AU2020100130A4 - Method for calculating net specific energy for material removal in cylindrical turning - Google Patents
Method for calculating net specific energy for material removal in cylindrical turning Download PDFInfo
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Abstract
The present invention provides a method for calculating a net specific energy for material removal in cylindrical turning, including the following steps: 1) establishing a calculation model for the net specific energy for material removal in cylindrical turning; 2) establishing a measurement method for the net specific energy for material removal in cylindrical turning; 3) calculating each undetermined coefficient in the calculation model for the net specific energy for material removal in cylindrical turning; and 4) calculating the net specific energy for material removal in cylindrical turning based on a turning parameter and a tool wear. The present invention first establishes the calculation model for the net specific energy for material removal in cylindrical turning based on a cutting power characteristic and a relationship between a cutting force and a turning parameter in cylindrical turning. Then the present invention establishes the measurement method for the net specific energy for material removal in cylindrical turning by using a power measurement instrument. The present invention calculates the undetermined coefficient in the model and calculates the net specific energy for material removal in cylindrical turning based on a cylindrical turning parameter and a tool wear. The present invention considers the influence of the turning parameter and the tool wear and has simplicity and high accuracy. The present invention has great significance for optimizing the turning parameter and the turning process to improve energy efficiency.
Description
METHOD FOR CALCULATING NET SPECIFIC ENERGY FOR MATERIAL REMOVAL IN CYLINDRICAL TURNING
TECHNICAL FIELD
The present invention relates to a method for calculating a net specific energy for material removal, and in particular, to a method for calculating a net specific energy for material removal in cylindrical turning.
BACKGROUND
Numerical control (NC) lathe is commonly used to machine the outer circle of shaft and disk parts, and is the most widely used NC machine tool. The main body of the NC lathe includes a spindle system, a feed movement system, a lathe body, a guide rail and a tool change system. The NC lathe consumes a lot of energy during turning. When the spindle system, the feed movement system, the tool change system and a coolant pump, etc. are not working after the NC lathe is started, the power of the NC lathe is called idle power of the NC lathe, which is a constant. Therefore, idle power consumption of the NC lathe depends on the working time of the machine, that is, the time from start to shutdown. The spindle system generally holds a workpiece for rotational movement. When the spindle system is rotating in an unloaded condition (without turning), the power consumed by the spindle system is called unloaded power of the spindle. The unloaded power of the spindle is closely related to the speed of the spindle. During turning, it is often necessary to pump a coolant to reduce the tool temperature and improve the surface quality of the workpiece. The power consumed by a coolant pump motor is constant.
The energy consumption of the NC lathe, the idle energy consumption of the NC lathe, the unloaded energy consumption of the spindle and the energy consumption of the coolant pump motor during NC turning are measured by using a power measurement instrument. The energy consumption of the coolant pump motor is zero in case of dry cutting. A net energy consumption for material removal in turning is obtained by deducting the idle energy consumption of the NC lathe, the unloaded energy consumption of the spindle and the energy consumption of the coolant pump motor from the energy consumption of the NC lathe. This calculation process requires multiple measurements with a multi-channel power measurement instrument, so that the calculation is complicated.
In turning, a ratio of the net energy consumption for material removal to a volume of a material removed is defined as a net specific energy for material removal. It is closely related to the turning parameters and tool status, and is an important index parameter for analyzing and optimizing the energy efficiency characteristics of the turning process.
The simple and accurate calculation of the net specific energy for material removal in cylindrical turning according to the turning parameters and tool wear status before turning has i
2020100130 24 Jan 2020 great significance to study the optimization of the turning parameters and turning process to improve energy efficiency. It has become an urgent technical problem for those skilled in the art.
SUMMARY
An objective of the present invention is to provide a simple and accurate method for calculating a net specific energy for material removal in cylindrical turning. The present invention has the following technical solutions. A method for calculating a net specific energy for material removal in cylindrical turning includes the following steps: 1) establishing a calculation model for the net specific energy for material removal in cylindrical turning; 2) establishing a measurement method for the net specific energy for material removal in cylindrical turning; 3) calculating each undetermined coefficient in the calculation model for the net specific energy for material removal in cylindrical turning; and 4) calculating the net specific energy for material removal in cylindrical turning based on a turning parameter and a tool wear.
Where:
in step 1), based on a cutting power characteristic and a relationship between a cutting force and a turning parameter in cylindrical turning, the calculation model for the net specific energy for material removal in cylindrical turning is established:
Unet = b x ap c x f1 x ne x (1 + w)f (1) where, Unet is the net specific energy for material removal in cylindrical turning; ap is a cutting depth; f is a feed speed; n is a spindle speed; w is a tool wear; b, c, d, e and f are undetermined coefficients;
in step 2), the measurement method for the net specific energy for material removal in cylindrical turning is established: first, using a power measurement instrument to measure, and calculating a net energy consumption for material removal in cylindrical turning; then calculating the net specific energy for material removal in cylindrical turning based on a volume of a material removed:
Enet Em ~ Eidle ~ Esu ~ Ecool (2)
Unet = Enet/Q (3) where, Enet is the net energy consumption for material removal in cylindrical turning; Em is an energy consumption of a numerical control (NC) lathe from the beginning of cylindrical turning to the end of turning; Eidie is an idle energy consumption of the NC lathe from the beginning of cylindrical turning to the end of turning; Esu is an unloaded energy consumption of a spindle of the NC lathe when the spindle rotates at a set speed in an unloaded condition from the beginning of cylindrical turning to the end of turning; ECOoi is an energy consumption of a coolant pump motor when a coolant is pumped from the beginning of cylindrical turning to the end of turning; the energy consumption ECOoi of the coolant pump motor is zero in case of dry cutting; Q
2020100130 24 Jan 2020 is a volume of a material removed in cylindrical turning, which is related to a turning parameter and a workpiece size;
in step 3), each undetermined coefficient in the calculation model for the net specific energy for material removal in cylindrical turning is calculated: determining a workpiece material and a tool material; for each cylindrical turning process, measuring a wear in a flank of a turning tool separately before and after machining, and taking an average value as the tool wear w in this cylindrical turning; selecting more than 13 sets of turning parameters to perform a cylindrical turning experiment, substituting the cutting depth ap, the feed speed f, the spindle speed n, the tool wear w, and the net specific energy Unet for material removal in cylindrical turning calculated by formulas (2) and (3) into formula (1) to obtain an overdetermined system, and calculating the undetermined coefficients b, c, d, e and f by using a least squares method;
in step 4), the net specific energy for material removal in cylindrical turning is calculated by formula (1) by using the same tool and workpiece materials as in step 3) according to the cutting depth ap, the feed speed f, the spindle speed n and the tool wear w.
Compared with the existing method, the present invention comprehensively considers the turning parameter and the tool wear status to calculate the net specific energy for material removal in cylindrical turning. The calculation method has simplicity and high calculation accuracy.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flowchart for calculating a net specific energy for material removal in cylindrical turning according to the present invention.
FIG. 2 is a flowchart for calculating an undetermined coefficient in a calculation model for calculating a net specific energy for material removal in cylindrical turning according to the present invention.
DETAILED DESCRIPTION
The present invention is described in further detail below with reference to FIG. 1 and FIG. 2.
In step 1), based on a cutting power characteristic and a relationship between a cutting force and a turning parameter in cylindrical turning, a calculation model for a net specific energy for material removal in cylindrical turning is established:
Unet = b x ap c x f1 x ne x (1 + w)f (1) where, Unet is the net specific energy for material removal in cylindrical turning; ap is a cutting depth; f is a feed speed; n is a spindle speed; w is a tool wear; b, c, d, e and f are undetermined coefficients.
In step 2), a measurement method for the net specific energy for material removal in
2020100130 24 Jan 2020 cylindrical turning is established: first, use a power measurement instrument to measure, and calculate a net energy consumption for material removal in cylindrical turning; then calculate the net specific energy for material removal in cylindrical turning based on a volume of a material removed:
Enet Em ~ Eidle ~ Esu ~ Ecool (2)
Unet = Enet/Q (3) where, Enet is the net energy consumption for material removal in cylindrical turning; Em is an energy consumption of a numerical control (NC) lathe from the beginning of cylindrical turning to the end of turning; Eidie is an idle energy consumption of the NC lathe from the beginning of cylindrical turning to the end of turning; Esu is an unloaded energy consumption of a spindle of the NC lathe when the spindle rotates at a set speed in an unloaded condition from the beginning of cylindrical turning to the end of turning; ECOoi is an energy consumption of a coolant pump motor when a coolant is pumped from the beginning of cylindrical turning to the end of turning; the energy consumption ECOoi of the coolant pump motor is zero in case of dry cutting; Q is a volume of a material removed in cylindrical turning, which is related to a turning parameter and a workpiece size.
In step 3), each undetermined coefficient in the calculation model for the net specific energy for material removal in cylindrical turning is calculated: determine a workpiece material and a tool material; for each cylindrical turning process, measure a wear in a flank of a turning tool separately before and after machining, and take an average value as the tool wear w in this cylindrical turning; select more than 13 sets of turning parameters to perform a cylindrical turning test, substitute the cutting depth ap, the feed speed f, the spindle speed n, the tool wear w, and the net specific energy Unet for material removal in cylindrical turning calculated by formulas (2) and (3) into formula (1) to obtain an overdetermined system, and calculate the undetermined coefficients b, c, d, e and f by using a least squares method.
In step 4), the net specific energy for material removal in cylindrical turning is calculated by formula (1) by using the same tool and workpiece materials as in step 3) according to the cutting depth ap, the feed speed f, the spindle speed n and the tool wear w.
The present invention was implemented by using a CKJ6163 NC lathe. The turned workpiece was a 45 # steel round rod with a diameter of 50 mm and a length of 200 mm. The turning tool was a CNMG120408 4025 carbide turning tool. A coolant was pumped during turning. A WT1800 power analyzer was used for power measurement and analysis. 14 cylindrical turning tests were carried out. In each test, a wear in a flank of the turning tool was measured separately before and after machining, and an average value was taken as a tool wear w in the turning test. Before the turning test, a power analyzer was used to measure an idle power of the 4
2020100130 24 Jan 2020
NC lathe, an unloaded power of a spindle at different speeds and a power of a coolant pump motor. The turning tests' parameter, tool wear and net specific energy for material removal are shown in Table 1.
Table 1 Tested and measured tool wear and net specific energy for material removal in turning
| Turning Test | Cutting Depth mm | Feed Speed mm/r | Spindle Speed r/min | Tool Wear mm | Measured Net Specific Energy for Material Removal J/mm3 |
| 1 | 0.3 | 0.2 | 600 | 0.1025 | 3.1272 |
| 2 | 0.3 | 0.25 | 700 | 0.1135 | 3.3462 |
| 3 | 0.3 | 0.3 | 800 | 0.1285 | 3.7770 |
| 4 | 0.6 | 0.15 | 600 | 0.1390 | 2.5103 |
| 5 | 0.6 | 0.2 | 450 | 0.1400 | 2.1237 |
| 6 | 0.6 | 0.25 | 800 | 0.1410 | 2.9832 |
| 7 | 0.6 | 0.3 | 700 | 0.1445 | 2.7863 |
| 8 | 1.1 | 0.2 | 800 | 0.1605 | 2.8206 |
| 9 | 1.1 | 0.25 | 450 | 0.1700 | 2.2192 |
| 10 | 1.1 | 0.3 | 600 | 0.1960 | 2.3526 |
| 11 | 1.5 | 0.15 | 800 | 0.2035 | 2.7110 |
| 12 | 1.5 | 0.2 | 700 | 0.2065 | 2.4318 |
| 13 | 1.5 | 0.25 | 600 | 0.2095 | 2.3335 |
| 14 | 1.5 | 0.3 | 450 | 0.2155 | 2.3601 |
The 14 sets of data in Table 1 were substituted into formula (1) to obtain an overdetermined system. Undetermined coefficients were calculated by using a least squares method as follows: b = 0.1011, c = -0.2615, d = 0.0643, e = 0.4625 and f = 2.10. A calculation model for the net specific energy for material removal based on the tool wear was:
Unet = 0.1011 x ap-°·2615 x ffi0643 x η0 4625 x (1 + w)210 (4)
A new set of turning parameters were used to verify the calculation accuracy of the method for calculating the net specific energy for material removal in the cylindrical turning. As shown in Table 2, a measured net specific energy for material removal was 3.0217 J/mm3, a net specific energy for material removal calculated by formula (4) was 2.8840 J/mm3, and a calculation accuracy was 95.4%. The cylindrical turning tests for 45 # steel prove that the calculation accuracy of the model is stable above 90%.
Table 2 Verification test of calculation model established for net specific energy for material removal in cylindrical turning
| Cutting Depth mm | Feed Speed mm/r | Spindle Speed r/min | Tool Wear mm | Measured Net Specific Energy for Material Removal J/mm3 | Calculated Specific Energy for Material Removal J/mm3 |
| 1.1 | 0.15 | 700 | 0.2495 | 3.0217 | 2.8840 |
The present invention comprehensively considers the influence of the turning parameter and
2020100130 24 Jan 2020 the tool wear to calculate the net specific energy for material removal in cylindrical turning. The calculation method has simplicity and high accuracy. The method of the present invention helps to optimize the turning parameter and the turning process to improve energy efficiency and achieve low-carbon manufacturing.
Claims (1)
1. A method for calculating a net specific energy for material removal in cylindrical turning, comprising the following steps: 1) establishing a calculation model for the net specific energy for material removal in cylindrical turning; 2) establishing a measurement method for the net specific energy for material removal in cylindrical turning; 3) calculating each undetermined coefficient in the calculation model for the net specific energy for material removal in cylindrical turning; and 4) calculating the net specific energy for material removal in cylindrical turning based on a turning parameter and a tool wear, wherein in step 1), based on a cutting power characteristic and a relationship between a cutting force and a turning parameter in cylindrical turning, the calculation model for the net specific energy for material removal in cylindrical turning is established:
Unet = b x ap c x f1 x ne x (1 + w)f (1) wherein, Unet is the net specific energy for material removal in cylindrical turning; ap is a cutting depth; f is a feed speed; n is a spindle speed; w is a tool wear; b, c, d, e and f are undetermined coefficients;
in step 2), the measurement method for the net specific energy for material removal in cylindrical turning is established: first, using a power measurement instrument to measure, and calculating a net energy consumption for material removal in cylindrical turning; then calculating the net specific energy for material removal in cylindrical turning based on a volume of a material removed:
Enet Em ~ Eidle ~ Esu ~ Ecool (2)
Unet = Enet/Q (3) wherein, Enet is the net energy consumption for material removal in cylindrical turning; Em is an energy consumption of a numerical control (NC) lathe from the beginning of cylindrical turning to the end of turning; Eidie is an idle energy consumption of the NC lathe from the beginning of cylindrical turning to the end of turning; Esu is an unloaded energy consumption of a spindle of the NC lathe when the spindle rotates at a set speed in an unloaded condition from the beginning of cylindrical turning to the end of turning; ECOoi is an energy consumption of a coolant pump motor when a coolant is pumped from the beginning of cylindrical turning to the end of turning; the energy consumption ECOoi of the coolant pump motor is zero in case of dry cutting; Q is a volume of a material removed in cylindrical turning, which is related to a turning parameter and a workpiece size;
in step 3), each undetermined coefficient in the calculation model for the net specific energy for material removal in cylindrical turning is calculated: determining a workpiece material and a tool material; for each cylindrical turning process, measuring a wear in a flank of a turning tool 7
2020100130 24 Jan 2020 separately before and after machining, and taking an average value as the tool wear w in this cylindrical turning; selecting more than 13 sets of turning parameters to perform a cylindrical turning experiment, substituting the cutting depth ap, the feed speed f, the spindle speed n, the tool wear w, and the net specific energy Unet for material removal in cylindrical turning calculated by formulas (2) and (3) into formula (1) to obtain an overdetermined system, and calculating the undetermined coefficients b, c, d, e and f by using a least squares method;
in step 4), the net specific energy for material removal in cylindrical turning is calculated by formula (1) by using the same tool and workpiece materials as in step 3) according to the cutting depth ap, the feed speed f, the spindle speed n and the tool wear w.
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201910160510.8A CN109800541A (en) | 2019-03-04 | 2019-03-04 | Only material is removed when a kind of cylindrical turning than energy calculation method |
| CN201910160510.8 | 2019-03-04 |
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| CN108673240A (en) * | 2018-07-24 | 2018-10-19 | 山东理工大学 | A kind of net material removal of numerical control milling based on tool abrasion is than energy computational methods |
| CN108673241B (en) * | 2018-07-30 | 2020-03-10 | 山东理工大学 | Method for calculating energy consumption of numerical control machine tool in cutting stage |
| CN108803495A (en) * | 2018-07-30 | 2018-11-13 | 山东理工大学 | Numerically controlled lathe energy consumption prediction technique when a kind of execution turnery processing program |
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