臺灣博碩士論文加值系統

顫振(chatter)是在切削加工的過程中一種自發性的振動，會造成工件和刀具產生激烈振動，因此降低工件的表面精度、限制材料移除率更甚者使得刀具磨損或斷裂，此現象在加工細長型工件時更為明顯，因此若能抑制顫振則能提昇加工性能。
本研究針對車削細長型工件的顫振抑制問題加以探討，設計一個壓電致動刀具以取代傳統車刀，並設計適應性控制器，輸入控制電壓驅動壓電致動刀具，動態改變車削深度，達到抑制顫振的目的。
本文分別應用有限元素分析法及實驗模態分析法，鑑別出精確的切削力對工件位移、切削力及控制電壓對壓電致動刀具位移的轉移函數，以供設計控制器之用。
本文設計的適應性控制器採用回授式濾波型最小均方(Filtered-X LMS, FXLMS)演算法，由於在實際的車削過程中，工件的位移量不容易量測，本文以力量感測器量測切削力，並經由工件的模式估測工件的位移量，做為控制器的回授訊號。先以電腦模擬驗證控制系統的性能，再應用dSPACE建構一個實驗架構，包含實體的壓電致動刀具和電腦模擬的車削動態實驗架構，做進一步驗證。本文將車床改裝，以架設壓電致動刀具，進行實際的車削實驗。模擬及車削實驗結果顯示穩定邊界值皆有提昇，驗證提出的模式估測FXLMS適應性控制架構能有效抑制顫振。

Chatter is a self-excited vibration during machining that causes violent vibration between the tool and the workpiece. Chatter degrades surface finish, causes wear or breakage of tools and limits the material removal rate. This phenomenon is more conspicuous on slender workpiece. Therefore, the ability to suppress chatter can improve machining performance significantly. In this study, the chatter suppression problem is investigated for slender workpieces in turning. A tool holder driven by a piezoelectric actuator is designed and controlled. The adaptive controller may change the chip width dynamically by controller signal voltage for chatter suppression in the turning process.Experimental modal analysis and ANSYS finite-element modal analysis are carried out for obtaining accurate frequency response functions of the workpiece and the cutting tool for designing controllers.
An adaptive controller is designed using the feedback filtered-x least mean square (FXLMS) algorithm in this study. The displacement of the workpiece is not easy to measure. In this paper, we measured the cutting force by using the force sensor. The feedback signal of the controller used an estimated transfer function relating the cutting force to the displacement in the turning process Simulation results show that the FXLMS controller can effectively suppress chatter in turning. A hardware-in-the-loop experiment is setup with the real piezo-actuated tool holder in the simulated cutting dynamic loop. To proceed with the machining experiment, the lathe was refitted to mount the piezo-actuated tool holder. The experimental results also indicate that the model estimate FXLMS controller can improve machining performance.

中文摘要 i
Abstract ii
目錄 iii
表目錄 viii
第一章 緒論 1
1.1 前言 1
1.2 國內外相關研究 2
1.3 研究動機 4
第二章 顫振模式與適應性控制方法 6
2.1 車削的顫振模式 6
2.2 主動式壓電致動刀具控制系統 9
2.2.1未控制的壓電致動刀具車削顫振模式 9
2.2.2控制的壓電致動刀具車削顫振模式 10
2.2.3“工件模式估測”壓電致動刀具車削顫振模式 11
2.3 FXLMS適應性控制器設計 12
2.4 適應性控制理論 14
2.4.1 主動式適應控制器 14
2.4.2 數位濾波器 15
2.4.3最小均方(Least-Mean-Square，LMS)演算法 16
2.4.4濾波型最小均方(Filtered-X LMS，FXLMS)演算法 19
第三章 系統鑑別與切削力量測 22
3.1 車床轉接座及切削力量測結構設計 22
3.1.1 轉接座及切削力量測結構設計及分析 22
3.1.2 切削力量測裝置校正 24
3.2 壓電致動刀具模擬與系統鑑別 25
3.2.1 壓電致動刀具之有限元素分析 26
3.2.2 切削力對刀具位移的轉移函數 26
3.2.3 控制電壓對刀具位移的轉移函數 27
3.3 工件系統鑑別 28
第四章 壓電致動刀具控制器模擬 32
4.1控制器模擬 32
4.1.1 未控制的壓電致動刀具顫振模擬 32
4.1.2刀具位移回授控制的壓電致動刀具顫振模擬 33
4.1.3 工件模式估測控制的壓電致動刀具顫振模擬 34
4.2 即時控制模擬車削動態實驗 37
第五章 實際車削實驗與結果 41
5.1 壓電致動刀具車削實驗設備與架構 41
5.2 工件表面精度測量方法 43
5.3 傳統刀具車削實驗 46
5.4 未控制的壓電致動刀具車削實驗 50
5.5 工件模式估測FXLMS控制的壓電致動刀具車削實驗 54
5.6 實驗結果比較 58
第六章 結論 60
參考文獻 61
附錄 壓電致動元件驅動電路製作 64
A1 壓電致動元件驅動電路設計 64
A2 驅動電路模擬與實驗 66
A2.1 壓電驅動電路模擬 66
A2.2 驅動電路量測實驗 67

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