Application of active disturbance rejection control to variable spindle speed noncircular turning process

In application of variable spindle speed machining to noncircular turning process, the tracking control of the fast tool servo yields a periodic sampling rate in the real-time domain. However, in the view of the angle domain, the sampling rate is constant. Moreover, the reference acceleration signal is easily available. This implies that it is advantageous to design the control system from the angle domain perspective, but the plant for a linear time-invariant system will become a periodically time-varying system. In this paper, the active disturbance rejection control strategy is applied to actively estimate the time-varying dynamics and other disturbances and compensate for them in the control law. The acceleration feed-forward strategy is employed to achieve better tracking performance. The stability analysis based on the lifting technique is proposed. Experimental machining results demonstrate the tracking performance of the proposed design, as well as the ability to increase machining stability using variable spindle speed machining.     

Stability of up-milling and down-milling, part 1: alternative analytical methods

The dynamic stability of the milling process is investigated through a single degree of freedom mechanical model. Two alternative analytical methods are introduced, both based on finite dimensional discrete map representations of the governing time periodic delay-differential equation.Stability charts and chatter frequencies are determined for partial immersion up- and down-milling, and for full immersion milling operations. A special duality property of stability regions for up- and down-milling is shown and explained.     

Effects of cutting conditions on dynamic cutting factor and process damping in milling

This paper investigates how cutting conditions affect dynamic cutting factor and system process damping in a dynamic milling process. By considering variation of edge plowing force, a frequency domain method is presented to identify the dynamic cutting factor through measured vibration in a milling process, and cutting conditions most suitable for the identification experiments are also discussed. A series of experiments are carried out to investigate the effects of cutting conditions on the dynamic cutting factor. This factor is shown to be significantly affected by the cutting speed, but relatively independent of the feed per tooth and the radial depth of cut. An average process damping model is further constructed and shown to be effective in representing the time-varying damping function. The average process damping is shown to increase rapidly at lower cutting speed, but remain constant as the cutting speed beyond a critical value.     

薄壁筒车削颤振稳定性预测

切削颤振是制约薄壁筒工件加工质量和效率的主要因素之一。采用半离散法对含有时滞项的动力学方程进行稳定性预测分析,结合薄壁筒工件切削振动试验,研究刀具、工件动力学参数匹配关系变化对切削加工稳定性的影响。通过仿真分析得出:随着刀具刚度或固有频率的提升,切削系统稳定性呈上升趋势,但过度提升刀具刚度并不会有效提升切削稳定性;在刀具与工件固有频率接近处,切削系统的稳定性较差;适当调整刀具动态特性参数有利于提高柔性工件切削加工的稳定性;切削过程中,时变的切削位置和工件尺寸会引起切削系统动态特性的变化。根据时变稳定性预测图,从稳定性分析角度解释了一次走刀切削试验中薄壁筒工件表面出现不同加工形貌的原因。     

基于模糊时变滑模的永磁同步电机调速系统设计

针对永磁同步电机突然加入负载时存在的转速波动和不稳定问题,提出一种基于积分时变滑模面和新型模糊增益趋近律的滑模调速方法。采用积分时变滑模面,在传统积分滑模面中加入一个时变项,借此提升系统的响应速度。改进传统的指数趋近律,加入非线性函数来削弱系统的抖振,同时根据不同的系统状态用模糊算法整定趋近律增益参数,着重于提升趋近速度和系统抗扰动能力。最后,使用李雅普诺夫稳定性判据证明了该控制系统的稳定性。在MATLAB/Simulink环境下将此控制策略与传统滑模控制策略进行对比,仿真结果表明：采用此控制方法的系统响应速度更快、抑制系统扰动和抖振的能力更强,具备更好的综合性能。     

一种柔性变压边力的智能冲压过程研究

板料成形时易产生破裂、起皱以及尺寸和形状精度不良的倾向。在伺服压机的基础上,研究一种柔性可变压边力的独立加载闭环控制系统。选择圆筒形工件为模拟对象,利用有限元软件分析圆筒形工件在不同定值下及变压边力下冲压仿真结果。比较得到成形圆筒形工件的最优压边力曲线以及冲压载荷随时间变化的曲线,加载到装置的控制系统,使压边单元与板材始终处于贴合状态。该闭环系统通过压机变载、变行程等不同的运动模式协同柔性压边装置对冲压成形过程进行控制,柔性控制压边力和冲模载荷,来适合零件不同变形阶段的特点。实验证明:该系统可以最大限度提高金属板材成形性能,不仅防止了板材变薄在尾部产生褶皱以及工件拉裂的情况,而且可以提高板材拉深极限。     

A full-discretization method for prediction of milling stability

This paper presents a full-discretization method based on the direct integration scheme for prediction of milling stability. The fundamental mathematical model of the dynamic milling process considering the regenerative effect is expressed as a linear time periodic system with a single discrete time delay, and the response of the system is calculated via the direct integration scheme with the help of discretizing the time period. Then, the Duhamel term of the response is solved using the full-discretization method. In each small time interval, the involved system state, time-periodic and time delay items are simultaneously approximated by means of linear interpolation. After obtaining the discrete map of the state transition on one time interval, a closed form expression for the transition matrix of the system is constructed. The milling stability is then predicted based on Floquet theory. The effectiveness of the algorithm is demonstrated by using the benchmark examples for one and two degrees of freedom milling models. It is shown that the proposed method has high computational efficiency without loss of any numerical precision. The code of the algorithm is also attached in the appendix.     

拼焊板等离子体弧柔性成形数值模拟

采用等离子体弧作为热源对低碳钢差厚拼焊板进行弯曲成形研究,并利用有限元分析软件ANSYS对差厚拼焊板进行弯曲成形模拟。通过分析匀速恒功率热源、变速恒功率热源及匀速变功率热源扫描差厚拼焊板的温度梯度和应力分布,给出了一种较好的拼焊板热成形方法,最后通过试验对有限元分析结果进行了验证。     

Design of an adaptive line enhancement system using a variable step-size affine-projection algorithm

This paper presents design of an adaptive line enhancement (ALE) system for improving sensor response using a variable step-size affine-projection algorithm (VSS APA). ALE is an adaptive technique that may be used to detect a periodic signal buried in a broadband noise background such as in rotating machinery fault diagnosis. However, most of the conventional methods for ALE system are based primarily on an adaptive filter with the least-mean-square (LMS) error algorithm. Unfortunately, convergence speed is limited when a filtering plant is varied, because the learning process of the adaptive algorithm fails to respond quickly enough to the changing operational conditions. This study proposed a VSS APA for improving both the convergence speed and the performance of the ALE system. Two applications were conducted to compare the performance of the proposed algorithm and various traditional adaptive filtering algorithms. The first application used the proposed ALE system to improve the response of a wheel speed sensor output signal; the other was used for reducing the background noise during rotating machinery fault diagnosis. Both the experimental results indicated that the ALE with VSS APA has an effective performance and convergence for both applications.     

一种基于幅值调制比率的风电机组齿轮箱失效自动识别方法

风电机组状态监测部位多,数据分析工作量大,人工故障识别的方式使得风电机组状态监测报告滞后。本研究提出一种基于幅值调制比率的风电机组齿轮箱失效自动识别方法,针对风电机组转速不平稳的特点首先对齿轮箱振动加速度信号进行时频分析得到机组的瞬时转速,然后进行阶比处理将等时间间隔信号序列重采样转换成等角度间隔信号序列,频域变换后选择一倍啮合频率和两倍啮合频率幅值较大值,计算调制间隔为转频的多频率点幅值累加和,再将与较大啮合频率处的幅值调制比率作为特征值表征齿轮箱的失效状态。恒速和变速风电机组齿轮箱振动数据分析结果都表明该特征值具有良好的故障与正常状态区分能力,且不同转速下该特征值具有稳定性。     

绝缘子智能水冲洗装置伺服驱动系统动态性能研究

为了提升绝缘子水冲洗的准确率和作业效率、降低操作人员的劳动强度，根据冲洗系统组成原理，设计一套智能水冲洗装置。建立传动系统动力学模型以及伺服控制系统模型，对系统动态响应进行分析，找出影响其动态特性的主要因素。根据时变速度环增益的方法，优化伺服系统的比例积分微分（PID）控制方案。通过仿真得到系统优化后的振动特性曲线，对比发现，系统初始响应时间缩短了19.76%。最后通过搭建现场实验装置进行验证，系统初始响应速度提高了16.1%，最大振幅降低了8.6%，波动时间缩短了10.2%。结果表明:在绝缘子冲洗过程中，时变速度环增益的优化控制方案能够有效降低智能水冲洗装置的振动振幅，缩短系统的响应时间，提高系统的稳定性。     

工业叶片磨抛加工过程接触控制优化

应用机器人磨抛技术对叶片进行磨抛加工过程中,由于非零逼近速度和不连续动态特性等因素使得磨抛加工接触过程存在力振荡与力过冲问题,严重影响叶片表面加工质量和系统稳定性.针对此问题,文章提出了一种磨抛加工过渡过程的优化振动抑制方法.以机器人砂带磨抛技术为研究对象,在输入整形技术的基础上引入正负交替的脉冲序列,设计出改进具有负...     

激励因素对人字齿行星齿轮系统动态特性的影响

为研究激励因素对人字齿行星齿轮传动系统动载稳定性的影响,综合考虑阻尼、时变啮合刚度、齿侧间隙和综合传动误差等激励参数,建立人字齿行星齿轮系统的纯扭转动力学模型。采用Runge-Kutta法进行数值求解;分析在不同啮合频率下,阻尼比、刚度波动系数和综合啮合误差等参数对系统内、外啮合副动载特性的影响;采用三维速度-频率扫描瀑布图、相图和Poincaré映射分析外啮合动载系数突出值。结果表明：内啮合具有更好的振动稳定性和均载性能;当阻尼比增大时动载系数总体呈减小趋势,动载系数随着刚度波动系数和综合啮合误差增大发生失稳现象,波动较剧烈;对动载突变的激励因素值分析,观测到超谐波共振现象;在临界转速时系统处于拟二倍周期振动状态,表明系统在给定区间内处于收敛状态。     

Effectiveness of continuous workpiece speed variation (CWSV) for chatter avoidance in throughfeed centerless grinding

The continuous rotation speed variation is demonstrated to be an efficient method to avoid regenerative chatter in different machining processes. This paper presents a time-domain dynamic model for throughfeed centerless grinding process that can predict chatter by means of part roundness error evolution. Continuous workpiece speed variation (CWSV) has been implemented in this model to analyze the influence of this disturbing method on the dynamic instability. Experimental results have validated the model and verified the effectiveness of CWSV for chatter avoidance and surface finish and dimensional tolerances improvement. It has been demonstrated that the selection of the optimal variation parameters is an important factor not only for chatter avoidance, but also for the stability of surface finish and dimensional tolerances since workpiece speed variation has a direct influence on throughfeed rate and grinding forces.     

Numerical procedure for simulation of multicomponent and multi-layered phase diffusion

A mass balance error-free numerical procedure for simulation of multicomponent and multi-layered phase diffusional reactions has been suggested, based on an explicit fixed grid finite difference method. Basically, a local equilibrium was assumed at each phase interface and one dimensional movement of interfaces was considered. Attention was paid to the treatments of newly formed thin phase layers and different molar volumes among interacting phases, together with the removal of a mass balance error. Specially derived finite difference forms were used to treat phase layers thinner than two inter-grid distances. A new flux balance equation which is independent from the molar volume differences among phases and leaves no mass balance error was developed by a transformation of space variable system and by a systematic analysis of sources of mass balance error, respectively. Through some model simulations, it could be shown that the present numerical procedure cantreat multi-layered phase diffusion including thin layered phases and can reproduce transitions of layer sequences during diffusional reactions successfully, leaving no mass balance error.     

Theoretical and experimental study of PI control, adaptive control and variable structure control for converted traditional milling machines

In this paper, the control plant is a traditional lead screw with a hand wheel-actuated milling machine that has been converted to a d.c. servo-motor control type. This old-fashioned machininingi table is a non-linear, time-varying system due to the effects of obvious backlash and irregular Coulomb friction between sliding surfaces. Three different control methods are employed for this plant to investigate the operating performance. The theoretical derivations of these control methods are described briefly. Since the control parameters have significant change, the traditional PI with relay control has to adjust the suitable gain values for each case. It is not a convenient application. The variable structure model-following control methods needs to select appropriate logical gain values and a suitable relay offset. Additionally, these two approaches cannot guarantee a stable closed-loop system. The third method for this non-linear system is a stable convergent one-step-ahead adaptive control algorithm. The experimental results show that these control methods give reasonable performance of transient response, tracking and robustness under the influence of the delay of the motor driver and 1 mm backlash of each axis. For a low speed trajectory tracking control (V_s < 3 mm/s), the traditional PI with relay control and the variable structure model-following control give better performance.     

变速变载条件下Inconel带材的成形性能

Inconel铟镍合金是核电设备中燃料组件格架条带的常见原材料。为了提高核燃料组件格架条带产品的冲制质量,对铟镍合金板料冲压成形性能进行了研究。针对该材料价格昂贵和各向异性明显的特点,采用有限元方法进行分析。首先通过试验方法得到材料力学性能参数,再利用有限元模拟分析在变速变载条件下铟镍合金的成形性能。研究了冲压成形速度、速度模式、压边力大小和载荷模式对铟镍合金成形性能的影响。最后通过模具冲制试验结果分析验证了有限元模拟分析的正确性。结果表明:通过有限元数值模拟分析更加了解了铟镍合金板料冲制性能,并为格架条带冲制提供了工艺参数。     

异形坯连铸机钢包回转台旋转框架有限元分析

异形坯连铸机钢包回转台旋转框架是冶金连铸连轧中的关键设备,是一大型空间焊接构件,为了加快引进设计国内消化和独立设计,用有限元分析软件在APOLLO4000工作站对该旋转框架进行了分析,搞清了旋转框架应力分布及变形,为今后独立设计同类型旋转框架打下基础。     

考虑冲击与齿根应力的齿轮接触稳定性分析

为研究齿轮冲击、运行工况等因素对齿根应力及齿轮接触稳定性的影响,阐明各因素间关联关系,应用能量守恒定理计算了变工况下齿轮啮合冲击力,并用修正后的齿根应力计算法对不同转矩下齿根应力进行计算。并以一对机匣齿轮为例,应用有限元法建立真实工况下齿轮动态啮合模型,计算齿轮动态接触力,与理论值进行对比,验证其合理性。随后分别分析不同工况对齿轮啮合冲击力、齿根应力与接触稳定性的影响,最后综合分析了转速、转矩、啮合冲击力、齿根应力之间关联关系,阐明了齿轮接触稳定性随工况变化的规律,为齿轮系统最佳工况选取及接触稳定性优化提供参考。分析结果表明：转矩变化会引起接触力、齿根应力与啮合冲击共同变化,其对接触稳定性的影响大于转速。     

Flank face texture design to suppress chatter vibration in cutting

Process damping is useful in improving chatter stability in a low cutting speed range. This paper presents a texture design on tool flank faces that can effectively generate process damping. A convex structure on the flank face dampens chatter vibration even at general cutting speeds. An orthogonal cutting simulation utilizing a finite element analysis was conducted to estimate process damping force coefficients that are the functions of cutting and vibration conditions and tool geometry. Sufficient damping effect was predicted using the proposed texture via a chatter stability analysis in frequency domain. Face turning experiments verified the significant chatter suppression effect.