【作者】 张鹏；

【导师】 张军；

【作者基本信息】 大连理工大学 ， 机械工程， 2025， 硕士

【摘要】 在机械生产加工领域,切削力的高精度测量直接决定加工过程的控制精度,是实现智能制造及自动化生产的重要前提和基础。四维力测力仪能够满足车、磨、刨、铣等大多加工方式的测力需求,具有广阔的应用场景。随着精密加工技术和多任务加工设备的发展,现代制造业对测力仪的测试精度提出了更高的要求,在以高性能复合材料为代表的异型构件加工领域,由于该类材料具有结构复杂、尺寸多变的特性,对测力仪多点位的输出一致性提出了新的挑战。本文基于实际测试加工需求,设计高精度压电式四维测力仪。系统研究了误差产生机理;并从测量方法、力敏单元标定、测力仪结构设计、数据后处理方面进行优化以提升测力仪精度。提出了用于四维力高精度测量的新型方案。对不同空间布局进行仿真分析,获得不同空间布局与结构变形的关系;建立不同测试方法传感器输出与被测四维力的映射关系,定义影响测量方法精度的关键误差,推导误差对不同测量方法的影响,采用数值仿真的方法进行了测量方案的理论精度对比,最终确定四向力传感器矩形布置的测量方案。实现了四向力传感器性能参数的高精度获取。理论分析加工误差对传感器测试精度的影响,基于四向力传感器冗余晶组的特殊结构,验证并获取传感器输出线性关系,提出优化标定方法,进一步分离标定误差,对该类型传感器进行更高精度的性能获取。设计了测力仪结构与数据后处理优化方法。完成了测力仪完整结构的设计和装配;提出测力仪预紧状态装配误差验证方法;提出灵敏度标定方法,量化其误差量级和受标定精度影响权重;提出四向力线性解耦方法;完成测力仪静、动态性能标定。完成了测量方案有效性和实际加工可用性的验证。设计扭矩变加载点实验,验证测量方法有效性并分析误差,进行测力仪实际钻削加工测试并与国际同类型商用测力仪对比,验证实际加工可用性。本文提出了立足于四向力传感器矩形布置的四维力测试方案,据此设计四维力测力仪,并在设计过程中对四维力测力仪的性能提升技术进行了研究,为测力仪方案选型、设计制造提供了一定的参考价值。更多还原

【Abstract】 In mechanical production and processing,the accurate measurement of cutting force is related to the control of the whole process,which is an indispensable technology for intelligent manufacturing and automated production.Piezoelectric force gauge is wid ely used in dynamic cutting force testing due to the advantages of high stiffness and high intrinsic frequency,in which the four-dimensional force gauge can meet the force measurement needs of turning,grinding,planing,milling and other machining modes,and it has a wide range of application scenarios.With the development of precision machining technology and multi-task machining equipment,the modern manufacturing industry has put forward higher requirements for the testing accuracy of the force gauge.In the field of processing of anisotropic components represented by high-performance composite materials,due to the complex structure of such materials,the characteristics of the size of the variable,the consistency of the output of the force gauge at multiple points has posed a new challenge.In this paper,based on the actual testing and processing needs,the design of high-precision piezoelectric four-dimensional force gauge.The error generation mechanism is systematically studied;and optimization is carried out in terms of measurement method,force-sensitive unit calibration,force gauge structure design,and data post-processing to enhance the testing accuracy of the force gauge.The overall scheme of rectangular arrangement of four-way force sensor is proposed.Ansys workbench software is used to analyze the different spatial layouts statically and obtain the relationship between the different spatial layouts and the structural deformation of the dynamometer;the mapping relationship between the sensor outputs of the different test schemes and the measured four-dimensional force is established,the key errors affecting the accuracy of the measurement method are defined,the effects of the errors in the torque transmission path are deduced,and the theoretical and accuracy comparisons of the measurement schemes are carried out by using the numerical simulation.Accuracy comparison.The method of analyzing the performance of the four-way force sensor is studied.The force-electric conversion model under the influence of error is established based on the rotation matrix,the influence of processing error on the testing accuracy of single sensor is analyzed theoretically,the calibration of sensor main direction with high accuracy is carried out to verify the correctness of the theory,and the performance parameters of the sensor main direction force are obtained;according to the characteristics of the redundant crystal group of the four-direction force sensor,the relationship between the four-direction output of the sensor is deduced,and it is verified that there is a linear relationship of the four-direction output of the sensor by comsol simulation,and the static output of the sensor is carried out.A linear relationship is derived from the redundant crystal group of the four-way force sensor,and the four-way output of the sensor is verified by comsol simulation to have a linear relationship.The structure and error control system of the force gauge is constructed.With the main objectives of reducing force deformation and improving sensitivity of the force gauge,parametric analysis is used to obtain the key dimensional parameters and design t he wiring scheme.The verification method of the assembly error in the preloaded state of the force gauge is proposed;the sensitivity calibration method is proposed to quantify the error magnitude and the weight affected by the calibration accuracy;the f our-way force linear decoupling method is proposed to calibrate the static and dynamic performance of the force gauge.The validity of the measurement program and the practical processing feasibility are verified.Design of torque variable loading point experiments to verify the validity of the measurement method and analyze the error,the actual drilling and processing test of the dynamometer and comparison with international advanced dynamometers of the same type to verify the availability of actual processing.This paper proposes a four-dimensional force test program based on the rectangular arrangement of the four-way force sensor,according to which the design of four-dimensional force dynamometer,and in the design process of four-dimensional force dynamometer performance enhancement technology research,for the dynamometer program selection,design and manufacture provides a certain reference value.更多还原