雙主軸輪圈加工專用機之結構優化設計與精度檢測分析

Optimal Structure Design and Accuracy Inspection Methods for a Double Spindles and Dual-Servo-Type Machine tool for Rim Manufacturing

王祺元(Chi-Yuan Wang)

指導教授 ： 王世明

中原大學/工學院/光機電及資電控產業研發碩士專班/碩士(2007年)

https://doi.org/10.6840/cycu200700779

摘要

工具機的發展日漸邁向產量大且加工精度高的目標，以輪圈加工產業為例，對於面對龐大的汽車鋁圈市場需求，工具機業者無不致力於開發新型機種，以高產能且切削精度高的工具機來加工光亮外型之鋁圈；因此，雙主軸輪圈加工機則而被開發；以較小的佔地空間，可造就出雙台加工機的產能，為目前因應此需求之新型設計。
本研究針對此新型機種，進行結構之優化設計，利用有限元素法配合ANSYS電腦輔助分析軟體，針對工具機之各子結構進行模態分析、動柔度分析及靜態剛性分析，依分析結果對各子結構剛性不足之處以及因雙主軸頭部較重，容易前傾下垂的特性，進行重新設計並改善，並以所設定之精度標準為前提，使用肋板取代實體結構，降低各子結構重量，整機總重由原始模型之28.39噸下降至11.97噸，下降57.83%，以使得伺服馬達進給速度加快，及減少材料之使用成本。
對於開發完成後之精度檢測，本研究分析出此雙軸工具機之各種誤差特性及其成因，並提出各種誤差檢測方式；其中利用S.M. Wang和Ehmann, K. F.所提出之單點法，為利用Ball Bar進行量測，並代入其所推導之公式以獲得體積誤差；並進而使用循圓量測系統以檢測出工具機之可能產生動態誤差的原因。
最後提出主從控制法以改善雙主軸頭部使用雙伺服馬達所產生的同動誤差，可提升加工的加速度；並可改善鞍座受雙伺服馬達驅動，同動誤差所造成之結構扭曲與驅動速度降低之缺點；最後研究中亦設計兩種切削模型以檢測兩主軸實際切削工件之高低差，及檢測平面切削時之輪廓誤差。

關鍵字

同動誤差 ； 雙主軸 ； 結構設計 ； 工具機 ； 主從控制

並列摘要

The development of tooling machines is oriented toward mass production and high precision. Taking car rim machining industry for example, while facing the increasing market demand, tooling manufacturers have devoted to develop new models for the demand of high productivity and high precision for the rims. Thus, double-spindles rim-machining machine has been developed. With smaller space needed, it could double the productivity, in order to meet the market demand.
This study aimed to optimize the structural design of this new model, and used Finite Element Method along with ANSYS software to conduct modal analysis on the sub-structures of the machine, dynamic flexibility, and static rigidity analysis. Based on the analysis results, problems of insufficient rigidity, tendency to tilt forward cause of heavy double-spindles structure were re-designed and improved. To minimize the weight of machine, ribs were used to replace the solid structure to lower the weights of sub-structures. The total weight of the machine was reduced from 28.39 tons to 11.97 tons, with a significant decrease of 57.83%. Therefore, the feeding speed of machine is able to increase, and the costs on materials is decreased.
This study conducted accuracy testing for the special machine configuration after the design, analyzed the error characteristics and causes of the tooling machine, and proposed error detecting methods. Method using telescope magnetic ball bar was proposed to detect the causes of 2-axes motion errors of the tooling machine.
Finally, this study used master-slave control method to improve the synchronus error caused by dual servomotor system. It can effectively redused the synchronus errors of the dual servomotor system, that will cause the inaccurate machining and structure-damage of machine. Machining patterns were designed to identify the height difference of two spindles and contouring error of machine incorporated with using CMM.

並列關鍵字

master-slave control ； double spindles ； structure design ； synchronus error ； machine tools

參考文獻

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