaft;

(5)运用质量点代替对整机结构刚性不产生影响的辅助结构,包括驱动电机和配重;(5) Use mass points to replace auxiliary structures that do not affect the structural rigidity of the whole machine, including drive motors and counterweights;

(6)为保证单元质量,删除或修改模型中尺寸<20mm的平面特征;(6) In order to ensure the quality of the unit, delete or modify the plane features with a size <20mm in the model;

(7)当零件数量较多时,对材料相同的螺栓连接部件进行合并;(7) When the number of parts is large, the bolted parts of the same material are combined;

(8)修改调整垫片模型尺寸,保证各零部件的准确装配。(8) Modify and adjust the size of the gasket model to ensure the accurate assembly of each component.

所述步骤2)中的参数化装配是指对于会随着机床运动轴位置改变而发生位置改变的机床大件,参数化其装配位置,对于不随着机床运动轴位置改变的其他零部件,不参数化其装配位置;其中会随着机床运动轴位置改变而发生位置改变的机床大件包括滑鞍、主轴箱、工作台和托板。The parametric assembly in the step 2) refers to parametrizing the assembly position of the large machine tool parts that change position with the position of the machine tool movement axis. For other parts that do not change with the position of the machine tool movement axis, do not Parameterize its assembly position; among them, the large parts of the machine tool that will change position with the position of the machine tool motion axis include slide saddle, headstock, worktable and pallet.

所述步骤3)中将机床加工空间正交化是指选择机床各个轴的行程、切削力、装夹工件重量作为正交试验因素,根据机床常用加工的行程范围、切削力范围、常加工工件重量,在Ansys Workbench中设置上述因素的上下限,利用Ansys Workbench的自动正交化功能,完成正交试验点的设计,得到正交化的加工空间点。In said step 3), orthogonalizing the machining space of the machine tool refers to selecting the stroke of each axis of the machine tool, the cutting force, and the weight of the clamped workpiece as the orthogonal test factors. For weight, set the upper and lower limits of the above factors in Ansys Workbench, and use the automatic orthogonalization function of Ansys Workbench to complete the design of orthogonal test points and obtain orthogonal processing space points.

所述步骤4)具体为:将参数化的装配体模型和正交化的加工空间点导入AnsysWorkbench容器中,并进行接触设定、网格划分和材料参数设定,其中对于机床整机结构,网格划分的单元尺寸为10mm至100mm之间,并在结构复杂、受力状况复杂以及关心的危险点处进行网格细化。The step 4) is specifically: importing the parameterized assembly model and the orthogonal processing space point into the AnsysWorkbench container, and performing contact setting, grid division and material parameter setting, wherein for the machine tool structure, The cell size of mesh division is between 10mm and 100mm, and mesh refinement is carried out at complex structures, complex stress conditions and dangerous points of concern.

所述步骤5)中的数据学习方式包括两个,具体如下:The data learning mode in the step 5) includes two, specifically as follows:

数据学习方式一:在机床各个轴位于固定位置时,设装配结合面为S,任取一点P0∈S,其坐标为(x0,y0,z0);以P0为圆心,以r为半径在结合面S上作圆,将包含在该圆域内的点Pi的变形量取加权算数平均,将该加权算数平均值作为P0点的变形量δ0,其中加权算数平均值的权值ρ为Pi与P0距离的倒数,Pi的变形量存在于Ansys Workbench容器的结果文件中,Pi的坐标为(xi,yi,zi),i=1~t,t为该圆域内所有点的总个数;其中δ0和ρ的计算公式如下:Data learning method 1: When each axis of the machine tool is at a fixed position, set the assembly joint surface as S, take a point P 0 ∈ S at random, and its coordinates are (x 0 , y 0 , z 0 ); take P 0 as the center of the circle, and r is the radius and draw a circle on the joint surface S, take the weighted arithmetic mean of the deformation of the point P i included in the circle, and take the weighted arithmetic mean as the deformation of point P 0 δ 0 , where the weighted arithmetic mean The weight ρ of is the reciprocal of the distance between P i and P 0. The deformation of P i exists in the result file of the Ansys Workbench container. The coordinates of P i are ( xi , y i , z i ), i=1~t , t is the total number of all points in the circle domain; the calculation formulas of δ 0 and ρ are as follows:

式中,di是点Pi与点P0的距离,δi为Pi的变形量;In the formula, d i is the distance between point P i and point P 0 , and δ i is the deformation of P i ;

数据学习方式二:设正交化的加工空间点的总个数为n,当机床各个轴位于加工空间点k对应的位置时,k=1~n,P0通过数据学习方式一得到的变形量为将机床各个轴位于n个加工空间点时P0得到的所有变形量取平均,作为P0在整个加工空间中的变形量其中通过下式计算:Data learning method 2: Let the total number of orthogonal processing space points be n, when each axis of the machine tool is located at the position corresponding to the processing space point k, k=1~n, P 0 is the deformation obtained through data learning method 1 The amount is Take the average of all the deformations obtained by P 0 when each axis of the machine tool is located at n processing space points, as the deformation of P 0 in the entire processing space in Calculated by the following formula:

所述步骤5)中装配结合面的设计具体为:Described step 5) in the design of assembling joint surface specifically is:

a)定义空间平面Fn为装配名义结合面,Fn的边界由初始的实际装配结合面的几何参数确定,Fn由网格化的散点Pij(Pijx,Pijy,Pijz)组成;a) Define the spatial plane F n as the nominal joint surface of the assembly, the boundary of F n is determined by the geometric parameters of the initial actual assembly joint surface, and F n is determined by the gridded scattered points P ij (P ijx ,P ijy ,P ijz ) composition;

b)定义面Fd为设计的结合面,Fd由点组成,由以下公式得到:b) Define the surface F d as the designed joint surface, and F d is defined by the point composition, It is obtained by the following formula:

其中δx、δy、δz分别为Pij通过数据学习方式二获得的其在x、y、z三个方向的变形量,Fd即为装配结合面设计的结果。Among them, δ x , δ y , and δ z are the deformations in the three directions of x, y, and z obtained by Pij through the second data learning method, respectively, and F d is the result of the design of the assembly joint surface.

所述步骤6)中装配结合面轮廓度公差设计具体为:In the step 6), the tolerance design of the assembly joint surface profile is specifically:

设结合面Fd允许的最大角度偏差为需要设计的结合面轮廓度公差为T,设m为[-1,1]之间的随机数,利用以下公式可以生成满足结合面轮廓度公差T要求的结合面Fd’,设Fd’上的点为 的计算公式如下:Let the maximum allowable angular deviation of the joint surface F d be The joint surface profile tolerance to be designed is T, let m be a random number between [-1,1], use the following formula to generate the joint surface F d ' that meets the joint surface profile tolerance T requirements, let F d ' The point on The calculation formula is as follows:

然后利用最小二乘法拟合得到结合面Fd’的最小二乘平面,设该最小二乘平面的法向量为则结合面Fd’导致的角度偏差为ω(ωxyz),ω的计算公式如下:Then use the least squares method to fit the least squares plane of the combined surface F d ', and set the normal vector of the least squares plane to be Then the angular deviation caused by the combined surface F d ' is ω(ω xyz ), and the calculation formula of ω is as follows:

重复n次上述运算,得到n组结合面轮廓度公差对应的n组角度偏差,利用数据回归方法得到结合面轮廓度公差T与角度偏差ω之间的映射关系,通过该映射关系,在给定角度偏差为时对应的结合面轮廓度公差即为设计出的装配结合面轮廓度公差。Repeat the above operations n times to obtain n groups of angle deviations corresponding to n groups of joint surface profile tolerances, and use the data regression method to obtain the mapping relationship between the joint surface profile tolerance T and the angle deviation ω. Through this mapping relationship, in a given The angular deviation is The corresponding joint surface profile tolerance is the designed assembly joint surface profile tolerance.

相对于现有技术,本发明的有益效果为:Compared with the prior art, the beneficial effects of the present invention are:

本发明提出的以抵消变形误差为目标的机床装配结合面设计方法,通过简化不影响分析结果的机床结构,减少了有限元分析计算量;同时,基于参数化装配方法,联合AnsysWorkbench软件构建了Ansys Workbench自动化求解与保存容器,极大的提高了分析效率;并且在构建两种数据学习方式的基础上,实现了机床三维装配结合面的科学定量化的反变形设计,避免了任意三维曲面函数表达的困境;通过对整个加工空间变形的装配结合面轮廓及其轮廓度公差设计,降低了制造难度,保证了工艺可行性。本发明通过基于数据学习方式来设计机床装配结合面,摆脱了三维变形曲面函数表达的难题,同时效果良好,主变形方向变形误差降低率达到了95.3%。The method for designing the joint surface of machine tool assembly with the goal of offsetting deformation errors proposed by the present invention reduces the calculation amount of finite element analysis by simplifying the machine tool structure that does not affect the analysis results; at the same time, based on the parametric assembly method, the Ansys Workbench software is combined to construct the Ansys Workbench automatically solves and saves the container, which greatly improves the analysis efficiency; and based on the construction of two data learning methods, it realizes the scientific and quantitative anti-deformation design of the three-dimensional assembly joint surface of the machine tool, avoiding the expression of arbitrary three-dimensional surface functions Dilemma; through the deformation of the entire processing space assembly joint surface contour and its contour tolerance design, the manufacturing difficulty is reduced and the process feasibility is guaranteed. The present invention designs the machine tool assembly joint surface based on the data learning method, gets rid of the difficult problem of expressing the function of the three-dimensional deformation surface, and has good effect at the same time, and the deformation error reduction rate of the main deformation direction reaches 95.3%.

附图说明Description of drawings

图1为某型号精密卧式坐标镗床,其中左边为实物图,右边为机床结构简图;Figure 1 is a precision horizontal jig boring machine of a certain model, in which the left is the physical map, and the right is a schematic diagram of the machine tool structure;

图2为参数化装配示意图,其中(a)、(b)、(c)分别为X、Y、Z方向装配距离参数化示意图;Figure 2 is a schematic diagram of parametric assembly, where (a), (b), and (c) are schematic diagrams of parameterized assembly distances in the X, Y, and Z directions, respectively;

图3为装配结合面选择图;Figure 3 is a selection diagram of the assembly joint surface;

图4为Ansys Workbench自动分析与提取数据容器的截图;Figure 4 is a screenshot of Ansys Workbench automatically analyzing and extracting data containers;

图5为主动设计的床身立柱结合面的设计结果图;Fig. 5 is the design result drawing of the joint surface of bed column of active design;

图6为无抗变形设计实际变形云图;Fig. 6 is the actual deformation cloud diagram of no anti-deformation design;

图7为有抗变形设计时实际变形云图;Figure 7 is the actual deformation cloud diagram when there is an anti-deformation design;

其中:1为立柱,2为滑鞍,3为主轴箱,4为工作台,5为托板,6为床身,7为X轴,8为X轴距离参数化,9为Y轴,10为Y轴距离参数化,11为Z轴,12为Z轴距离参数化,13为滑鞍主轴箱结合面,14为工件工作台结合面,15为立柱滑鞍结合面,16为床身立柱结合面,17为床身工作台结合面。Among them: 1 is the column, 2 is the saddle, 3 is the spindle box, 4 is the worktable, 5 is the pallet, 6 is the bed, 7 is the X axis, 8 is the X axis distance parameterization, 9 is the Y axis, 10 11 is the Z axis, 12 is the Z axis distance parameterization, 13 is the joint surface of the saddle headstock, 14 is the joint surface of the workpiece table, 15 is the joint surface of the column and the saddle, and 16 is the bed column Joint surface, 17 is bed workbench joint surface.

具体实施方式Detailed ways

以某型精密坐标镗床的床身立柱结合面主动设计为例,结合附图对本发明进行详细说明。Taking the active design of the joint surface of the bed column of a certain type of precision coordinate boring machine as an example, the present invention will be described in detail with reference to the accompanying drawings.

一、Ansys Workbench自动分析与提取加工空间变形1. Ansys Workbench automatically analyzes and extracts processing space deformation

(1)机床结构简化(1) Machine tool structure simplification

1)删除零件中小尺寸(尺寸<20mm)的圆角和倒角;1) Delete the fillet and chamfer of the small size (size <20mm) in the part;

2)删除安装螺栓孔、螺钉孔、注油孔等不影响分析计算的小特征;2) Delete small features such as mounting bolt holes, screw holes, and oil injection holes that do not affect the analysis and calculation;

3)传动系统简化:去掉大框架结构内部的齿轮,涡轮蜗杆等传动机构。在整机分析中只保留外壳体、主轴和传动轴三个零件,通过更改其材料密度属性来等效原始结构的质量特征。删除所有电机模型,在分析模型中以质量点等效代替;3) Simplification of the transmission system: the transmission mechanisms such as gears and worm gears inside the large frame structure are removed. In the analysis of the whole machine, only the outer casing, the main shaft and the transmission shaft are kept, and the quality characteristics of the original structure are equivalent by changing their material density properties. Delete all motor models and replace them with mass point equivalents in the analysis model;

4)将丝杠用圆柱模型代替;4) Replace the lead screw with a cylindrical model;

5)由于网格划分中最小网格尺寸的限制,删除或修改尺寸过小(<20mm)的凸台或凹槽特征;5) Due to the limitation of the minimum mesh size in mesh division, delete or modify the boss or groove features that are too small (<20mm);

机床实际模型如图1(a)所示,简化完成之后的该机床如图1(b)所示。The actual model of the machine tool is shown in Figure 1(a), and the machine tool after simplification is shown in Figure 1(b).

(2)机床参数化装配(2) Parametric assembly of machine tools

在CAD软件中装配机床零件时,为了能实现上述自动提取加工空间变形要求,对滑鞍左侧到立柱左侧的距离(图2(a))、主轴箱下侧到滑鞍下侧的距离(图2(b))、托板前侧到立柱前侧的距离(图2(c))进行了参数化处理。When assembling machine tool parts in CAD software, in order to achieve the above-mentioned automatic extraction of processing space deformation requirements, the distance from the left side of the saddle to the left side of the column (Figure 2(a)), the distance from the lower side of the headstock to the lower side of the saddle (Fig. 2(b)), and the distance from the front side of the pallet to the front side of the column (Fig. 2(c)) were parameterized.

(3)正交化加工空间(3) Orthogonal processing space

选择参数化的装配位置、切削力、装夹工件重量作为正交设计因素,根据机床实际可能情况,在ANSYS Workbench中设置好这些因素的上下限,利用Ansys Workbench的自动正交化功能,完成正交试验点的设计。Select the parameterized assembly position, cutting force, and clamped workpiece weight as the orthogonal design factors, set the upper and lower limits of these factors in ANSYS Workbench according to the actual situation of the machine tool, and use the automatic orthogonalization function of Ansys Workbench to complete the orthogonal design. Hand in the design of test points.

将机床的X、Y、Z轴位置,切削力,工件重量作为正交试验的因素,其取值的范围如表1所示。The X, Y, Z axis position of the machine tool, the cutting force, and the weight of the workpiece are taken as the factors of the orthogonal test, and the range of values is shown in Table 1.

表1正交试验因素取值范围Table 1 Orthogonal test factor value range

(4)Ansys Workbench自动分析与提取变形数据(4) Ansys Workbench automatically analyzes and extracts deformation data

1)将参数化装配处理的CAD文件直接通过Ansys Workbench的Geometry模块导入到Ansys Workbench容器中。通过布尔运算将相关零件合并,可以减少模型中零件数量,减少结合面的设置,降低有限元计算量。在Ansys Workbench材料参数库中,选择和建立分析模型中需要的材料参数。在本实施例中,结合面主要分为两类,一类是螺栓连接或贴塑面粘接的固定结合面,一类是导轨连接的滑动结合面。分析中将螺栓连接和贴塑面粘接的固定连接结合面设置为Bonded(粘接),而导轨连接的滑动结合面设置为No separation(滑动不分离)。1) Import the CAD file processed by parametric assembly directly into the Ansys Workbench container through the Geometry module of Ansys Workbench. Combining related parts through Boolean operations can reduce the number of parts in the model, reduce the setting of joint surfaces, and reduce the amount of finite element calculations. In the Ansys Workbench material parameter library, select and establish the material parameters required in the analysis model. In this embodiment, the bonding surface is mainly divided into two types, one is a fixed bonding surface for bolt connection or bonding with a plastic surface, and the other is a sliding bonding surface for rail connection. In the analysis, the fixed connection joint surface of the bolt connection and the plastic surface bonding is set as Bonded (bonded), while the sliding joint surface of the guide rail connection is set as No separation (sliding without separation).

2)网格划分2) Mesh division

由于机床整机模型几何尺寸较大,零部件数量较多且结构复杂,可以设置网格尺寸为50mm,在结构复杂和主轴端部等重点关心区域进行网格细化。Due to the large geometric size of the machine tool model, the large number of parts and the complex structure, the mesh size can be set to 50mm, and the mesh is refined in key areas such as the complex structure and the end of the spindle.

3)边界条件施加3) Boundary conditions are applied

在Ansys Workbench软件中设置静刚度分析边界条件,包括:重力、切削力、地脚螺栓固定约束等。进行静力结构分析,选择如图3所示的装配结合面,将这些结合面的分析结果进行保存。Set static stiffness analysis boundary conditions in Ansys Workbench software, including: gravity, cutting force, anchor bolt fixing constraints, etc. For static structural analysis, select the assembly joint surfaces shown in Figure 3, and save the analysis results of these joint surfaces.

上述设置完成之后,便搭建完成结合面在整个加工空间的变形量自动求解与保存容器(Ansys Workbench容器)。如图4所示。After the above settings are completed, the container (Ansys Workbench container) for automatically solving and saving the deformation of the joint surface in the entire processing space is built. As shown in Figure 4.

二、基于数据学习的装配结合面设计2. Design of assembly joint surface based on data learning

(1)数据学习方式定义(1) Definition of data learning method

1)定义学习方式一:在机床各个轴位于固定位置时,设装配结合面为S,任取一点P0∈S,其坐标为(x0,y0,z0);以P0为圆心,以r为半径在结合面S上作圆;将包含在该圆域内的点Pi(i=1~t,t为该圆域内所有点的总个数)的变形量取加权算数平均;将该加权算数平均值作为P0点的变形量,其中加权算数平均值的权值为Pi与P0距离的倒数,Pi的变形量存在于Ansys Workbench容器的结果文件中,Pi的坐标为(xi,yi,zi)。1) Define learning method 1: when each axis of the machine tool is at a fixed position, set the assembly joint surface as S, take a point P 0 ∈ S at random, and its coordinates are (x 0 , y 0 , z 0 ); take P 0 as the center of the circle , make a circle on the joint surface S with r as the radius; take the weighted arithmetic mean of the deformation of the point P i (i=1~t, t is the total number of all points in the circle) contained in the circle; The weighted arithmetic mean is taken as the deformation of point P 0 , where the weight of the weighted arithmetic mean is the reciprocal of the distance between P i and P 0 , the deformation of P i exists in the result file of the Ansys Workbench container, and the value of P i The coordinates are (x i , y i , z i ).

式中,di是点Pi与点P0的距离。δ0为P0的变形量,δi为Pi的变形量In the formula, d i is the distance between point P i and point P 0 . δ 0 is the deformation of P 0 , δ i is the deformation of P i

2)定义学习方式二:设加工空间正交化产生的正交实验点总个数为n,P0通过学习方式一去学习正交试验点k(k=1~n)的变形数据获得变形量将这n个正交试验点通过学习得到的变形量取平均作为点P0在整个加工空间中的变形量其中为当机床各个轴位于正交试验点k对应的位置时由学习方式一得到的P0的变形量δ0 2) Define the second learning method: set the total number of orthogonal experimental points generated by the orthogonalization of the processing space as n, and P 0 learn the deformation data of the orthogonal experimental point k (k=1~n) through the first learning method to obtain the deformation quantity Take the average of the deformation obtained by learning the n orthogonal test points as the deformation of point P 0 in the entire processing space in is the deformation δ 0 of P 0 obtained by learning method 1 when each axis of the machine tool is located at the position corresponding to the orthogonal test point k

三、装配结合面设计3. Assembly interface design

1)定义空间平面Fn为装配名义结合面,Fn的边界由初始的实际装配结合面的几何参数确定,由网格化的散点Pij(Pijx,Pijy,Pijz)组成。1) Define the spatial plane F n as the nominal joint surface of the assembly. The boundary of F n is determined by the geometric parameters of the initial actual assembly joint surface, and is composed of gridded scattered points P ij (P ijx ,P ijy ,P ijz ).

2)定义面Fa为变形后的实际结合面,Fa由点P′ij(P′ijx,P′ijy,P′ijz)组成,P′ij由以下公式得到:2) Define the surface F a as the actual joint surface after deformation. F a is composed of points P′ ij (P′ ijx , P′ ijy , P′ ijz ), and P′ ij is obtained by the following formula:

P′ijx=Pijxx P′ ijx =P ijxx

P′ijy=Pijyy P′ ijy =P ijyy

P′ijz=Pijzz P′ ijz =P ijzz

δx、δy、δz分别为Pij通过学习方式二获得的x、y、z三个方向的变形量。δ x , δ y , and δ z are the deformation amounts in the x, y, and z directions obtained by P ij through the second learning method, respectively.

3)定义面Fd为设计的结合面,Fd由点组成,由以下公式得到:3) Define the surface F d as the combined surface of the design, and F d is defined by the point composition, It is obtained by the following formula:

将Fd作为装配结合面设计的结果。所设计的Fd可以减弱甚至抵消装加工空间的变形误差,预期可以提高机床12%的机床加工精度。Use F d as a result of the assembly interface design. The designed F d can weaken or even offset the deformation error of the machining space, and it is expected to improve the machining accuracy of the machine tool by 12%.

采用本文提出的上述装配结合面设计方法,考虑整个加工空间受载变形,通过学习方式二的变形数据获取以及公式进行设计,得到图5的设计结果。Using the above-mentioned assembly joint surface design method proposed in this paper, considering the deformation of the entire processing space under load, the design is obtained through the acquisition of deformation data and formulas in the second learning method, and the design results in Figure 5 are obtained.

四、装配结合面轮廓度公差设计4. Tolerance design of assembly joint surface profile

轮廓度公差设计方法:设结合面Fd允许的最大角度偏差为需要设计的结合面轮廓度公差为T,设m为[-1,1]之间的随机数。利用以下公式可以生成满足公差T要求的结合面Fd’,设Fd’上的点为 Design method of contour tolerance: set the maximum allowable angular deviation of the joint surface F d as The profile tolerance of the joint surface to be designed is T, and m is a random number between [-1,1]. The following formula can be used to generate the joint surface F d ' that meets the requirements of the tolerance T. Let the points on F d ' be

利用最小二乘法拟合得到Fd’的最小二乘平面,设该最小二乘平面的法向量为那么Fd’导致的角度偏差ω(ωxyz)为:The least squares plane of F d ' is obtained by fitting the least squares method, and the normal vector of the least squares plane is set as Then the angular deviation ω(ω xyz ) caused by F d ' is:

设有n次蒙特卡洛运算,即有n组轮廓度公差导致的n组角度偏差。利用数据回归方法可以得到轮廓度公差T与角度偏差ω之间的映射关系。在给定角度偏差之后,即可完成轮廓度公差的设计。There are n Monte Carlo operations, that is, there are n sets of angular deviations caused by n sets of profile tolerances. The mapping relationship between the contour tolerance T and the angle deviation ω can be obtained by using the data regression method. Deviation at a given angle After that, the design of profile tolerance can be completed.

具体的,利用本发明提出的结合面轮廓度公差设计方法,利用线性回归方法,采用matlab进行数值计算,将最大角度偏差为设定为1×10-7rad,得到结合面轮廓度公差T为0.010mm。Specifically, using the design method of joint surface profile tolerance proposed by the present invention, using the linear regression method, using matlab to carry out numerical calculations, the maximum angle deviation is Set as 1×10 -7 rad, the joint surface profile tolerance T is 0.010mm.

为了验证设计效果及本方法的有效性,在参数化装配位置取1100,850,1130(x0/y0/z0)时,将本设计结果再次用Ansys Workbench进行计算,并对比有无结合面抗变形设计时,床身立柱结合面导致的角度偏差以及平面度,如表2所示。In order to verify the design effect and the effectiveness of this method, when the parameterized assembly position is 1100, 850, 1130 (x 0 /y 0 /z 0 ), the design results are calculated again with Ansys Workbench, and compared with or without combination In the anti-deformation design of the surface, the angle deviation and flatness caused by the joint surface of the bed column are shown in Table 2.

表2床身立柱结合面变形角度偏差Table 2 Deformation Angle Deviation of Joint Surface of Bed Column

从表2中可以发现,采用本方法(有抗变形设计)后角度偏差大大减小到可以忽略不计的程度,在主变形Y方向上,角度偏差降低了95.3%,同时结合面的平面度也变得更好。It can be found from Table 2 that after adopting this method (with anti-deformation design), the angle deviation is greatly reduced to a negligible level. In the Y direction of the main deformation, the angle deviation is reduced by 95.3%, and the flatness of the joint surface is also reduced. become better.

将Ansys Workbench计算的床身立柱结合面变形结果数据用matlab显示出来,可以明显的发现无抗变形设计时,如图6所示,结合面变形量数量级在10-6,有抗变形设计之后,如图7所示,数量级降低到10-7,抗变形效果十分显著。Using matlab to display the deformation result data of the joint surface of the bed column calculated by Ansys Workbench, it can be clearly found that when there is no anti-deformation design, as shown in Figure 6, the order of magnitude of deformation of the joint surface is 10 -6 . As shown in Figure 7, the order of magnitude is reduced to 10 -7 , and the anti-deformation effect is very significant.

Claims (7)

1.一种以抵消变形误差为目标的机床装配结合面设计方法,其特征在于,包括以下步骤:1. A method for designing the joint surface of machine tool assembly with the aim of counteracting deformation error, is characterized in that, comprises the following steps: 1)在CAD软件中根据静力学分析要求和机床结构特点进行机床实体模型简化;1) Simplify the solid model of the machine tool in the CAD software according to the static analysis requirements and the structural characteristics of the machine tool; 2)在CAD软件中参数化装配机床实体模型,得到参数化的装配体模型;2) Parametrically assemble the solid model of the machine tool in the CAD software to obtain a parametric assembly model; 3)利用Ansys Workbench软件将机床加工空间正交化,得到正交化的加工空间点;3) Use Ansys Workbench software to orthogonalize the machining space of the machine tool to obtain the orthogonalized machining space points; 4)将参数化的装配体模型和正交化的加工空间点导入到Ansys Workbench容器中;4) Import the parametric assembly model and the orthogonal processing space point into the Ansys Workbench container; 5)基于Ansys Workbench容器中得到的加工空间变形数据,利用数据学习方式,完成装配结合面的设计;5) Based on the processing space deformation data obtained in the Ansys Workbench container, use the data learning method to complete the design of the assembly joint surface; 6)基于蒙特卡洛方法以及最小二乘法,联合数据回归方法,完成装配结合面轮廓度公差设计;6) Based on the Monte Carlo method and the least square method, combined with the data regression method, the tolerance design of the assembly joint surface profile is completed; 所述步骤5)中的数据学习方式包括两个,具体如下:The data learning mode in the step 5) includes two, specifically as follows: 数据学习方式一:在机床各个轴位于固定位置时,设装配结合面为S,任取一点P0∈S,其坐标为(x0,y0,z0);以P0为圆心,以r为半径在结合面S上作圆,将包含在该圆域内的点Pi的变形量取加权算数平均,将该加权算数平均值作为P0点的变形量δ0,其中加权算数平均值的权值ρ为Pi与P0距离的倒数,Pi的变形量存在于Ansys Workbench容器的结果文件中,Pi的坐标为(xi,yi,zi),i=1~t,t为该圆域内所有点的总个数;其中δ0和ρ的计算公式如下:Data learning method 1: When each axis of the machine tool is at a fixed position, set the assembly joint surface as S, take a point P 0 ∈ S at random, and its coordinates are (x 0 , y 0 , z 0 ); take P 0 as the center of the circle, and r is the radius and draw a circle on the joint surface S, take the weighted arithmetic mean of the deformation of the point P i included in the circle, and take the weighted arithmetic mean as the deformation of point P 0 δ 0 , where the weighted arithmetic mean The weight ρ of is the reciprocal of the distance between P i and P 0. The deformation of P i exists in the result file of the Ansys Workbench container. The coordinates of P i are ( xi , y i , z i ), i=1~t , t is the total number of all points in the circle domain; the calculation formulas of δ 0 and ρ are as follows: 式中,di是点Pi与点P0的距离,δi为Pi的变形量,ρi是点Pi的变形量δi的权值;In the formula, d i is the distance between point P i and point P 0 , δ i is the deformation amount of P i , and ρ i is the weight of the deformation amount δ i of point P i ; 数据学习方式二:设正交化的加工空间点的总个数为n,当机床各个轴位于加工空间点k对应的位置时,k=1~n,P0通过数据学习方式一得到的变形量为将机床各个轴位于n个加工空间点时P0得到的所有变形量取平均,作为P0在整个加工空间中的变形量其中通过下式计算:Data learning method 2: Let the total number of orthogonal processing space points be n, when each axis of the machine tool is located at the position corresponding to the processing space point k, k=1~n, P 0 is the deformation obtained through data learning method 1 The amount is Take the average of all the deformations obtained by P 0 when each axis of the machine tool is located at n processing space points, as the deformation of P 0 in the entire processing space in Calculated by the following formula: 2.根据权利要求1所述的以抵消变形误差为目标的机床装配结合面设计方法,其特征在于,所述步骤1)中机床实体模型简化包括以下步骤:2. the machine tool assembly interface design method aiming at counteracting deformation error according to claim 1, is characterized in that, in described step 1), simplification of machine tool solid model comprises the following steps: (1)删除尺寸<20mm的圆角和倒角;(1) Delete fillets and chamfers with dimensions <20mm; (2)删除不影响分析计算的特征,包括螺钉孔、螺栓孔和注油孔;(2) Delete the features that do not affect the analysis and calculation, including screw holes, bolt holes and oil injection holes; (3)传动系统简化,包括:减速箱内部使用等效质量代替进行结构简化,丝杠结构使用简单圆柱代替;(3) Simplification of the transmission system, including: the equivalent mass is used inside the reduction box to simplify the structure, and the screw structure is replaced by a simple cylinder; (4)主轴结构简化,进行整机分析时,主轴作为整体结构考虑,使用等效实体模型和等效质量代替主轴;(4) The structure of the main shaft is simplified. When analyzing the whole machine, the main shaft is considered as the overall structure, and the equivalent solid model and equivalent mass are used instead of the main shaft; (5)运用质量点代替对整机结构刚性不产生影响的辅助结构,包括驱动电机和配重;(5) Use mass points to replace auxiliary structures that do not affect the structural rigidity of the whole machine, including drive motors and counterweights; (6)为保证单元质量,删除或修改模型中尺寸<20mm的平面特征;(6) In order to ensure the quality of the unit, delete or modify the plane features with a size <20mm in the model; (7)当零件数量较多时,对材料相同的螺栓连接部件进行合并;(7) When the number of parts is large, the bolted parts of the same material are combined; (8)修改调整垫片模型尺寸,保证各零部件的准确装配。(8) Modify and adjust the size of the gasket model to ensure the accurate assembly of each component. 3.根据权利要求1所述的以抵消变形误差为目标的机床装配结合面设计方法,其特征在于,所述步骤2)中的参数化装配是指对于会随着机床运动轴位置改变而发生位置改变的机床大件,参数化其装配位置,对于不随着机床运动轴位置改变的其他零部件,不参数化其装配位置;其中会随着机床运动轴位置改变而发生位置改变的机床大件包括滑鞍、主轴箱、工作台和托板。3. The machine tool assembly joint surface design method aiming at counteracting deformation errors according to claim 1, characterized in that, the parameterized assembly in said step 2) refers to the For large machine tool parts whose positions change, parameterize their assembly positions, and for other components that do not change with the position of the machine tool movement axis, do not parameterize their assembly positions; among them, for large machine tool parts that change position with the change of machine tool movement axis positions Includes saddle, headstock, table and pallet. 4.根据权利要求1所述的以抵消变形误差为目标的机床装配结合面设计方法,其特征在于,所述步骤3)中将机床加工空间正交化是指选择机床各个轴的行程、切削力、装夹工件重量作为正交试验因素,根据机床常用加工的行程范围、切削力范围、常加工工件重量,在AnsysWorkbench中设置上述因素的上下限,利用Ansys Workbench的自动正交化功能,完成正交试验点的设计,得到正交化的加工空间点。4. The method for designing the joint surface of a machine tool assembly with the aim of offsetting deformation errors according to claim 1, wherein in said step 3), orthogonalizing the machining space of the machine tool refers to selecting the stroke, cutting and cutting of each axis of the machine tool The force and the weight of the clamped workpiece are used as the orthogonal test factors. According to the stroke range, cutting force range, and workpiece weight of the machine tool commonly used, the upper and lower limits of the above factors are set in AnsysWorkbench, and the automatic orthogonalization function of Ansys Workbench is used to complete the test. Orthogonal test points are designed to obtain orthogonal processing space points. 5.根据权利要求1所述的以抵消变形误差为目标的机床装配结合面设计方法,其特征在于,所述步骤4)具体为:将参数化的装配体模型和正交化的加工空间点导入AnsysWorkbench容器中,并进行接触设定、网格划分和材料参数设定,其中对于机床整机结构,网格划分的单元尺寸为10mm至100mm之间,并在结构复杂、受力状况复杂以及关心的危险点处进行网格细化。5. The method for designing the joint surface of a machine tool assembly aiming at offsetting deformation errors according to claim 1, wherein said step 4) is specifically: combining the parameterized assembly model and the orthogonalized processing space point Import it into the AnsysWorkbench container, and perform contact setting, mesh division and material parameter setting. For the structure of the machine tool, the unit size of the mesh division is between 10mm and 100mm, and it is used in complex structures, complex stress conditions and Mesh refinement is carried out at the dangerous points of concern. 6.根据权利要求1所述的以抵消变形误差为目标的机床装配结合面设计方法,其特征在于,所述步骤5)中装配结合面的设计具体为:6. The method for designing the assembly joint surface of a machine tool with the aim of offsetting deformation errors according to claim 1, wherein the design of the assembly joint surface in the step 5) is specifically: a)定义空间平面Fn为装配名义结合面,Fn的边界由初始的实际装配结合面的几何参数确定,Fn由网格化的散点Pij(Pijx,Pijy,Pijz)组成;a) Define the spatial plane F n as the nominal joint surface of the assembly, the boundary of F n is determined by the geometric parameters of the initial actual assembly joint surface, and F n is determined by the gridded scattered points P ij (P ijx ,P ijy ,P ijz ) composition; b)定义面Fd为设计的结合面,Fd由点组成,由以下公式得到:b) Define the surface F d as the designed joint surface, and F d is defined by the point composition, It is obtained by the following formula: 其中δx、δy、δz分别为Pij通过数据学习方式二获得的其在x、y、z三个方向的变形量,Fd即为装配结合面设计的结果。Among them, δ x , δ y , and δ z are the deformations in the three directions of x, y, and z obtained by Pij through the second data learning method, respectively, and F d is the result of the design of the assembly joint surface. 7.根据权利要求6所述的以抵消变形误差为目标的机床装配结合面设计方法,其特征在于,所述步骤6)中装配结合面轮廓度公差设计具体为:7. The method for designing the assembly joint surface of a machine tool with the aim of offsetting deformation errors according to claim 6, wherein the design of the profile tolerance of the assembly joint surface in the step 6) is specifically: 设结合面Fd允许的最大角度偏差为需要设计的结合面轮廓度公差为T,设m为[-1,1]之间的随机数,利用以下公式可以生成满足结合面轮廓度公差T要求的结合面Fd’,设Fd’上的点为 的计算公式如下:Let the maximum allowable angular deviation of the joint surface F d be The joint surface profile tolerance to be designed is T, let m be a random number between [-1,1], use the following formula to generate the joint surface F d ' that meets the joint surface profile tolerance T requirements, let F d ' The point on The calculation formula is as follows: 然后利用最小二乘法拟合得到结合面Fd’的最小二乘平面,设该最小二乘平面的法向量为NK,则结合面Fd’导致的角度偏差为ω(ωxyz),ω的计算公式如下:Then use the least squares method to fit the least squares plane of the joint surface F d ', assuming the normal vector of the least squares plane is NK, then the angle deviation caused by the joint surface F d ' is ω(ω xy , ω z ), the calculation formula of ω is as follows: 重复n次上述运算,得到n组结合面轮廓度公差对应的n组角度偏差,利用数据回归方法得到结合面轮廓度公差T与角度偏差ω之间的映射关系,通过该映射关系,在给定角度偏差为时对应的结合面轮廓度公差即为设计出的装配结合面轮廓度公差。Repeat the above operations n times to obtain n groups of angle deviations corresponding to n groups of joint surface profile tolerances, and use the data regression method to obtain the mapping relationship between the joint surface profile tolerance T and the angle deviation ω. Through this mapping relationship, in a given The angular deviation is The corresponding joint surface profile tolerance is the designed assembly joint surface profile tolerance.
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