高性能流体静压支承系统的基础研究

Fluid hydrostatic bearings are important basic components in equipment manufacturing. The conventional design theory and methodology are difficult to facilitate the innovation and development of high performance hydrostatic bearings and are severely challenged as the equipment manufacture is directed to produce the extreme types, i.e., products of heavy-duty/super-heavy-duty, and precision/ultra-precision, etc. The research aims at the urgent and important engineering requirements in developing heavy-duty /super-heavy-duty machine tools and ultra-precision manufacturing equipment. It investigates into the fundamental issues of fluid hydrostatic bearing systems in an extreme environment of high speed, heavy-duty, multiple disturbances. The issues to be studied: (1) the nonlinear dynamics of hydrostatic bearings in the condition of high-speed, heavy-duty, and multiple disturbances; (2) the innovative and optimal configuration of hydrostatic bearing systems; (3) the active control strategies of causative hydrostatic performance, in which the interdisciplinary and in-depth studies are carried out from aspects of theory, methodology, key technique, experiment and application to reveal the constituent relationships of fluid-solid-heat coupling on macro-meso-micro scope, to develop the dynamic model, ultra-precise measurement and control of high performance, response enhancing mechanism, and the innovative configuration of hydrostatic bearings in the condition of high speed, heavy-duty and multiple disturbances. The research outcomes are to facilitate the development of high performance bearings theoretically and technically, and be applied to the typical equipment. This is to raise our nation's self innovation ability on high-end equipment.

流体静压支承系统是制造装备的重要基础部件，随着制造装备向重型/超重型和精密/超精密方向发展，其设计与控制的理论方法面临着严峻挑战。本项目面向我国发展精密重型/超重型加工机床、超精密制造装备的重大需求，以高速、重载、多源强扰动等极端条件下的流体静压支承为研究对象，围绕流体静压支承的关键问题：（1）高速、重载、多源强扰动条件下流体静压支承的非线性动力学特性解析；（2）高性能流体静压支承系统结构创新；（3）流体静压支承系统使役性能主动控制方法，从理论、方法、关键技术、实验与应用等层面，展开多学科交叉基础研究，建立流体静压支承在上述极端条件下的动力学模型，揭示宏观-介观-微观跨尺度流-固-热耦合动力学本构关系，提出系统响应能力增强机制和结构创新方法，建立支承性能高精度检测与主动控制理论。相关成果在典型装备上应用，为高性能运动支承部件的开发提供理论支持，提高我国高端制造装备的自主创新能力。

流体静压支承具有承载力大、近零摩擦、效率高、运动平稳、隔离振动及适应性好等特点，是高端数控制造装备提高性能的最优选择。本项目围绕国家重大需求——高端数控制造装备，开展高性能流体静压支承系统的基础研究，首先在动力学行为规律方面，建立了高速重载静压支承系统的流固热耦合模型，提出了静压支承特性高效计算和建模方法，揭示了静压主轴稳定性的影响因素和判定方法，研究了润滑剂非牛顿性对径向轴承主轴非线性稳定边界的影响规律，研究了气浮转台止推轴承轴向和翻转支承特性，以及气浮转台径向轴承支承特性。然后在结构创新与优化方面，提出了基于非高斯粗糙表面的静压导轨结构优化方法，提出了考虑管道弹性和平台姿态的液压支承设计方法，提出了气体静压主轴非线性等效模型建模方法，通过设计方法研究为结构的优化设计和主动控制器的设计提供依据和支撑。随后在使役性能检测与控制方面，建立了重型静压回转工作台的流量控制模型，提出了静压支承系统两端轴承油膜间隙比例调控策略，研究了压电主动控制气浮支承结构的静态特性和动刚度特性，提出了高性能流体静压支承主动控制方法，通过主动控制有效提升了流体静压支承的抗扰动能力和静动态性能。最后在原型系统研制方面，建立了流体静压支承综合性能的检测评定系统新架构，搭建了一系列新型流体静压支承系统试验台，设计了流体静压支承系统静动特性和热效应实验，通过实验研究有效验证了相关理论模型的正确性，阐明了流体静压支承系统运转过程中的动力学行为和工况之间的关联规律，为流体静压支承系统精确主动控制提供了基础。本项目研究成果对提升我国高端数控制造装备行业竞争力和可持续发展能力具有重要意义。