CN108673241B - Method for calculating energy consumption of numerical control machine tool in cutting stage - Google Patents
Method for calculating energy consumption of numerical control machine tool in cutting stage Download PDFInfo
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Abstract
The invention provides a method for calculating energy consumption of a numerical control machine tool in a cutting stage, which comprises the following steps of: 1) establishing a numerical control machine cutting specific energy calculation model according to the relation between the cutting parameters and the energy consumption of the numerical control machine and considering the influence of the cutter abrasion on the energy consumption of the machine tool, 2) carrying out a numerical control cutting experiment, measuring and calculating each undetermined coefficient in the numerical control machine cutting specific energy calculation model by means of a power analyzer, and 3) calculating the cutting specific energy of the numerical control machine according to the cutting parameters and the cutter abrasion energy by using the numerical control machine cutting specific energy calculation model obtained in the step 1) and the step 2) and calculating the energy consumption of the numerical control machine in the cutting stage according to the volume of the removed material for a group of new process parameters under the condition that the cutter material, the workpiece material and the processing mode. The method has the advantages that: the influence of no-load energy consumption of a main shaft of the numerical control machine tool and the influence of tool abrasion loss are comprehensively considered to calculate the energy consumption of the numerical control machine tool in the cutting stage, the calculation method is simple, and the calculation precision is high.
Description
Technical Field
The invention relates to an energy consumption calculation method for a numerical control machine tool, in particular to an energy consumption calculation method for a cutting stage numerical control machine tool.
Background
Global energy crisis and climate warming are becoming more severe. The numerical control machine tool is powerful in function and multiple in energy consumption parts, and mainly comprises a main shaft servo driving system, a feed shaft servo driving system, a cooling and lubricating system, a numerical control device and a PLC (programmable logic controller) part, and auxiliary systems such as a lighting device, a fan, a chip removal system and a tool changer. Computing the energy consumption of a numerically controlled machine tool based on machine tool components is very complex.
The working process of the numerical control machine tool can be divided into a cutting stage and a non-cutting stage. The numerical control machine tool energy consumption in the cutting stage only refers to the numerical control machine tool energy consumption in the material removing process. The non-cutting stage after the numerical control machine tool is started comprises auxiliary processes of tool changing, workpiece changing and the like. Therefore, on the premise of ensuring the processing quality, the smaller the energy consumption of the numerical control machine tool in the cutting stage, the better.
In the cutting stage, the energy consumption of the numerically controlled machine tool per unit volume of material removed is called the specific energy of cutting of the numerically controlled machine tool. If the cutting specific energy of the numerical control machine tool is known, the energy consumption of the numerical control machine tool in the cutting process can be calculated and predicted according to the cutting parameters and the material removal volume before the numerical control machining. Kara et al, in a paper "Unit Process engineering consistent modules for Material removal" published in academic journal "CIRP Annals-manufacturing technology" (2011 No. 1: P37-40), propose a method for producing a protein from a protein by using a protein-based protein mixtureEmpirical model Sec = C for numerical control machine tool cutting specific energy0+C1MRR, where Sec is the specific energy of cutting of the numerical control machine, MRR is the material removal rate, C0And C1Is a constant. The empirical model does not consider the no-load energy consumption of a main shaft of the numerical control machine tool and the influence of tool abrasion on the energy consumption of the numerical control machine tool.
In conclusion, how to simply and accurately calculate the energy consumption of the numerical control machine tool in the cutting stage according to the cutting parameters and the tool abrasion loss has important guiding significance for researching how to optimize the cutting parameters to reduce the energy consumption of the machine tool, and becomes a technical problem which needs to be solved urgently by technical personnel in the field.
Disclosure of Invention
The invention aims to provide a simple and accurate method for calculating the energy consumption of a numerical control machine tool in a cutting stage. The technical scheme is as follows: the method comprises the following steps: 1) establishing a numerical control machine cutting specific energy calculation model, 2) measuring and calculating each undetermined coefficient in the numerical control machine cutting specific energy calculation model by means of a power analyzer, and 3) calculating the energy consumption of the numerical control machine in the cutting stage according to cutting parameters and tool abrasion loss under the condition that the tool material, the workpiece material and the machining mode are the same.
The method is characterized in that:
in the step 1), cutting stage numerical control machine power PtotalDivided into standby power PidleCutting material power PcuttingMain shaft no-load power PsnoAnd has:
Pcutting=k0*MRR*(1+VB) (1)
wherein k is0Is constant and is related to the workpiece material and the cutter material; VB is the abrasion loss of the cutter; MRR is the material removal rate.
Psno=S*n+C (2)
Wherein n is the rotating speed of the main shaft of the numerical control machine; s and C are coefficients. Then
Ptotal=Pidle+Pcutting+Psno= Pidle+k0*MRR*(1+VB)+S*n+C (3)
Obtaining the cutting specific energy Sec of the numerical control machine tool:
Sec= Ptotal/MRR=k0*(1+VB)+S*n/MRR+(Pidle+C)/MRR= k0*(1+VB)+k1*n/MRR+k2/MRR (4)
wherein k is0、k1And k2Is the undetermined coefficient.
In step 2), each undetermined coefficient in a numerical control machine tool cutting specific energy calculation model is measured and calculated by means of a power analyzer, and after a tool material, a workpiece material and a machining mode are determined, a numerical control cutting experiment is carried out:
for each cutting process, measuring the energy consumption E of the numerical control machine tool from the beginning of cutting to the end of cutting at the power supply inlet end of the numerical control machine tool by using a power analyzer, and obtaining the cutting specific energy Sec = E/Q of the numerical control machine tool in the cutting process according to the energy consumption E of the numerical control machine tool and the volume Q of the removed material;
for each cutting process, respectively measuring the abrasion loss of the rear tool face of the tool before and after the cutting process, and taking an average value as the abrasion loss VB of the tool in the cutting process; according to the back draft apSide cutting amount aeCalculating the material removal rate MRR = a by the feeding speed Fp*ae*F。
Selecting more than 13 groups of cutting parameters to carry out a cutting experiment, substituting the tool wear extent VB, the material removal rate MRR, the main shaft rotating speed n and the numerical control machine tool cutting specific energy Sec into a formula (4) to obtain an over-determined equation set, and calculating a coefficient k to be determined based on a least square method0、k1And k2。
In the step 3), under the condition that the cutter material, the workpiece material and the processing mode are the same, for a group of new process parameters, firstly, the numerical control machine cutting specific energy Sec is calculated by using the numerical control machine cutting specific energy calculation model obtained in the step 1) and the step 2) according to the cutting parameters and the cutter abrasion loss, and then, the numerical control machine energy consumption E = Sec Q in the cutting stage is calculated according to the removed material volume Q.
Compared with the prior art, the invention has the advantages that: the influence of no-load energy consumption of a main shaft of the numerical control machine tool and the influence of tool abrasion loss are comprehensively considered to calculate the energy consumption of the numerical control machine tool in the cutting stage, the calculation method is simple, and the calculation precision is high.
Drawings
Fig. 1 is a flow chart of energy consumption calculation of the cutting stage numerical control machine tool of the invention.
FIG. 2 is a flow chart of the calculation of undetermined coefficients in the numerical control machine tool cutting specific energy calculation model.
Detailed Description
The invention is described in further detail below with reference to fig. 1 and 2.
In the step 1), according to the relation between the cutting parameters and the energy consumption of the numerical control machine tool and considering the influence of the abrasion of a cutter on the energy consumption of the machine tool, establishing a numerical control machine tool cutting specific energy calculation model:
Sec=k0*(1+VB)+k1*n/MRR+k2/MRR (5)
wherein Sec is the numerical control machine cutting specific energy; VB is the tool wear; n is the rotation speed of the main shaft of the numerical control machine; MRR is material removal rate; k is a radical of0、k1And k2Is the undetermined coefficient.
In step 2), each undetermined coefficient in a numerical control machine tool cutting specific energy calculation model is measured and calculated by means of a power analyzer, and after a tool material, a workpiece material and a machining mode are determined, a numerical control cutting experiment is carried out:
and for each cutting process, measuring the energy consumption E of the numerical control machine tool from the beginning of cutting to the end of cutting by using a power analyzer at the power supply inlet end of the numerical control machine tool, and obtaining the cutting specific energy Sec = E/Q of the numerical control machine tool in the cutting process according to the energy consumption E of the numerical control machine tool and the volume Q of the removed material.
For each cutting process, respectively measuring the abrasion loss of the rear tool face of the tool before and after the cutting process, and taking an average value as the abrasion loss VB of the tool in the cutting process; according to the back draft apSide cutting amount aeCalculating the material removal rate MRR = a by the feeding speed Fp*ae*F。
Selecting more than 13 groups of cutting parameters to carry out cutting experiments, substituting the tool wear VB, the material removal rate MRR, the spindle rotating speed n and the numerical control machine tool cutting specific energy Sec into a formula (5) to obtain an over-determined equationGroup, calculating a coefficient k to be determined based on a least square method0、k1And k2。
In the step 3), under the condition that the cutter material, the workpiece material and the processing mode are the same, for a group of new process parameters, firstly, the numerical control machine cutting specific energy Sec is calculated by using the numerical control machine cutting specific energy calculation model obtained in the step 1) and the step 2) according to the cutting parameters and the cutter abrasion loss, and then, the numerical control machine energy consumption E = Sec Q in the cutting stage is calculated according to the removed material volume Q.
The invention is realized in an XD-40A vertical numerical control milling machine. The milling workpiece is a 45# steel rectangular block 200mm multiplied by 150mm multiplied by 60mm, the cutter is a hard alloy end milling cutter with the diameter of 20mm, and a WT1800 power analyzer is adopted. And (3) carrying out 14 plane milling experiments, respectively measuring the wear loss of the rear cutter face of the milling cutter before and after processing in each experiment, and taking the average value as the wear loss VB of the milling cutter in the milling experiment. In each milling experiment, the energy consumption of the numerical control machine tool from the beginning to the end of cutting is measured at the power inlet end of the numerical control machine tool by using a power analyzer, and the energy consumption is divided by the volume of the material removed in the milling to obtain the cutting specific energy of the numerical control machine tool. The cutting parameters, the tool abrasion loss and the numerical control machine cutting specific energy in the experiment can be shown in table 1.
TABLE 1 milling test and actual measured cutter wear loss and numerical control machine tool cutting specific energy
Substituting 14 groups of data in the table 1 into a formula (5) to obtain an overdetermined equation set, and solving a coefficient to be determined based on a least square method as follows: k is a radical of0=5.0，k1=5.0，k2= 48195. The numerical control machine tool cutting specific energy calculation model is as follows:
Sec=5.0*(1+VB)+5.0*n/MRR+48195/MRR (6)
and under the condition that the cutter material, the workpiece material and the processing mode are the same, verifying the effectiveness of the numerical control machine tool energy consumption calculation method in the cutting stage by using a new set of cutting parameters, as shown in the table 2. Removing material volume when milling a layer of materialQ=1*200*150=30000 mm3. The numerical control machine tool cutting specific energy calculated by the formula (6) is 21.85J/mm3The calculated energy consumption of the cutting stage numerical control machine tool is 655.5 KJ; actually measured cutting specific energy of the numerical control machine tool is 21.76J/mm3The measured numerical control machine tool energy consumption in the cutting stage is 652.8 KJ. The calculation precision of the energy consumption of the cutting stage numerical control machine tool is 99.6 percent.
Table 2 verification test of the numerical control machine tool energy consumption calculation method at the established cutting stage
The invention comprehensively considers the influence of the no-load energy consumption of the main shaft of the numerical control machine tool and the abrasion loss of the cutter to calculate the energy consumption of the numerical control machine tool in the cutting stage, and has simple calculation method and high calculation precision. The invention is beneficial to various numerical control devices to select energy-saving processing parameters and reduce the energy consumption of the machine tool.
Claims (1)
1. A method for calculating energy consumption of a numerical control machine tool in a cutting stage comprises the following steps: 1) establishing a numerical control machine cutting specific energy calculation model, 2) measuring and calculating each undetermined coefficient in the numerical control machine cutting specific energy calculation model by means of a power analyzer, 3) calculating the energy consumption of the numerical control machine in a cutting stage according to cutting parameters and tool abrasion loss under the condition that a tool material, a workpiece material and a processing mode are the same, and the method is characterized in that:
in the step 1), according to the relation between the cutting parameters and the energy consumption of the numerical control machine tool and considering the influence of the abrasion of a cutter on the energy consumption of the machine tool, establishing a numerical control machine tool cutting specific energy calculation model:
Sec=k0*(1+VB)+k1*n/MRR+k2/MRR （1）
wherein Sec is the numerical control machine cutting specific energy; VB is the tool wear; n is the rotation speed of the main shaft of the numerical control machine; MRR is material removal rate; k is a radical of0、k1And k2Is the undetermined coefficient;
in step 2), each undetermined coefficient in a numerical control machine tool cutting specific energy calculation model is measured and calculated by means of a power analyzer, and after a tool material, a workpiece material and a machining mode are determined, a numerical control cutting experiment is carried out:
for each cutting process, measuring the energy consumption E of the numerical control machine tool from the beginning of cutting to the end of cutting at the power supply inlet end of the numerical control machine tool by using a power analyzer, and obtaining the cutting specific energy Sec = E/Q of the numerical control machine tool in the cutting process according to the energy consumption E of the numerical control machine tool and the volume Q of the removed material;
for each cutting process, respectively measuring the abrasion loss of the rear tool face of the tool before and after the cutting process, and taking an average value as the abrasion loss VB of the tool in the cutting process; according to the back draft apSide cutting amount aeCalculating the material removal rate MRR = a by the feeding speed Fp*ae*F；
Selecting more than 13 groups of cutting parameters to carry out a cutting experiment, substituting the tool wear extent VB, the material removal rate MRR, the main shaft rotating speed n and the numerical control machine tool cutting specific energy Sec into a formula (1) to obtain an over-determined equation set, and calculating a coefficient k to be determined based on a least square method0、k1And k2；
In the step 3), under the condition that the cutter material, the workpiece material and the processing mode are the same, for a group of new process parameters, firstly, the numerical control machine cutting specific energy Sec is calculated by using the numerical control machine cutting specific energy calculation model obtained in the step 1) and the step 2) according to the cutting parameters and the cutter abrasion loss, and then, the numerical control machine energy consumption E = Sec Q in the cutting stage is calculated according to the removed material volume Q.
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| CN109754332B (en) * | 2019-01-08 | 2022-08-09 | 西北工业大学 | Cutting force-based energy consumption model modeling method for machine tool milling process |
| CN109800541A (en) * | 2019-03-04 | 2019-05-24 | 山东理工大学 | Only material is removed when a kind of cylindrical turning than energy calculation method |
| CN109902448B (en) * | 2019-04-24 | 2022-05-17 | 西北工业大学 | Machine tool machining process energy consumption model modeling method considering cutter abrasion |
| CN110560921A (en) * | 2019-08-22 | 2019-12-13 | 浙江科技学院 | total energy consumption prediction method for laser cutting based on shortest distance |
| CN113601265B (en) * | 2021-09-01 | 2022-05-27 | 重庆科技学院 | Method for estimating energy consumption ratio of front tool face and rear tool face of cutter in machining |
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