CN109839895A - A kind of method that cutter geometrical structure parameter and working process parameter optimize jointly - Google Patents
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Abstract
The present invention provides a kind of method that cutter geometrical structure parameter and working process parameter optimize jointly, structural parameters, working process parameter and respective value range including determining cutter；Working process parameter orthogonal test and tool structure parameter orthogonal test are constructed in each value range, the cutting force data and cutting temperature data obtained according to two groups of orthogonal tests obtains cutting Force Model and the cutting temperature model；According to cutting Force Model and the cutting temperature model, cutter geometrical structure parameter optimization object function is constructed；According to editing objective to be optimized, the working process parameter that determination need to optimize constructs working process parameter optimization object function；According to above-mentioned two optimization object function, constructs common Optimized model and seek optimal solution, the corresponding value of tool structure parameter and working process parameter after being optimized.Implement the present invention, comprehensively considers each editing objective during actual processing, obtain optimal tool structure parameter and working process parameter.
Description
Technical Field
The invention relates to the technical field of machining, in particular to a method for jointly optimizing geometrical structure parameters and machining process parameters of a cutter.
Background
The design of the structural parameters of the cutter is very important for playing the advantages of the material performance of the cutter, and the good cutter structure can improve the processing efficiency by times. Similarly, whether the cutting process parameters are set reasonably or not is directly related to the processing efficiency and the production cost, and has decisive influence on the processing quality of the workpiece.
At present, the research on optimization of structural parameters and processing technological parameters of a cutter is very much, and the more representative methods include tinguo, golden swallow, Liu Pajie, Yulang, "testing and modeling of the forming milling force of a U71Mn steel rail", tool technology, 2018, 11 th stage, and pages 32-38; for another example, Zhang hong Yuan, Gu Yuan, Tang hong, the influence of "high speed milling process parameters on the milling force and surface morphology of AM50A magnesium alloy", school newspaper of northwest university of industry, 2018, phase 1, page 124 and 131; for another example, trekking, wangde and honour, "optimization research of turning parameters based on energy consumption and surface roughness", machine tool hydraulic pressure, 2018, phase 21, 136 and 140 pages; for another example, Zhaoshao Shujun, Zeng Guilin, Liu Zhong, Ma Shu text, "application of BP neural network in optimization of structure parameters of end mill", "combined machine tool and automatic processing technology", 2017, 6 th stage, pages 18-25, etc.
From the research, it can be found that the existing parameter optimization is only limited to the unilateral optimization of the tool structure parameters and the machining process parameters, and the tool structure parameters and the machining process parameters are not optimized simultaneously. Therefore, the method for researching the joint optimization of the geometric structure parameters and the machining process parameters of the cutter has important significance for comprehensively considering all machining targets (such as cutting force, cutting temperature, surface quality, cutter service life, material removal rate, machining cost and the like) in the actual machining process and fully playing the cutting performance of the cutter.
Disclosure of Invention
The technical problem to be solved by the embodiments of the present invention is to provide a method for jointly optimizing geometric parameters and machining process parameters of a tool, which can comprehensively consider each machining target in an actual machining process to obtain optimal structural parameters and machining process parameters of the tool.
In order to solve the above technical problem, an embodiment of the present invention provides a method for jointly optimizing geometric parameters and machining process parameters of a tool, including the following steps:
determining structural parameters and processing technological parameters of the cutter, and acquiring value ranges corresponding to the structural parameters and the processing technological parameters respectively;
constructing a machining process parameter orthogonal test and a cutter structure parameter orthogonal test in the value ranges corresponding to the obtained structural parameters and the machining process parameters respectively, and obtaining a cutting force model and a cutting temperature model by adopting an alternate fitting mode according to the cutting force and the cutting temperature obtained by the two sets of orthogonal tests; the orthogonal test of the processing technological parameters is that the structural parameters of the cutter are fixed, and n horizontal orthogonal tests are set for each processing technological parameter; the cutter structure parameter orthogonal test is characterized in that the processing technological parameters are fixed, and n horizontal orthogonal tests are set for each cutter structure parameter; n is a positive integer; (ii) a
According to the obtained cutting force model and cutting temperature model, a tool geometric structure parameter optimization objective function taking the minimum cutting force and the minimum cutting temperature as optimization objectives is constructed by utilizing a linear weighting method;
determining a plurality of processing targets to be optimized, determining processing technological parameters to be optimized according to the determined plurality of processing targets to be optimized, and further constructing an optimization objective function of the processing technological parameters by adopting a linear weighting method based on the determined plurality of processing targets to be optimized;
and constructing a common optimization model of the geometrical parameters of the tool and the processing technological parameters according to the geometrical parameter optimization objective function of the tool and the processing technological parameter optimization objective function of the tool, and solving the optimal solution of the common optimization model of the geometrical parameters of the tool and the processing technological parameters to obtain respective corresponding values of the optimized geometrical parameters of the tool and the processing technological parameters.
The value range of the structural parameters of the cutter is determined according to cutting processing experience and a cutter manual; the machining process parameters of the cutter are determined according to cutting and machining experiences, a machining process manual, machine tool constraints, cutter constraints and workpiece constraints.
The cutting force model is obtained by solving the cutting force data obtained by the orthogonal test of the processing technological parameters and the orthogonal test of the cutter structural parameters by a circulation method; wherein,
the specific steps of the cyclic solution adopted by the cutting force model are that firstly, a cutting force empirical formula is deduced according to the orthogonal test result of the processing technological parameters, the coefficients of the structural parameters of the cutter are increased on the premise of not changing the fixed coefficients of the processing technological parameters, and the coefficients of the structural parameters of the cutter are fitted by using the orthogonal test result of the structural parameters; then, fitting a new coefficient of the processing technological parameter again by using the orthogonal test result of the processing technological parameter without changing the fixed coefficient of the structural parameter of the cutter, fitting a coefficient of the structural parameter of the cutter by using the orthogonal test result of the structural parameter of the cutter without changing the exponential coefficient of the processing technological parameter; and repeating the orthogonal test of the machining process parameters and the orthogonal test of the structural parameters for multiple times alternately until the coefficients of the machining process parameters and the structural parameters in the empirical formula of the cutting force reach stable values, thereby obtaining the cutting force model.
The cutting temperature model is formed by fitting the cutting temperature data obtained by the orthogonal test of the processing technological parameters and the orthogonal test of the cutter structural parameters by adopting a quadratic nonlinear least square regression method.
Wherein the plurality of machining objectives to be optimized include surface quality, tool life, material removal rate, and machining cost.
The embodiment of the invention has the following beneficial effects:
according to the invention, the optimal cutter structure parameters and processing technological parameters are obtained by comprehensively considering all processing targets in the actual processing process.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is within the scope of the present invention for those skilled in the art to obtain other drawings based on the drawings without inventive exercise.
FIG. 1 is a flow chart of a method for tool geometry parameter and machining process parameter co-optimization according to an embodiment of the present invention;
fig. 2 is a flowchart of the optimal solution of the co-optimization model of the geometric parameters of the tool and the machining process parameters in step S5 in the method for co-optimizing the geometric parameters of the tool and the machining process parameters according to the embodiment of the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention will be described in further detail with reference to the accompanying drawings.
As shown in fig. 1, a method for jointly optimizing geometric parameters and machining process parameters of a tool according to an embodiment of the present invention includes the following steps:
step S1, determining structural parameters and processing technological parameters of the cutter, and acquiring value ranges corresponding to the structural parameters and the processing technological parameters respectively;
s2, constructing a machining process parameter orthogonal test and a cutter structure parameter orthogonal test in the value ranges corresponding to the acquired structural parameters and the acquired machining process parameters respectively, and acquiring a cutting force model and a cutting temperature model by adopting an alternate fitting mode according to the cutting force and the cutting temperature acquired by the two sets of orthogonal tests; the orthogonal test of the processing technological parameters is that the structural parameters of the cutter are fixed, and n horizontal orthogonal tests are set for each processing technological parameter; the cutter structure parameter orthogonal test is characterized in that the processing technological parameters are fixed, and n horizontal orthogonal tests are set for each cutter structure parameter; n is a positive integer;
step S3, according to the obtained cutting force model and cutting temperature model, a tool geometric structure parameter optimization objective function taking the minimum cutting force and the minimum cutting temperature as optimization objectives is constructed by utilizing a linear weighting method;
step S4, determining a plurality of processing targets to be optimized, determining processing technological parameters to be optimized according to the determined plurality of processing targets to be optimized, and further constructing an optimization objective function of the processing technological parameters by adopting a linear weighting method based on the determined plurality of processing targets to be optimized; (ii) a
And step S5, constructing a common optimization model of the geometrical parameters of the tool and the processing parameters according to the geometrical parameter optimization objective function of the tool and the processing parameters optimization objective function of the tool, and solving an optimal solution of the common optimization model of the geometrical parameters of the tool and the processing parameters to obtain respective corresponding values of the optimized geometrical parameters of the tool and the processing parameters.
Specifically, in step S1, the structural parameters and the machining process parameters of the tool are determined according to the structure and the machining conditions of the tool, and in the machining process, the structural parameters and the machining process parameters of the tool can only be valued within a range that satisfies the limiting conditions due to the limitation of machining equipment and the like. At this time, the value range of the structural parameter of the tool is determined according to the cutting processing experience and the tool manual, and the processing technological parameter of the tool is determined according to the cutting processing experience, the processing technological manual, the machine tool constraint, the tool constraint and the workpiece constraint.
In step S2, the tool configuration parameters are fixed, n levels are set for each machining process parameter, orthogonal tests of the machining process parameters are performed, then the machining process parameters are fixed, n levels are set for each tool configuration parameter, orthogonal tests of the tool configuration parameters are performed, and cutting force data and cutting temperature data of each set of the tests are recorded.
At the moment, the cutting force model comprehensively considers the cutter structure parameters and the processing technological parameters, and the model is obtained by solving the cutting force data obtained by the orthogonal test of the processing technological parameters and the orthogonal test of the cutter structure parameters by a circulation method; wherein,
the specific steps of the cyclic method solving adopted by the cutting force model are that firstly, a cutting force empirical formula is deduced according to the orthogonal test result of the processing technological parameters, the coefficients of the structural parameters of the cutter are increased on the premise of not changing the fixed coefficients of the processing technological parameters, and the coefficients of the structural parameters of the cutter are fitted by using the orthogonal test result of the structural parameters; then, fitting a new coefficient of the processing technological parameter again by using the orthogonal test result of the processing technological parameter without changing the fixed coefficient of the structural parameter of the cutter, fitting a coefficient of the structural parameter of the cutter by using the orthogonal test result of the structural parameter of the cutter without changing the exponential coefficient of the processing technological parameter; and repeating the orthogonal test of the machining process parameters and the orthogonal test of the structural parameters for multiple times alternately until the coefficients of the machining process parameters and the structural parameters in the empirical formula of the cutting force reach stable values, thereby obtaining the cutting force model.
Similarly, the cutting temperature model also comprehensively considers the cutter structure parameters and the processing technological parameters, and the model is formed by adopting a quadratic nonlinear least square regression fitting method according to cutting temperature data obtained by a processing technological parameter orthogonal test and a cutter structure parameter orthogonal test.
In step S3, a tool geometry parameter optimization objective function with minimum cutting force and minimum cutting temperature as optimization objectives is established by a linear weighting method.
In step S4, the actual machining condition is combined, the machining process parameter to be optimized is determined according to the multiple machining targets to be optimized (surface quality, tool life, material removal rate, machining cost), and an optimization objective function of the machining process parameter is constructed by using a linear weighting method based on the multiple machining targets to be optimized. .
In step S5, a common optimization model of the geometric parameters of the tool and the machining process parameters is established according to the geometric parameter optimization objective function of the tool and the machining process parameter optimization objective function of the tool, and the optimal structural parameters of the tool and the machining process parameters during comprehensive consideration are obtained by a cyclic method, where the optimization process is shown in fig. 2. It should be noted that the optimization process adopts a common convergence algorithm, belongs to a common technical means, and is not described herein again.
It can be understood that the common optimization model of the geometric structure parameters and the machining process parameters of the tool can adjust the optimization weights of the targets according to different optimization targets to obtain the optimal structure parameters and the machining process parameters under specific requirements, and when the machine tool, the tool material and the workpiece material change, only the corresponding coefficients of the objective function and the constraint condition need to be adjusted, and the optimization can be applied to a new optimization problem.
Taking the milling of aviation aluminum alloy 7075 by a hard alloy cutter as an example, an application scenario of the method for jointly optimizing geometric structure parameters and machining process parameters of the cutter in the embodiment of the invention is further explained as follows:
1. because of the limitation of processing equipment and the like, the structural parameters and the processing technological parameters can only be valued within the range meeting the limitation conditions, and the following constraint conditions are determined:
(1) surface roughness constraint
In the formula, RamaxRoughness is required for maximum.
(2) Constraint of milling speed
v≥vhigh
In the formula, vhighThe lowest speed of high-speed milling.
(3) Constraint of machining allowance
apmin≤ap≤apmax
In the formula, apmin，apmaxRespectively the minimum and maximum allowable axial cutting depths.
(4) Machine tool spindle speed constraint
nmin≤n≤nmax
In the formula, nmin，nmaxThe cutting speed and the main shaft of the machine tool have the following relations respectively with the lowest rotating speed and the highest rotating speed allowed by the machine tool:the cutting speed constraint can be expressed as follows:
(5) machine tool feed rate constraint
vfmin≤vf≤vfmax
In the formula, vfmin，vfmaxA minimum feed speed and a maximum feed speed provided for the machine tool, respectively. The following relationship exists between the feeding speed of the machine tool and the feeding amount per tooth of the cutter: v. off＝fz×FfXn, the feed rate per tooth can be expressed as follows:
(6) machine tool spindle torque restraint
In the formula, MmaxD is the diameter of the tool, which is the maximum torque allowed by the spindle of the machine tool.
(7) Machine tool effective power constraint
Wherein η is the machine tool transmission efficiency, PmaxThe maximum power of the machine tool motor.
(8) Axial cut depth restraint
The depth of cut of the tool must be less than the length of the edge or else cause the machining to terminate, as expressed below:
ap≤Lr
in the formula, LrThe edge length of the cutter.
(9) Radial cut depth constraint
Because of the tool diameter limitation, the radial cut should be less than or equal to the tool diameter, or otherwise cause a discontinuity in the machining, as expressed below:
ae≤d
(10) tool stiffness constraint
In the formula, FrFor radial cutting force, l is the overhang length, E is the modulus of elasticity of the tool, I is the moment of inertia, δmaxThe maximum deformation allowed for the tool.
(11) Tool life constraint
For the cutter, the set processing technological parameters must enable the cutter to have a certain service life, otherwise, the cutter is damaged quickly, which is not beneficial to reducing the production cost and the production time. Therefore, the service life of the tool must be longer than a certain minimum service time after the processing technological parameters are set, as follows:
Tlife≤Tlifemin
(12) cutting temperature restraint
Cutting temperature directly affects tool wear and workpiece surface quality, and thermal stress generated by discontinuous cutting in the cutting process can accelerate fatigue failure and wear of the tool. There is a complex exponential relationship between the cutting temperature and the machining process parameters, and the constraint condition of the cutting temperature can be expressed as follows:
Kxvd1fz d2ap d3ae d4≤Txmax
in the formula, KxD1, d2, d3 and d4 are corresponding coefficients respectively.
2. Fixing machining process parameters, setting 4 levels for each cutter structure parameter, performing an orthogonal test 1, fixing the cutter structure parameters, setting 4 levels for each machining process parameter, performing an orthogonal test 2, recording the cutting force and the cutting temperature of each group of tests, and calculating a general new model of the cutting force by a circulation method, wherein the model expression is as follows:
in the formula, a0，d0Is a constant number, ai，bi，ci,，di,，ei，fi(i is 1,2,3,4) is a coefficient of each parameter.
3. According to the results of the orthogonal test, a quadratic nonlinear least square regression fitting is adopted to obtain a cutting temperature general new model, and the model expression is as follows:
in the formula, g0Is a constant number, gi，mi，ni(i is 1,2,3,4) is a coefficient of each parameter.
4. Establishing a tool geometric structure parameter optimization objective function taking the minimum cutting force and the minimum cutting temperature as optimization objectives by adopting a linear weighting method, wherein the function expression is as follows:
f＝min[k1F0/F(xi)+k2T0/T(xi)]
5. when processing aviation aluminum alloy, the balance among surface quality, cutter life, material removal rate and processing cost needs to be realized.
(1) The quality of the machined surface of the aviation aluminum alloy is one of the main parameters for judging the quality of the workpiece, and the roughness of the surface of the workpiece is preferably smaller. According to the experimental study of the surface roughness of workpieces by a plurality of scholars, the general mathematical model of the quality R of a machined surface is as follows:
in the formula, CR，c1，c2，c3，c4Respectively, corresponding influence coefficients.
(2) When an aviation aluminum alloy workpiece is machined, the surface quality of the workpiece is reduced due to the failure of a cutter, so that the fatigue property, the strength and other material mechanical properties of the part are reduced, and the service life of an airplane is shortened. Tool failure also increases the time for tool change adjustment, and contributes to a greater proportion of the total machining cost. According to Taylor's formula, the tool life TlifeThe average replacement time of the cutter is determined, and the expression is as follows:
in the formula, Ctool，t1，t2，t3The coefficients are calculated by a test statistical method.
(3) In general, the material removal amount of an aviation aluminum alloy workpiece is very large, so the material removal rate of milling is necessarily taken as a target for milling optimization, and for the milling process, the material removal rate can be expressed as the rotation number n of a main shaft and the axial cutting depth apRadial cutting depth aeFeed per tooth fzAnd number of milling cutter teeth NfThe expression is as follows:
MRR＝n·ap·ae·fz·Nf
(4) the lowest machining cost means the lowest cost for producing each workpiece, and the production cost of a single workpiece can be calculated as follows:
in the formula, tct，tm，totThe cutting time, the tool changing time and the auxiliary time of the working procedure are respectively, T is the service life of the tool, and M is the depreciation cost and the whole-field expenditure of the machine tool in unit time.
6. The linear weighting method is adopted to establish a processing technology parameter optimization objective function, and the expression is as follows:
in the formula, w1，w2，w3，w4The weights of the machining efficiency, the cutter life, the machining cost and the surface quality are respectively, and the sum of the four weights is 1. MRR0，Tlife0，Cu0，R0Respectively machining efficiency, tool life, machining cost and cutting force before optimization.
7. On the basis of the research of the geometric structure parameter and the processing technology parameter model of the hard alloy cutter, a model for simultaneously optimizing the geometric structure parameter and the processing technology parameter of the milling cutter is established, and the expression is as follows:
Z＝[fmin(x)&Mmin(x)]
two optimization objects f of the common optimization objective Zmin(x) And Mmin(x) The constraint equations are different, the respective optimization targets are different, and the structural parameters and the processing technological parameters of the cutter are gradually optimized by adopting a circulation method. Under the set of optimized parameters, the cutting force, the cutting temperature, the surface quality of a workpiece, the service life of a cutter, the material removal rate and the processing cost are in reasonable ranges, and the set of optimized processing parameters has very good usability and is recommended to use. The common optimization model can adjust the optimization weight of each target according to different optimization targets so as to obtain the optimal cutter structure parameters and processing technological parameters under specific requirements.
The common optimization model established in this example is built according to the machine tool parameters used in the milling test and the machining process of milling the aviation aluminum alloy 7075 by the hard alloy cutter, and each coefficient in the model is set and specified in the machining range. When the machine tool, the cutter material and the workpiece material are changed, only the corresponding coefficients of the objective function and the constraint condition need to be adjusted, and the method can be applied to a new optimization problem. Therefore, the model established by the example has universality.
The embodiment of the invention has the following beneficial effects:
according to the invention, the optimal cutter structure parameters and processing technological parameters are obtained by comprehensively considering all processing targets in the actual processing process. It will be understood by those skilled in the art that all or part of the steps in the method for implementing the above embodiments may be implemented by relevant hardware instructed by a program, and the program may be stored in a computer-readable storage medium, such as ROM/RAM, magnetic disk, optical disk, etc.
While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.
Claims (5)
1. A method for jointly optimizing geometrical structure parameters and machining process parameters of a cutter is characterized by comprising the following steps:
determining structural parameters and processing technological parameters of the cutter, and acquiring value ranges corresponding to the structural parameters and the processing technological parameters respectively;
constructing a machining process parameter orthogonal test and a cutter structure parameter orthogonal test in the value ranges corresponding to the obtained structural parameters and the machining process parameters respectively, and obtaining a cutting force model and a cutting temperature model by adopting an alternate fitting mode according to the cutting force and the cutting temperature obtained by the two sets of orthogonal tests; the orthogonal test of the processing technological parameters is that the structural parameters of the cutter are fixed, and n horizontal orthogonal tests are set for each processing technological parameter; the cutter structure parameter orthogonal test is characterized in that the processing technological parameters are fixed, and n horizontal orthogonal tests are set for each cutter structure parameter; n is a positive integer;
according to the obtained cutting force model and cutting temperature model, a tool geometric structure parameter optimization objective function taking the minimum cutting force and the minimum cutting temperature as optimization objectives is constructed by utilizing a linear weighting method;
determining a plurality of processing targets to be optimized, determining processing technological parameters to be optimized according to the determined plurality of processing targets to be optimized, and further constructing an optimization objective function of the processing technological parameters by adopting a linear weighting method based on the determined plurality of processing targets to be optimized;
and constructing a common optimization model of the geometrical parameters of the tool and the processing technological parameters according to the geometrical parameter optimization objective function of the tool and the processing technological parameter optimization objective function of the tool, and solving the optimal solution of the common optimization model of the geometrical parameters of the tool and the processing technological parameters to obtain respective corresponding values of the optimized geometrical parameters of the tool and the processing technological parameters.
2. The method for jointly optimizing geometric parameters and machining process parameters of a tool according to claim 1, wherein the range of values of the structural parameters of the tool is determined according to cutting and machining experience and a tool manual; the machining process parameters of the cutter are determined according to cutting and machining experiences, a machining process manual, machine tool constraints, cutter constraints and workpiece constraints.
3. The method for jointly optimizing geometric parameters and machining process parameters of a tool according to claim 1, wherein the cutting force model is obtained by solving the cutting force data obtained by the orthogonal test of the machining process parameters and the orthogonal test of the structural parameters of the tool by a circulation method; wherein,
the specific steps of the cyclic solution adopted by the cutting force model are that firstly, a cutting force empirical formula is deduced according to the orthogonal test result of the processing technological parameters, the coefficients of the structural parameters of the cutter are increased on the premise of not changing the fixed coefficients of the processing technological parameters, and the coefficients of the structural parameters of the cutter are fitted by using the orthogonal test result of the structural parameters; then, fitting a new coefficient of the processing technological parameter again by using the orthogonal test result of the processing technological parameter without changing the fixed coefficient of the structural parameter of the cutter, fitting a coefficient of the structural parameter of the cutter by using the orthogonal test result of the structural parameter of the cutter without changing the exponential coefficient of the processing technological parameter; and repeating the orthogonal test of the machining process parameters and the orthogonal test of the structural parameters for multiple times alternately until the coefficients of the machining process parameters and the structural parameters in the empirical formula of the cutting force reach stable values, thereby obtaining the cutting force model.
4. The method for jointly optimizing geometric parameters and machining process parameters of a tool according to claim 1, wherein the cutting temperature model is fit by quadratic non-linear least squares regression based on the cutting temperature data obtained from the orthogonal test of machining process parameters and the orthogonal test of structural parameters of the tool.
5. The method of claim 1 wherein the plurality of machining objectives to be optimized include surface quality, tool life, material removal rate, and machining cost.
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