高速主轴多阶、复杂空间振动行为的动平衡抑制机理研究

Since the vibration of machine tool spindle always shows multi-mode and spatial-varying characteristics, the vibration suppressing operation in single-degree-of-freedom couldn't meet the needs of high-accuracy machining. To solve this problem, the dynamic-balancing-based spatial vibration suppressing mechanism for high-speed spindle is presented.The main research contents are as follows:(1) To present the online extracting technique and signal processing method for the spatial variation, and analyze the internal relationship between the spatial variation and the unbalance status. Then, establish the unbalance associating model of the spatial vibration behavior considering the influence of the swivel head and the multi-fault.(2) To present the identification method of the unbalance which shows a continuous spatial distribution without trial weights, and study the counterweight balancing strategy which considering the base vibration and the rotor vibration with weight coefficients. Then, to analyze the coupling relationship and the decoupling methods among different type of faults, and reveal the synchronous vibrationg suppressing mechanism between the unbalance induced vibration and other faults induced vibration.This research brings the spatial vibration behavior into the effect of unbalance, and aim to suppress the spatial vibration by dynamic balancing operation, the research results will provide the theoretical and technical foundations for ensuring the smooth and accurate operation of high-speed spindle.

高速主轴振动通常呈现多阶、空间变化特征，仅考虑单一自由度振动的抑制已不再满足高精度加工需要。针对这一问题，开展高速主轴多阶、复杂空间振动行为的动平衡抑制机理研究。研究内容包括：（1）提出高速主轴空间振动行为的在线提取技术及信号处理方法，全面解析主轴空间振动与失衡状态之间的内在数学关系，构建考虑摆头、多故障干扰等因素的主轴空间振动的失衡关联模型；（2）提出空间连续分布不平衡量的无试重识别方法及考虑基座振动、不同方位转子振动权重的平衡配重策略；研究多故障下空间振动的耦合关系以及解耦方法，揭示主轴失衡与非失衡振动的同步抑制机理。本课题将主轴多阶、复杂空间振动纳入动平衡控制范畴，旨在通过动平衡手段实现主轴空间振动的综合抑制，为保障高速主轴的平稳、精确运行提供理论与技术支持。

受制造和装配误差、材料不均匀等因素影响，高速主轴不平衡故障几乎不可避免，而现场工况干扰进一步恶化了主轴运行状态，这导致了高速主轴转子轴承系统空间振动轨迹较为复杂，针对高速主轴空间振动问题，本课题开展高速主轴动平衡抑制机理研究，主要工作如下：（1）构建了高速主轴运行状态智能测试平台，实现了高速主轴的振动数据的测试、分析与处理；提出了主轴转子空间振动信号的分析与评估方法，实现了对转子整体误差的评定；提出了噪声干扰下高速主轴回转误差精确提取策略，实现了对传感器噪声干扰信号的抑制。（2）构建了高速主轴系统五自由度动力学模型，分析了高速主轴转子空间振动力学行为，研究了高速主轴转子在不同失衡激励下的空间响应特性；研究了主轴及其安装基座的轴系精度误差建模、辨识方法，实现了轴系精度误差的辨识。（3）提出了基于正反问题的不平衡量求解策略，实现了不平衡量的快速识别；提出了连续分布式不平衡量识别方法，实现了分布式不平衡量的识别；提出了不平衡量迁移校正策略，实现不平衡量的等效截面精确校正；（4）提出了非失衡平稳振动干扰下主轴纯失衡振动数据的提取方法，实现了多故障下主轴失衡振动的抑制；提出了高速主轴转子轴承系统空间振动的动平衡综合抑制方法，实现了主轴不同测点、多自由度振动的综合抑制。