面向深腔加工的加长电动刀杆动力学特性测试与分析

Dynamic characteristics testing and analysis of extended electric toolholder for deep cavity machining

  • 摘要: 为研究加长电动刀杆在深腔加工中的动力学特性及加工误差形成机理,以某型加长电动刀杆为研究对象,采用锤击模态试验、空载不同转速试验及切削过程动态测试,对刀杆系统固有频率、空载振动位移、切削振动响应、弹性让刀变形及回弹过切进行测试与分析。结果表明,刀杆主要固有频率为55、250、510、620、840、115014051730 Hz,其中55 Hz附近低阶模态对动态稳定性影响较大;空载转动时端部径向位移整体稳定,水平方向位移由72.5 μm降至3 000 r/min时的60 μm,竖直方向保持在52~56.5 μm;切削过程显著放大刀杆动态响应,水平切削和竖直切削下弹性让刀量分别为239~248 μm和242~275 μm,回弹过切量为50~82 μm。研究表明,在深腔加工工况下,切削载荷引起的弹性让刀变形是影响加工精度的主要因素,应优先提高刀杆前端及连接支撑刚度,并优化切削参数以降低瞬时切削力。

     

    Abstract: To investigate the dynamic characteristics of an extended electric toolholder and the formation mechanism of machining errors in deep cavity machining, an extended electric toolholder was selected as the research object. Hammer impact modal testing, unload variable-speed testing, and cutting process dynamic testing were conducted to identify the natural frequencies of the toolholder system and to evaluate the unloaded vibration displacement, cutting vibration response, elastic tool deflection, and rebound overcutting. The results indicate that the primary natural frequencies of the toolholder are 55, 250, 510, 620, 840, 1 150, 1 405, and 1 730 Hz, with the low-order mode near 55 Hz having a significant influence on dynamic stability. Under unload rotation, the radial displacement at the tool tip remains stable; the horizontal displacement decreases from 72.5 μm to 60 μm at 3 000 r/min, while the vertical displacement remains within 52-56.5 μm. The cutting process considerably amplifies the dynamic response. The elastic tool deflections under horizontal and vertical cutting are 239-248 μm and 242-275 μm, respectively, with rebound overcutting of 50-82 μm. The results demonstrate that, under the present deep cavity machining conditions, cutting-load-induced elastic deflection is the dominant factor affecting machining accuracy. Therefore, improving the stiffness of the toolholder front end and supporting connections, together with optimizing cutting parameters to reduce instantaneous cutting forces, should be prioritized.

     

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