基于能耗的铣削功率分析及切削参数多目标优化

Power Analysis and Multi-objective Cutting Parameter Optimization in Milling Based on Energy Saving

数控加工过程中的能源消耗与环境问题密切相关,为实现低碳制造,利用功率测试系统对机床加工过程中的功率进行实时记录,研究切削参数对机床功率的影响。首先,根据工业三相电的功率计算方法及数控机床中电能的分配情况设计了功率测试硬件的连接方法,并结合LabVIEW虚拟仪器编程完成了数控机床功率测试平台的搭建。然后,根据加工合金铸铁的推荐切削参数范围,运用响应曲面法设计了铣削实验,确定优化目标及约束条件,分析切削速度、每齿进给量、轴向切削深度和径向切削深度对机床加工过程功率的影响,并建立了切削参数与目标函数之间的回归方程和对应的响应面模型。最后,对回归方程进行优化,使其预测目标函数值更准确,同时对四个切削参数进行了优化,得到低碳高效的切削参数组合。实验结果表明:优化切削参数后,机床Y轴功率减小了11.34%,材料去除率MRR增大了9.96%;优化切削参数后提高了加工效率,降低了机床的功耗,能够实现缸体铣削过程的低碳高效化。

The power consumption in the process of CNC machining is closely related to the environmental issues.In order to realize the low-carbon and green machining,a power monitoring system is built up to record the power consumption in real-time.The influence of cutting parameters on machine tool power effect is studied experimentally.Hardware connection method of the monitoring system is designed based on the calculation theory of the industrial three-phase electric power and distribution of CNC machine electricity.Power consumption is calculated by the measured electricity and voltage through a LabVIEW program.According to the processing of alloy cast iron recommended cutting parameters,the milling experiments are carried out to build the relationship between the power consumption and process parameters by central composite design(CCD).The influence of cutting parameters to power consumption is analyzed quantitatively.Finally,the regression function is optimized to predict more accurately,optimal parameters combination which realizes low carbon are acquired as well.Experimental results indicate that,comparing with before optimization,the power consumption of Y axis reduces by 11.34%and material removing rate increases by 109.96%.Study of the parameters′optimization can improve the machining efficiency and realize the goal of high efficiency and low carbon machining.