Self-adaptive supporting clamp and method for chatter suppression and deformation monitoring in turning of large rotary thin-walled workpiece

Abstract

The invention belongs to the technical field of mechanical design, and discloses a self-adaptive supporting clamp and method for chatter suppression and deformation monitoring in turning of a large rotary thin-walled workpiece. The self-adaptive supporting clamp comprises a base, a clamping unit, a positioning unit, an auxiliary supporting unit, a deformation monitoring unit, a vibration monitoring unit, a feedback unit and a control system. The self-adaptive supporting clamp is a supporting system which is more suitable for flutter suppression and deformation control in vertical turning of rotary workpieces in the machining positioning and layout mode. The inner supporting clamp for vertical turning of the outer surface of the rotary thin-wall part has the efficient vibration reduction characteristic, the good fitting degree and the large supporting adjusting range, and the supporting requirements of workpieces with different diameters and heights can be met. Through the deformation monitoring unit, the vibration monitoring unit and the feedback unit, the supporting state is self-adaptively adjusted in real time according to the deformation and chatter conditions in the machining process, the deformation and chatter phenomena in the machining process are reduced or avoided, the machining precision is guaranteed, and the rejection rate is reduced.

Description

Technical Field

[0001] This invention belongs to the field of mechanical design technology and relates to an adaptive support fixture and method for chatter suppression and deformation monitoring in the turning of large rotating thin-walled parts. Background Technology

[0002] In high-end manufacturing sectors such as aerospace, energy, and defense, the continuous improvement of equipment performance places increasingly stringent demands on key structural components, making lightweighting a core development trend. Large, rotating, thin-walled components (such as engine casings and fuel tanks) typically have a high aspect ratio and weak overall structural rigidity. During turning, with the removal of a large amount of material (material removal rate exceeding 60%), the residual stress inside the component is unevenly released and redistributed, easily inducing deformation. Simultaneously, the component's weak rigidity makes it highly susceptible to chatter and deformation under cutting forces. These problems interact, making it difficult to control machining accuracy and surface quality, and in severe cases, even leading to component scrap.

[0003] To suppress chatter and control deformation, traditional processes often rely on conservative strategies that sacrifice efficiency, such as drastically reducing machining parameters. However, this significantly reduces material removal efficiency, prolongs manufacturing cycles, fails to fully utilize the potential of modern high-performance machine tools and cutting tools, and results in low economic efficiency. Clamping and support technology is a core element in addressing deformation and chatter, but existing technologies have significant shortcomings, such as insufficient fit, inadequate support rigidity, lack of dynamic adaptive compensation capabilities, and a disconnect between chatter suppression and deformation monitoring. The fixture of this invention not only improves the overall and local stiffness of the workpiece, effectively suppressing chatter, but also senses deformation trends in real time during machining, dynamically compensates for support, ensures high-precision machining, and significantly improves the quality, efficiency, and reliability of machining large, thin-walled parts. Summary of the Invention

[0004] The key to overcoming the bottleneck of high-quality and high-efficiency machining of large, rotating, thin-walled parts lies in researching and developing an innovative support and clamping technology that integrates chatter suppression and real-time deformation monitoring. This invention proposes an adaptive multi-point support system that can dynamically adapt to workpiece deformation throughout the turning process, actively and intelligently apply multi-point support, and can sense chatter status and deformation degree in real time.

[0005] The technical solution of this invention:

[0006] An adaptive support fixture for chatter suppression and deformation monitoring in turning of large rotary thin-walled parts includes a base plate 7, a clamping unit 6, a positioning ring 13, an auxiliary support unit, a deformation monitoring unit, a vibration monitoring unit, a support force monitoring unit, and a control system.

[0007] The base plate 7 is fixedly mounted on the lathe to support other parts of the adaptive support fixture; multiple clamping units 6 are located at the upper edge of the base plate 7 to clamp the reference end face of the large rotary thin-walled part 1 to be processed; a positioning ring 13 is located on the base plate 7, inside the clamping unit 6, to determine the reference position of the large rotary thin-walled part 1 to be processed and restrict its degrees of freedom; an auxiliary support unit is located at the center of the base plate 7 to support the inner surface of the large rotary thin-walled part 1 to be processed and to provide dynamic auxiliary support force; a vibration monitoring unit and a deformation monitoring unit are located on the auxiliary support unit to monitor the deformation and chatter of the large rotary thin-walled part 1 to be processed in real time during the processing. The auxiliary support unit and vibration monitoring unit transmit the deformation and vibration monitoring results to the computer via the slip ring 17. Based on the monitoring results, the support force of the large rotary thin-walled part 1 to be processed is adjusted in a timely manner to ensure that the auxiliary support unit provides appropriate support force, forming a closed loop. The control system is connected to the auxiliary support unit, deformation monitoring unit, support force monitoring unit, vibration monitoring unit and motion feedback unit. The control system receives deformation signals from the deformation monitoring unit and frequency domain signals from the vibration monitoring unit, generates control commands according to the preset control algorithm, and dynamically adjusts the support force provided by the auxiliary support unit to achieve chatter suppression and active compensation for the deformation of the large rotary thin-walled part 1 to be processed during the processing.

[0008] The auxiliary support unit mainly consists of an auxiliary support plate 2, an auxiliary support guide rod 3, an auxiliary support connecting rod 4, a stepper motor 5, an auxiliary support pin 8, a guide rod 9, a motor mounting platform 10, a lead screw 11, a mounting platform column 12, an auxiliary support quick-assembly platform 14, and a lead screw slider 21. The auxiliary support unit is mounted on the base plate 7 via the auxiliary support quick-assembly platform 14. The motor mounting platform 10 and the auxiliary support quick-assembly platform 14 are connected by the mounting platform column 12. The stepper motor 5 is mounted on the motor mounting platform 10, and its output shaft is connected to one end of the lead screw 11. The other end of the lead screw 11 is mounted on the auxiliary support quick-assembly platform 14. The auxiliary support plate 2 is connected to one end of the auxiliary support guide rod 3 and the auxiliary support connecting rod 4. The other end of the auxiliary support guide rod 3 is mounted on the guide rod 9 of the motor mounting platform 10. Inside the hole, the other end of the auxiliary support rod 4 is connected to the lead screw slider 21; the auxiliary support pin 8 is made of high-damping metal rubber and is installed on the auxiliary support plate 2 to achieve adjustable circumferential distribution density or preset radial angle intervals; the auxiliary support pin 8 applies a supporting force pointing towards the axis of the fixture to the large rotary thin-walled part 1 to be processed, adapting to the processing of large rotary thin-walled parts 1 of different sizes; the position of the auxiliary support pin 8 along the height direction of the auxiliary support plate 2 is adjustable and is set in the easily deformable area and the position corresponding to the easily chattering area of ​​the large rotary thin-walled part 1 to be processed; the two ends of the guide rod 9 are connected to the auxiliary support quick-mount table 14 and the motor mounting table 10 respectively; the lead screw slider 21 has a through hole, which is fitted onto the lead screw 11 and the guide rod 9 and is clearance-fitted with both.

[0009] The vibration monitoring unit includes a pressure sensor 20 and a vibration sensor 19, which are arranged close to or overlapping with the auxiliary support guide rod 3 to monitor the main dynamic compensation force.

[0010] The deformation monitoring unit includes a displacement sensor 18, which is positioned away from the auxiliary support guide rod 3 to provide additional stability support.

[0011] The base plate 7 is mounted on two support bearings 16 connected by bearing connecting rings 15 to prevent wires from getting tangled during the turning process.

[0012] The auxiliary support unit is controlled by a stepper motor 5 driving a lead screw 11 to open and close the entire auxiliary support unit, thereby achieving high-precision position adjustment, support force control, and response speed.

[0013] The displacement sensor 18, vibration sensor 19, and pressure sensor 20 are embedded in the contact end of the auxiliary support nail 8.

[0014] The control system is based on an established force-deformation-chatter mapping model and predicts the deformation and vibration trends of the large rotating thin-walled part 1 to be processed based on real-time monitoring data. When the deformation detected in real time exceeds 1 mm or chatter occurs, a feedback signal is promptly given to drive the stepper motor 5 to adjust the support force, thereby reducing deformation or suppressing chatter. The control system calculates the required optimal support force in real time based on the feedback signal from the deformation monitoring unit, combined with the mechanical properties of the workpiece material and processing parameters.

[0015] The method for machining large rotary thin-walled parts using the adaptive support fixture includes the following steps:

[0016] a) Initial positioning is provided by positioning ring 13;

[0017] b) Start the control system to open the auxiliary support unit to contact the inner surface of the large rotary thin-walled part 1 to be processed, and achieve the final positioning of the large rotary thin-walled part 1 to be processed.

[0018] c) The large rotary thin-walled part 1 to be processed is clamped in the clamping unit 6;

[0019] d) Begin turning;

[0020] e) During the processing, the deformation monitoring unit detects the deformation of the large rotary thin-walled part 1 to be processed in real time, and the vibration monitoring unit monitors the vibration and feeds the signal back to the control system.

[0021] f) The control system generates control commands in real time based on the received feedback signals and the preset control algorithm;

[0022] g) Control commands drive the auxiliary support unit to dynamically adjust the support force of each support point in order to avoid flutter and compensate for the deformation of the large rotary thin-walled part 1 to be processed;

[0023] h) Continue with steps e)-g) until processing is complete.

[0024] The beneficial effects of this invention are:

[0025] (i) A ball-head tangential contact design is adopted to ensure precise contact between each support point and the workpiece surface. Finite element simulation analysis is used to identify areas of weak stiffness, and the layout and quantity of support units are optimized accordingly, significantly improving the overall structural stiffness of the workpiece during machining. This design effectively suppresses workpiece deformation and chatter during machining.

[0026] (ii) High damping material is used as auxiliary support, which can quickly absorb and attenuate the flutter energy when flutter occurs. This design effectively suppresses the flutter phenomenon during the processing.

[0027] (II) Integrating contact displacement sensors, vibration sensors, and force sensing systems, along with a self-developed closed-loop control algorithm, enables real-time monitoring of workpiece deformation and chatter frequency characteristics during processing. The system response time is less than 5ms, and the support force can be dynamically adjusted according to working conditions to control processing deformation within ±1mm, suppress chatter, and significantly improve product qualification rate.

[0028] (III) This technical solution upgrades the traditional passive support to an active intelligent support system, which can reduce manual adjustment time and increase production efficiency by 30% while ensuring processing accuracy, and has significant economic benefits and application value. Attached Figure Description

[0029] Figure 1 This is a flowchart of the clamping process of the present invention;

[0030] Figure 2 This is a schematic diagram of the device clamping assembly of the present invention;

[0031] Figure 3 This is a three-dimensional schematic diagram of the device of the present invention;

[0032] Figure 4 This is a schematic diagram of the auxiliary support unit of the present invention;

[0033] Figure 5 This is a front view of the device of the present invention;

[0034] Figure 6 This is a schematic diagram of the base assembly of the present invention;

[0035] Figure 7 This is a schematic diagram of the sensor installation layout of the present invention;

[0036] Figure 8 This is a schematic diagram of the sensor installation method of the present invention;

[0037] Figure 9 This is a simplified kinematic diagram of the auxiliary support unit mechanism of the present invention;

[0038] Figure 10 This is a schematic diagram of the functional modules of the control system of the present invention.

[0039] In the diagram: 1. Large rotary thin-walled part to be processed; 2. Auxiliary support plate; 3. Auxiliary support guide rod; 4. Auxiliary support connecting rod; 5. Stepper motor; 6. Clamping unit; 7. Base plate; 8. Auxiliary support nail; 9. Guide rod; 10. Motor mounting platform; 11. Lead screw; 12. Mounting platform column; 13. Positioning ring; 14. Auxiliary support quick-release platform; 15. Bearing connecting ring; 16. Support bearing; 17. Electric slip ring; 18. Displacement sensor; 19. Vibration sensor; 20. Pressure sensor; 21. Lead screw slider. Detailed Implementation

[0040] The specific embodiments of the present invention will be further described below with reference to the accompanying drawings and technical solutions.

[0041] like Figures 2-6 As shown, this embodiment of the invention discloses an adaptive support fixture for chatter suppression and deformation monitoring in the turning of large rotary thin-walled parts, including a base plate 7, a clamping unit 6, a positioning ring 13, an auxiliary support unit, a deformation monitoring unit, a vibration monitoring unit, a support force monitoring unit, and a control system.

[0042] The base plate 7 is fixedly mounted on the lathe to support other parts of the adaptive support fixture; 12 clamping units 6 are located at the upper edge of the base plate 7 to clamp the reference end face of the large rotary thin-walled part 1 to be processed; a positioning ring 13 is located on the base plate 7, inside the clamping unit 6, to determine the reference position of the large rotary thin-walled part 1 to be processed and restrict its degrees of freedom; an auxiliary support unit is located at the center of the base plate 7 to support the inner surface of the large rotary thin-walled part 1 to be processed and provide dynamic auxiliary support force; a vibration monitoring unit and a deformation monitoring unit are located on the auxiliary support unit to monitor the deformation and chatter of the large rotary thin-walled part 1 to be processed in real time during the processing. The auxiliary support unit and vibration monitoring unit transmit the deformation and vibration monitoring results to the computer via the slip ring 17. Based on the monitoring results, the support force of the large rotary thin-walled part 1 to be processed is adjusted in a timely manner to ensure that the auxiliary support unit provides appropriate support force, forming a closed loop. The control system is connected to the auxiliary support unit, deformation monitoring unit, support force monitoring unit, vibration monitoring unit and motion feedback unit. The control system receives deformation signals from the deformation monitoring unit and frequency domain signals from the vibration monitoring unit, generates control commands according to the preset control algorithm, and dynamically adjusts the support force provided by the auxiliary support unit to achieve chatter suppression and active compensation for the deformation of the large rotary thin-walled part 1 to be processed during the processing.

[0043] like Figure 4As shown, the auxiliary support unit mainly consists of an auxiliary support plate 2, an auxiliary support guide rod 3, an auxiliary support connecting rod 4, a stepper motor 5, an auxiliary support pin 8, a guide rod 9, a motor mounting platform 10, a lead screw 11, a mounting platform column 12, an auxiliary support quick-assembly platform 14, and a lead screw slider 21. The auxiliary support unit is mounted on the base plate 7 via the auxiliary support quick-assembly platform 14. The motor mounting platform 10 and the auxiliary support quick-assembly platform 14 are connected by the mounting platform column 12. The stepper motor 5 is mounted on the motor mounting platform 10, and its output shaft is connected to one end of the lead screw 11. The other end of the lead screw 11 is mounted on the auxiliary support quick-assembly platform 14. The auxiliary support plate 2 is connected to one end of the auxiliary support guide rod 3 and the auxiliary support connecting rod 4. The other end of the auxiliary support guide rod 3 is mounted on the motor mounting platform 10. Inside the guide hole, the other end of the auxiliary support rod 4 is connected to the lead screw slider 21; the auxiliary support pin 8 is made of high-damping metal rubber and is installed on the auxiliary support plate 2 to achieve adjustable circumferential distribution density or preset radial angle intervals; the auxiliary support pin 8 applies a supporting force pointing towards the axis of the fixture to the large rotary thin-walled part 1 to be processed, adapting to the processing of large rotary thin-walled parts 1 of different sizes; the position of the auxiliary support pin 8 along the height direction of the auxiliary support plate 2 is adjustable and is set in the easily deformable area and the position corresponding to the easily chattering area of ​​the large rotary thin-walled part 1 to be processed; the two ends of the guide rod 9 are connected to the auxiliary support quick-mount table 14 and the motor mounting table 10 respectively; the lead screw slider 21 has a through hole, which is fitted onto the lead screw 11 and the guide rod 9 and is clearance-fitted with both.

[0044] like Figure 5 As shown in Figure 6, the base plate 7 is mounted on two support bearings 16 connected by bearing connecting rings 15 to prevent wires from getting tangled during the turning process.

[0045] like Figure 7 As shown, the vibration monitoring unit includes a pressure sensor 20 and a vibration sensor 19, which are positioned close to or overlapping with the auxiliary support guide rod 3 to monitor the main dynamic compensation force. The deformation monitoring unit includes a displacement sensor 18, which is positioned away from the auxiliary support guide rod 3 to provide additional stability support.

[0046] like Figure 8 As shown, the displacement sensor 18, vibration sensor 19 and pressure sensor 20 are embedded in the contact end of the auxiliary support nail 8.

[0047] like Figure 9 As shown, the auxiliary support unit is controlled by a stepper motor 5 driving a lead screw 11 to open and close the entire auxiliary support unit, thereby achieving high-precision position adjustment, support force control, and response speed.

[0048] like Figure 10As shown, the control system is based on the established force-deformation-chatter mapping model and predicts the deformation and vibration trend of the large rotating thin-walled part 1 to be processed based on real-time monitoring data. When the deformation detected in real time exceeds 1 mm or chatter occurs, a feedback signal is promptly given to drive the stepper motor 5 to adjust the support force, thereby reducing deformation or suppressing chatter. The control system calculates the required optimal support force in real time based on the feedback signal from the deformation monitoring unit, combined with the mechanical properties of the workpiece material and processing parameters.

[0049] like Figure 1 As shown, the method for turning large rotary thin-walled parts using the adaptive support fixture includes the following steps:

[0050] a) Initial positioning is provided by positioning ring 13;

[0051] b) Start the control system to open the auxiliary support unit to contact the inner surface of the large rotary thin-walled part 1 to be processed, and achieve the final positioning of the large rotary thin-walled part 1 to be processed.

[0052] c) The large rotary thin-walled part 1 to be processed is clamped in the clamping unit 6;

[0053] d) Begin turning;

[0054] e) During the processing, the deformation monitoring unit detects the deformation of the large rotary thin-walled part 1 to be processed in real time, and the vibration monitoring unit monitors the vibration and feeds the signal back to the control system.

[0055] f) The control system generates control commands in real time based on the received feedback signals and the preset control algorithm;

[0056] g) Control commands drive the auxiliary support unit to dynamically adjust the support force of each support point in order to avoid flutter and compensate for the deformation of the large rotary thin-walled part 1 to be processed;

[0057] h) Continue with steps e)-g) until processing is complete.

[0058] It should be noted that the above description is only an embodiment of the present invention and is not intended to limit the present invention. Therefore, any modifications, equivalent substitutions, improvements, etc., within the equivalent meaning and scope of the claims of the present invention should be included within the protection scope of the present invention.

Claims

1. An adaptive support fixture for chatter suppression and deformation monitoring in the turning of large, rotating, thin-walled parts, characterized in that, The adaptive support fixture includes a base plate (7), a clamping unit (6), a positioning ring (13), an auxiliary support unit, a deformation monitoring unit, a vibration monitoring unit, a support force monitoring unit, and a control system; The base plate (7) is fixedly mounted on the lathe to support other parts on the adaptive support fixture; multiple clamping units (6) are set at the edge of the upper surface of the base plate (7) to clamp the reference end face of the large rotary thin-walled part (1) to be processed; the positioning ring (13) is set on the base plate (7) and located inside the clamping unit (6) to determine the reference position of the large rotary thin-walled part (1) to be processed and restrict its degree of freedom; An auxiliary support unit is located at the center of the base plate (7) to support the inner surface of the large rotary thin-walled part (1) to be processed, providing dynamic auxiliary support force. A vibration monitoring unit and a deformation monitoring unit are located on the auxiliary support unit to monitor the deformation and chatter of the large rotary thin-walled part (1) to be processed in real time during the processing. The auxiliary support unit and the vibration monitoring unit transmit the monitoring results of deformation and vibration to the computer through an electric slip ring (17). The support force of the large rotary thin-walled part (1) to be processed is adjusted in a timely manner according to the monitoring results, so that the auxiliary support unit provides a suitable support force and forms a closed loop. The control system is connected to the auxiliary support unit, the deformation monitoring unit, the support force monitoring unit, the vibration monitoring unit and the motion feedback unit. The control system receives the deformation signal from the deformation monitoring unit and the frequency domain signal from the vibration monitoring unit. According to the preset control algorithm and the force-deformation-chatter mapping model, the control command is generated to dynamically adjust the support force provided by the auxiliary support unit, thereby realizing the suppression of chatter during the processing and the active compensation of the deformation of the large rotary thin-walled part (1) to be processed.

2. The adaptive support fixture according to claim 1, characterized in that, The auxiliary support unit mainly consists of an auxiliary support plate (2), an auxiliary support guide rod (3), an auxiliary support connecting rod (4), a stepper motor (5), an auxiliary support pin (8), a guide rod (9), a motor mounting platform (10), a lead screw (11), a mounting platform column (12), an auxiliary support quick-assembly platform (14), and a lead screw slider (21). The auxiliary support unit is mounted on the base plate (7) via the auxiliary support quick-assembly platform (14). The motor mounting platform (10) and the auxiliary support quick-assembly platform (14) are connected by the mounting platform column (12). The stepper motor (5) is mounted on the motor mounting platform (10), and its output shaft is connected to one end of the lead screw (11). The other end of the lead screw (11) is mounted on the auxiliary support quick-assembly platform (14). The auxiliary support plate (2) is connected to one end of the auxiliary support guide rod (3) and the auxiliary support connecting rod (4). The other end of the auxiliary support guide rod (3) is mounted on the motor mounting platform (14). Inside the guide hole of the machine mounting table (10), the other end of the auxiliary support connecting rod (4) is connected to the lead screw slider (21); the auxiliary support nail (8) is made of high damping material metal rubber, which is installed on the auxiliary support plate (2) to achieve adjustable distribution density along the circumference or with preset radial angle intervals; the auxiliary support nail (8) applies a support force pointing towards the axis of the fixture to the large rotary thin-walled part (1) to be processed, which is suitable for processing large rotary thin-walled parts (1) of different sizes; the position of the auxiliary support nail (8) along the height direction of the auxiliary support plate (2) is adjustable, and it is set in the easily deformable area and the position corresponding to the easily chattering area of ​​the large rotary thin-walled part (1) to be processed; the two ends of the guide rod (9) are connected to the auxiliary support quick-mount table (14) and the motor mounting table (10) respectively; the lead screw slider (21) has a through hole, which is fitted onto the lead screw (11) and the guide rod (9), and is clearance-fitted with both.

3. The adaptive support fixture according to claim 1, characterized in that, The vibration monitoring unit includes a pressure sensor (20) and a vibration sensor (19), which are set close to or overlapping with the auxiliary support guide rod (3) to monitor the main dynamic compensation force.

4. The adaptive support fixture according to claim 1, characterized in that, The deformation monitoring unit includes a displacement sensor (18) which is positioned away from the auxiliary support guide rod (3) to provide additional stability support.

5. The adaptive support fixture according to claim 1, characterized in that, The base plate (7) is mounted on two support bearings (16) that are connected by bearing connecting rings (15) to avoid the wires getting tangled during the turning process.

6. The adaptive support fixture according to claim 1, characterized in that, The auxiliary support unit is controlled by a stepper motor (5) driving a lead screw (11) to open and close the entire auxiliary support unit, thereby achieving high-precision position adjustment, support force control and response speed.

7. The adaptive support fixture according to claim 1, characterized in that, The displacement sensor (18), vibration sensor (19) and pressure sensor (20) are embedded in the contact end of the auxiliary support nail (8).

8. The adaptive support fixture according to claim 1, characterized in that, The control system is based on an established force-deformation-chatter mapping model, and predicts the deformation and vibration trends of the large rotating thin-walled part (1) to be processed based on real-time monitoring data; when the real-time monitored deformation exceeds 1mm or chatter occurs, The system provides feedback signals to drive the stepper motor (5) to adjust the support force, thereby reducing deformation or suppressing chatter. The control system calculates the required optimal support force in real time based on the feedback signals from the deformation monitoring unit, combined with the mechanical properties of the workpiece material and the processing parameters.

9. A method for turning large rotary thin-walled parts using the adaptive support fixture according to any one of claims 1-8, characterized in that, Including the following steps: a) Initial positioning is provided by positioning ring (13); b) Start the control system to open the auxiliary support unit to contact the inner surface of the large rotary thin-walled part (1) to be processed, and achieve the final positioning of the large rotary thin-walled part (1) to be processed; c) The large rotary thin-walled part (1) to be processed is clamped in the clamping unit (6); d) Begin turning; e) During the processing, the deformation monitoring unit detects the deformation of the large rotary thin-walled part (1) to be processed in real time, and the vibration monitoring unit monitors the vibration and feeds the signal back to the control system. f) The control system generates control commands in real time based on the received feedback signals and the preset control algorithm; g) Control commands drive the auxiliary support unit to dynamically adjust the support force of each support point in order to avoid flutter and compensate for the deformation of the large rotary thin-walled part to be processed (1); h) Continue with steps e)-g) until processing is complete.

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