Abstract
An optical free-form surface milling machine is designed according to the process characteristics and cutting force of optical components manufacturing. The Z-axis column of the milling machine is designed by a mechanical shunt. In this paper, based on the principle of multibody dynamics (MBD), a virtual prototype (VP) of the optical free-form surface milling machine was established by the ADAMS software. The Z-axis characteristics of the milling machine were simulated and studied, and a modal analysis was carried out to obtain the natural frequencies and vibration modes of the milling machine. The simulation results show that the Z-axis of the milling machine has excellent dynamic characteristics when the gravity balance device is not working. The average torque of the Z-axis motor is 0.5 N·m when the gravity balance device is working, the average torque of the Z-axis motor is 0.1 N·m, and the average torque is reduced by 80%; therefore, the gravity balance device can obviously lower the load of the Z-axis motor, and improve the efficiency of the milling machine.
Highlights
In the whole process chain of optical free-form surface machining, precision milling has a great influence on the surface and sub-surface quality of optical free-form surfaces, and its machining effect will directly determine the efficiency and feasibility of subsequent machining such as grinding and polishing
Based on ergonomics theory and product modeling design theory, an optical free-form surface milling machine using a mechanical shunt design for Z-axis columns is developed and a virtual prototype (VP) of the optical free-form surface milling machine is established based on the basic theory of multibody dynamics (MBD)
The optical free-form surface milling machine model is introduced into the ADAMS/View module to establish the virtual prototype of the Z-axis motor that is installed on the roof
Summary
In the whole process chain of optical free-form surface machining, precision milling has a great influence on the surface and sub-surface quality of optical free-form surfaces, and its machining effect will directly determine the efficiency and feasibility of subsequent machining such as grinding and polishing. This paper establishes a virtual prototype of the optical free-form surface milling machine, based on the model, the influence of the gravity balance device on the Z-axis dynamics of the milling machine was studied from a quantitative and qualitative perspective. Based on ergonomics theory and product modeling design theory, an optical free-form surface milling machine using a mechanical shunt design for Z-axis columns is developed and a virtual prototype (VP) of the optical free-form surface milling machine is established based on the basic theory of multibody dynamics (MBD). The obtained dynamic performance information of the optical free-form surface milling machine provides a theoretical reference for the selection of manufacturing process parameters, and, at the same time, provides data for the design of Z-axis components and the control system. The virtual prototype technology used in the design stage of a machine tool can obtain more accurate dynamic characteristic information than traditional design methods of a machine tool
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