机器人旋转超声钻削铝合金叠层构件毛刺特性

胡力闯; 郑侃; 董松; 薛枫; 束静; 苗迪迪

doi:10.13700/j.bh.1001-5965.2019.0221

机器人旋转超声钻削铝合金叠层构件毛刺特性

doi: 10.13700/j.bh.1001-5965.2019.0221

南京理工大学机械工程学院, 南京 210094

详细信息

作者简介:
胡力闯  男，硕士研究生。主要研究方向：机器人超声加工工艺

郑侃  男，博士, 副教授，硕士生导师。主要研究方向：先进制造技术

董松  男，博士研究生。主要研究方向：先进制造技术

薛枫  男，硕士研究生。主要研究方向：超声加工技术

束静  女，硕士研究生。主要研究方向：超声加工技术

苗迪迪  男，硕士研究生。主要研究方向：超声加工技术

通讯作者:
郑侃. E-mail: zhengkan@njust.edu.cn

中图分类号: V261.92
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出版历程
- 收稿日期: 2019-05-11
- 录用日期: 2019-08-31
- 网络出版日期: 2020-02-20

Burr characteristics of robotic rotary ultrasonic drilling aluminum alloy stacked components

Department of Mechanical Engineering, Nanjing University of Science and Technology, Nanjing 210094, China

More Information

Corresponding author: ZHENG Kan. E-mail: zhengkan@njust.edu.cn

摘要

摘要:
针对铝合金叠层构件机器人制孔容易产生钻削毛刺，严重影响飞机装配精度和效率等问题，提出基于弱刚度环境下机器人旋转超声制孔毛刺高度的计算方法。首先，通过实验验证了高频的振动冲击对毛刺高度的影响规律，建立了机器人旋转超声钻削铝合金叠层构件的钻削力经验公式。然后，结合经典薄板弯曲理论和能量法，分析了超声振动及钻削位置刚性对机器人钻削铝合金叠层板毛刺形成的影响机制。实验结果显示：所提计算方法的相对误差在13%以内，具有较高的精度。
- 叠层构件 /
- 钻削毛刺 /
- 计算方法 /
- 机器人 /
- 超声振动
Abstract:
It is easy to generate burr on the edge of holes when industrial robot drills the aluminum alloy stacked component. The assembly accuracy and efficiency of aircraft are severely affected. Aimed at the problem of robotic low stiffness, a model is developed to compute the burr height of holes produced by robotic rotary ultrasonic drilling. First, the impact of high frequency vibration on the burr height is invesgated by drilling experiments. Then, the empirical formula of drilling force in robotic rotary ultrasonic drilling aluminum alloy stacked component is obtained by analysing the experimental results. Furthermore, based on the classical thin plate bending theory and energy method, the influence mechanism of ultrasonic vibration and drilling position rigidity on the burr height of drilling is clarified. Finally, verification experiments are carried out and the results show that this method has high calculation accuracy and the relative error is within 13%.
- stacked component /
- drilling burr /
- calculation method /
- robot /
- ultrasonic vibration

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图 1 制孔实验平台与旋转超声装置

Figure 1. Hole making experimental platform and rotary ultrasonic device

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图 2 轴向钻削力随时间的变化

Figure 2. Drilling axial force versus time

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图 3 毛刺高度的测量

Figure 3. Measurement of burr height

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图 4 旋转超声钻削和普通钻削下钻削力和毛刺高度对比

Figure 4. Comparison of drilling force and burr height between rotary ultrasonic drilling and general drilling

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图 5 单层板钻削毛刺形成过程

Figure 5. Single-layer plate drilling burr formation process

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图 6 叠层材料钻削毛刺形成过程

Figure 6. Laminated material drilling burr formation process

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图 7 四边简单支撑的矩形薄板力学分析

Figure 7. Mechanical analysis of rectangular thin plates with four sides simply supported

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表 1 实验中的因素和水平

Table 1. Factors and levels in experiment

实验	因素	水平
实验	因素	A	B	C	D	E
单因素实验	主轴转速/(r·min^-1)	2 000	2 500	3 000	3 500	4 000
	进给速度/(mm·min^-1)	60	72	84	96	108
	超声电流/mA	0	200
	机器人位姿	P₁
正交实验	主轴转速/(r·min^-1)	1 000	2 000	3 000	4 000	5 000
	进给速度/(mm·min^-1)	36	48	60	72	84
	超声电流/mA	150	175	200	225	250
	机器人位姿	P₁	P₂	P₃	P₄	P₅

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表 2 各位姿下机器人在轴相关坐标系中的坐标

Table 2. Coordinates in axis-dependent coordinate system of robot under different position and posture

位姿	机器人相邻两轴夹角/(°)
位姿	θ₁	θ₂	θ₃	θ₄	θ₅	θ₆
P₁	-0.86	-77.31	76.6	0	90.72	-15.86
P₂	-0.86	-77.3	77.06	0	90.25	-15.86
P₃	-0.86	-77.3	77.55	0	89.76	-15.86
P₄	-0.86	-77.27	78.0	0	89.29	-15.86
P₅	-0.86	-77.23	78.42	0	88.83	-15.86

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表 3 毛刺高度计算方法的相对误差

Table 3. Relative error of burr height calculation method

上下层板	序号	毛刺高度/μm		相对误差/%
上下层板	序号	预测值	实测值	相对误差/%
上层板	1	116.24	124.10	6.33
	2	115.98	125.04	7.25
	3	114.45	130.91	12.57
	4	117.98	119.50	1.27
	5	122.45	124.13	1.35
下层板	1	168.45	158.38	6.36
	2	169.03	154.55	9.37
	3	180.89	169.47	6.74
	4	180.22	160.93	11.99
	5	147.28	143.52	2.62

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