汽车模具加工系统-铣削过程耦合动力学研究及工艺规划

Automotive panel die hardened steel machining accuracy and surface quality directly affects the automobile production and its upgrading, which is characterized by high hardness, large outline size, processing complex surface features and etc. the milling process of that prone to flutter, leading to deterioration in surface quality.In this project automotive panel die milling system as the research object, consider the state of the physical factors affecting the milling of its dynamics modeling, analysis auto mold CNC machining process in the dynamics of the whole system during the milling processing.Interaction between integrated CNC machining systems and complex dynamic curve mold milling process is discussed, with which the mold surface milling complex flutter stability are analyzed and forecasted.Considering NC system stiffness properties and surface characteristics of different types of automobiles mold stiffness characteristics, an integrated automotive die NC system stiffness field model is established, with which performance composite stiffness variation is analyzed.The tool path and process parameters optimization are based on milling stability and overall stiffness of the field, and the automotive mold without chatter stability of milling process offline programming method are put forward. The result of this project is providing theoretical support and practical basis for the realization of a stable system of automobile panel milling hardened steel mold.

汽车覆盖件淬硬钢模具的加工精度和表面加工质量直接影响了汽车生产与换型，其特点是材料硬度高、轮廓尺寸大、加工型面特征复杂等特点，铣削加工过程易发生颤振，导致加工表面品质恶化。本项目以汽车模具铣削加工系统为研究对象，考虑铣削状态下物理因素的影响对其进行动力学建模，分析汽车模具数控加工工艺系统在全行程域内的动力学特性分布规律。综合数控加工系统动力学特性和复杂曲面模具动态铣削加工过程之间的交互过程，进行复杂曲面模具铣削颤振稳定性预测与分析。考虑数控加工系统刚度性能和不同型面特征的汽车模具刚度特性，建立汽车模具数控加工系统综合刚度场模型，分析综合刚度性能变化规律。基于铣削稳定性和综合刚度场进行刀具路径和工艺参数优化，提出面向汽车模具无颤振稳定铣削加工工艺离线规划方法。从而为实现汽车覆盖件淬硬钢模具的稳定铣削提供系统的理论支持和实践依据。

汽车覆盖件淬硬钢模具的加工精度和表面加工质量直接影响了汽车生产与换型，其特点是材料硬度高、轮廓尺寸大、加工型面特征复杂等特点，铣削加工过程易发生颤振，导致加工表面品质恶化。.本项目以汽车模具数控加工机床的主轴系统为研究对象，考虑了铣削状态下物理因素的影响建立主轴-刀柄-刀具结合面和主轴-轴承结合面的接触特性理论模型，并引入到主轴系统动力学有限元模型中，获得了铣削状态下主轴系统动力学特性。.对汽车模具型腔曲线和复杂曲面铣削过程的瞬态切屑厚度、切入切出角、刀具-工件接触区域等进行了理论分析，并综合主轴系统动力学特性，建立了模具型腔曲线和复杂曲面的铣削动力学模型，进行了铣削稳定性预测，获得了型腔曲线特征和型面曲率特征的铣削稳定性变化规律。.对汽车模具铣削加工用四轴数控加工中心，考虑机床横梁、刀具、摆头关节、主轴-刀柄-刀具的结合面以及模具的曲面特征等，根据四轴加工工艺系统的运动链模型，建立了四轴加工系统综合刚度场模型，获得了四轴加工系统在刀具空间位姿下的综合刚度性能分布规律。基于复杂曲面铣削稳定性和加工系统综合刚度场进行了铣削刀具路径和工艺参数优化，进行了典型汽车模具无颤振稳定铣削加工工艺规划，提出了表面质量确保前提下、最大生产率的工艺规划方法，从而为实现汽车覆盖件淬硬钢模具的稳定铣削提供系统的理论支持和实践依据。