Design of Optical Free-Form Surface Milling Machine Based on Mechanical Shunt and Dynamic Analysis
Abstract
:1. Introduction
2. Design of Optical Free-Form Surface Milling Machine
3. Function Description of Optical Free-Form Surface Milling Machine
3.1. Features of Optical Free-Form Surface Milling Machine
3.2. Advantages of Optical Free-Form Surface Milling Machine
4. Establishment and Simulation of Virtual Prototype for Optical Free-Form Surface Milling Machine
4.1. ADAMS Dynamics Equation
4.2. Virtual Prototype of Optical Free-Form Surface Milling Machine
4.3. Virtual Simulation of Optical Free-Form Surface Milling Machine
5. Conclusions
- (1)
- An optical free-form surface milling machine is creatively designed (Patent No.: ZL 2020 1 0008995. 1), and a virtual prototype (VP) of the optical free-form surface milling machine is established based on the basic theory of rigid multibody dynamics (RMBD) and the basic theory of flexible multibody dynamics (FMBD). The dynamic simulation research on the optical free-form surface milling machine is carried out according to the comparison method. The results show that the simulation results of the rigid multibody dynamics model and the flexible multibody dynamics model are numerically consistent. The virtual prototype technology used in the design stage of machine tools can obtain more accurate dynamic characteristic information than traditional design methods of machine tools.
- (2)
- The Z-axis characteristics of optical free-form surface milling machine is analyzed. The simulation results show that the Z-axis of the optical free-form surface milling machine has excellent dynamic characteristics. The Z-axis load can be reduced effectively and the load fluctuation range becomes more gentle when the gravity balance device is working. When the gravity balance device is not working, the average torque of Z-axis motor is 0.5 N·m, when the gravity balance device is working, the average torque of Z-axis motor is 0.1 N·m, and the average torque is reduced by 80%. When the gravity balance device is not working, the average force of Z-axis end bearing is 3000 N, when the gravity balance device is working, the average force of Z-axis end bearing is 750 N and the average force is reduced by 75%. Therefore, the gravity balance device can suppress the load fluctuation of Z-axis and obviously improve the efficiency of the milling machine.
- (3)
- The natural frequencies of optical free-form surface milling machine adopting different structural schemes and material schemes are analyzed. The simulation results show that the first vibration mode of the milling machine affecting manufacturing precision is the third order, and the optimal dynamic characteristic design scheme is that the Z-axis motor is installed on the roof and the structure material is natural granite; the first natural frequency of milling machine affecting manufacturing precision is 68 HZ. The structure material using natural granite compared with cast iron can significantly improve the dynamic characteristics of the machine tool.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
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Order | Structural Schemes | Material Schemes | Frequency (HZ) | Mode |
---|---|---|---|---|
1 | Z-axis motor is installed on the roof | Cast iron | 28.93 | The external frame of milling machine swingsaround the Y-axis |
Natural granite | 34.445 | |||
Z-axis motor is installed on the column | Cast iron | 24.237 | ||
Natural granite | 26.011 | |||
2 | Z-axis motor is installed on the roof | Cast iron | 57.651 | The external frame of milling machine swingsaround the X-axis |
Natural granite | 63.086 | |||
Z-axis motor is installed on the column | Cast iron | 57.027 | ||
Natural granite | 61.171 | |||
3 | Z-axis motor is installed on the roof | Cast iron | 61.382 | The internal frame of milling machine swingsaround Y-axis |
Natural granite | 68.173 | |||
Z-axis motor is installed on the column | Cast iron | 58.306 | ||
Natural granite | 62.119 | |||
4 | Z-axis motor is installed on the roof | Cast iron | 64.686 | Torsional vibration of milling machine external frame around Z-axis |
Natural granite | 73.179 | |||
Z-axis motor is installed on the column | Cast iron | 63.457 | ||
Natural granite | 70.952 | |||
5 | Z-axis motor is installed on the roof | Cast iron | 75.199 | The internal frame of milling machine swingsaround the X-axis |
Natural granite | 83.764 | |||
Z-axis motor is installed on the column | Cast iron | 72.21 | ||
Natural granite | 76.863 | |||
6 | Z-axis motor is installed on the roof | Cast iron | 96.653 | Torsional vibration of milling machine internal frame around Z-axis |
Natural granite | 108.8 | |||
Z-axis motor is installed on the column | Cast iron | 92.83 | ||
Natural granite | 99.533 | |||
7 | Z-axis motor is installed on the roof | Cast iron | 109.11 | The slide carriage and its mounting parts vibratein Z-axis direction |
Natural granite | 119.29 | |||
Z-axis motor is installed on the column | Cast iron | 109.45 | ||
Natural granite | 119.9 | |||
8 | Z-axis motor is installed on the roof | Cast iron | 113.41 | The slide carriage and its mounting parts swingaround the Y-axis |
Natural granite | 129.55 | |||
Z-axis motor is installed on the column | Cast iron | 113.21 | ||
Natural granite | 123.5 | |||
9 | Z-axis motor is installed on the roof | Cast iron | 150.79 | The external frame of milling machine vibratesin Z-axis direction |
Natural granite | 168.73 | |||
Z-axis motor is installed on the column | Cast iron | 118.75 | ||
Natural granite | 129.17 |
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Li, Q.; Yu, T.; Wang, Z.; Wang, W. Design of Optical Free-Form Surface Milling Machine Based on Mechanical Shunt and Dynamic Analysis. Appl. Sci. 2021, 11, 11764. https://doi.org/10.3390/app112411764
Li Q, Yu T, Wang Z, Wang W. Design of Optical Free-Form Surface Milling Machine Based on Mechanical Shunt and Dynamic Analysis. Applied Sciences. 2021; 11(24):11764. https://doi.org/10.3390/app112411764
Chicago/Turabian StyleLi, Qi, Tianbiao Yu, Zixuan Wang, and Wanshan Wang. 2021. "Design of Optical Free-Form Surface Milling Machine Based on Mechanical Shunt and Dynamic Analysis" Applied Sciences 11, no. 24: 11764. https://doi.org/10.3390/app112411764
APA StyleLi, Q., Yu, T., Wang, Z., & Wang, W. (2021). Design of Optical Free-Form Surface Milling Machine Based on Mechanical Shunt and Dynamic Analysis. Applied Sciences, 11(24), 11764. https://doi.org/10.3390/app112411764