面向大批量生产的刀具磨损在线识别技术研究-机械电子工程专业毕业论文.docxVIP

华 华 中 科 技 大 学 硕 士 学 位 论 文 I I 摘 要 刀具磨损已经成为影响工件加工精度、表面质量，导致机床发生振动、噪声等的重 要原因。多年以来针对刀具磨损状态识别一直在进行相关方面的研究，但都处于研究阶 段，应用于实际生产的刀具磨损状态识别方法尚未见相关报道。现有的刀具磨损状态识 别方法，难以适用于大批量生产中切削参数波动的情况。本文提出了一种基于电流信号 的刀具磨损状态定量识别方法，其主要研究内容如下： 根据大批量生产的特点，以及刀具的磨损规律，本文提出了监测可直接从伺服获取 的驱动电流信号，通过刀具磨损规律学习，实现对刀具磨损状态进行识别的方法。并确 定试验方案，完成加工中心面铣削刀具磨损状态识别的试验设计，建立了电流信号监测 试验系统并完成相关试验； 采用小波分析技术对信号进行时频域分析，获取刀具切削电流信号在多个时频域内 的特征量，并通过特征敏感性分析，获取表征刀具磨损状态敏感性高的信号特征量； 通过刀具磨损规律学习，利用 BP 神经网络训练获得刀具寿命模型，并由神经网络 模式识别技术完成对刀具寿命的定量识别。利用该方法对刀具磨损状态识别，获得的结 果表明：在刀具磨损后期，部分识别结果的误差在 10%以内，既保证及时更换磨损刀具， 又提高了刀具利用率。 建立刀具磨损量与信号特征量之间的关系模型，实时识别刀具的磨损量，并补偿因 刀具磨损造成的工件尺寸误差。补偿后的工件尺寸误差减小到仅为补偿前误差的 25%， 显著提高了刀具切削工件的加工精度。 关键词：刀具磨损；在线识别；磨损量补偿；小波分析；神经网络 II II Abstract Tool wear has influence on the workpiece machining accuracy, surface quality, and leads to machine vibration, noise and other unpredictable consequences. For many years, there have been various research on the identification of tool wear, but all are in the study stage. The tool wear identification theory, which is applied in practical production, still does’t have related report. Existing methods of tool wear monitoring are hardly suitable for mass production of cutting parameter fluctuation. This paper presents a tool wear identify method which based on the analysis of current signals. The main research contents are as follows: According to the characteristics in mass production and the tool wear rule, this paper presents a tool wear identify method, which monitoring drive current signal of spindle motor and through the tool wear rule learning. By determining the experimental program, we finish the experiment design of surface milling tool wear identification in machining center. Then to establish the current signal monitoring experimental system, and complete related experiment. By analysising the current signal using wavelet packet analysis, many eigenvalues of tool cutting current signal are got. Through the analysis of sensitivity between tool wear and eigenvalue, the eigenwalues of h