CN112100827A - Power consumption modeling method considering tool wear in machine tool milling process - Google Patents

Power consumption modeling method considering tool wear in machine tool milling process Download PDF

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CN112100827A
CN112100827A CN202010889022.3A CN202010889022A CN112100827A CN 112100827 A CN112100827 A CN 112100827A CN 202010889022 A CN202010889022 A CN 202010889022A CN 112100827 A CN112100827 A CN 112100827A
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power consumption
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吴宝海
徐健
张莹
谭淼龙
燕直
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Northwestern Polytechnical University
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Abstract

The invention relates to a power consumption modeling method for a machine tool milling process considering cutter abrasion, in particular to a method for introducing a milling force abrasion coefficient related to abrasion, correcting a milling force model, and calculating cutting power through the corrected milling force model considering cutter abrasion, so that a power consumption model for the machine tool milling process considering cutter abrasion is established, and the prediction precision of the power consumption model is greatly improved.

Description

Power consumption modeling method considering tool wear in machine tool milling process
Technical Field
The invention belongs to the field of machining, and relates to a power consumption modeling method for a machine tool milling process considering cutter abrasion.
Background
The machine manufacturing industry is an important prop industry of national economy in China. At present, the machinery manufacturing industry in China generally has the problems of high energy consumption, low efficiency and the like, and is a key focus field for implementing major strategies of energy conservation, emission reduction, environmental protection and the like in China. The numerical control machine tool is used as an energy consumption main body in the mechanical manufacturing industry, has multiple energy sources, and is complex and changeable in energy consumption characteristics and energy consumption flow, and has a large energy-saving optimization space. The cutter is a key component and a main consumable in the machining process, so that the research on the cutter abrasion is very important to prolong the service life of the cutter and reduce the energy consumption of a machine tool.
The document "Wang Q, Zhang D, Tang K, et al. energy management control model for milling process conditioning automatic load and its application [ J ]. The International Journal of Advanced machining Technology,2019,105(10): 4309. 4323." proposes a power consumption model modeling method for milling process of machine tool based on milling force, which uses milling force to calculate cutting power, thereby predicting total power consumption of milling process of machine tool, but does not consider The influence of tool wear on power consumption of machine tool, and influences The prediction result, so it is difficult to predict power consumption of machine tool in actual machining accurately.
Disclosure of Invention
The technical problem solved by the invention is as follows: in order to solve the problem that the prediction accuracy of an existing machine tool milling process energy consumption model modeling method is poor, the invention provides a power consumption modeling method of a machine tool milling process considering cutter abrasion, and particularly relates to a method for introducing a milling force abrasion coefficient related to cutter abrasion, correcting a milling force model, and calculating cutting power through the corrected milling force model, so that the power consumption model of the machine tool milling process considering cutter abrasion is established, and the prediction accuracy of the power consumption model is greatly improved. The method comprises the steps of firstly introducing a milling force wear coefficient related to cutter wear, correcting a milling force model, calculating cutting power through the corrected milling force model considering the cutter wear, further establishing an idle cutting power consumption model in machine tool machining and an auxiliary power consumption model generated along with cutting, and finally establishing a total power consumption model of the machine tool considering the cutter wear.
The technical scheme of the invention is as follows: the power consumption modeling method of the machine tool milling process considering tool abrasion is characterized by comprising the following steps of:
step one, a traditional milling force model is introduced, and the model does not consider tool abrasion;
dFt(ψ，z)＝KtedS+KtcStsinψdz
dFr(ψ，z)＝KredS+KrcStsinψdz
dFa(ψ，z)＝KaedS+KacStsinψdz
wherein dFt、dFr、dFaRespectively tangential, radial and axial cutting forces, K, acting on the height dz infinitesimalte、Kre、KaeExpressing the cutting edge force coefficient of the tool, Ktc、Krc、KacRepresenting the cutting force coefficient of the tool, dS representing the cutting edge infinitesimal length, dz representing the axial cutting depth infinitesimal length, StThe feed per tooth is expressed, psi represents the radial immersion angle of the cutting edge infinitesimal;
step two, introducing a milling force abrasion coefficient delta K related to abrasiontw、ΔKrwAnd obtaining a milling force model considering tool wear:
Figure BDA0002656364330000021
Figure BDA0002656364330000022
wherein
Figure BDA0002656364330000023
The tangential and radial cutting forces acting on the height dz infinitesimal after the cutter is worn are considered;
step three, dividing the power consumption of the milling process of the machine tool into idle cutting power consumption, cutting power consumption and extra load auxiliary power consumption generated along with cutting, and respectively carrying out modeling prediction on the three types of power consumption so as to calculate and predict the total power consumption of the milling process of the machine tool considering the cutter abrasion; the prediction model is as follows:
Ptotal＝Paircutting+Pcutting+Padd
wherein, PtotalRepresenting the total power consumption of the milling process, PaircuttingIndicating the power consumption of the undercut during the milling process, PcuttingRepresents the cutting power consumption during milling, PaddIndicating accompaniment in milling processAdditional load-assisted energy consumption with cutting;
step four, establishing a cutting power consumption model considering the milling process of the tool abrasion machine tool:
Figure BDA0002656364330000024
where r is the radius of the tool, n is the rotational speed of the machine spindle, f is the feed rate, Pcutting wCutting power to account for tool wear;
the milling power consumption model is as follows:
Figure BDA0002656364330000031
wherein
Figure BDA0002656364330000032
In order to average the power consumption of the cutting,
Figure BDA0002656364330000033
n is the number of teeth of the tool
Step five, establishing a free cutting power consumption model of the milling process of the machine tool, namely measuring the free cutting power consumption of the machine tool in a non-cutting state at different rotating speeds, fitting the obtained data, and establishing the free cutting power consumption model:
Paircutting＝f(n)
wherein n is the machine tool spindle speed, and f (n) is a unitary quadratic function expressed as n;
step six, establishing an additional load power consumption model of milling:
the fitting showed from the data that:
Figure BDA0002656364330000034
wherein C is0、C1The coefficients obtained for the experiment;
step seven, considering the power consumption model of the milling process of the machine tool with the cutter abrasion as follows:
Figure BDA0002656364330000035
effects of the invention
The invention has the technical effects that:
1. firstly, the milling force abrasion coefficient delta K related to the cutter abrasion is introducedtw、ΔKrwThe method comprises the steps of establishing a milling force model considering tool abrasion, further establishing an idle cutting power consumption model in machine tool machining and an auxiliary power consumption model generated along with cutting, and finally establishing a total power consumption model considering tool abrasion. Compared with the energy consumption model without considering the cutter abrasion in the background technology, the prediction precision of the energy consumption model of the machine tool milling process considering the cutter abrasion is higher than the actual processing fit degree, and the more serious the cutter abrasion is, the higher the prediction precision of the energy consumption model is.
2. The method considers the inevitable cutter wear factors in the actual machining into the milling power consumption model of the machine tool, has higher fitting degree with the actual machining, and has high application value to the actual mechanical production.
3. The method can also be used for monitoring the abrasion of the cutter in the actual production process and the like, and has wide application prospect.
Detailed Description
The technical scheme adopted by the invention for solving the technical problems is as follows: a power consumption modeling method for a milling process of a machine tool considering cutter abrasion is characterized by comprising the following steps:
step one, a traditional milling force model without considering tool wear is introduced:
Figure BDA0002656364330000041
wherein Kte、Kre、KaeExpressing the cutting edge force coefficient of the tool, Ktc、Krc、KacDenotes the coefficient of cutting force of the tool, dS denotes the cutting edgeInfinitesimal length, dz denotes the axial cutting infinitesimal length, StIndicating the feed per tooth and psi the radial dip angle of the cutting edge element.
Step two, introducing a milling force abrasion coefficient delta K related to abrasiontw、ΔKrwEstablishing a milling force model:
dFrw＝σ·VB·dS＝Eh·VB·dS＝ΔKrw·dS (2)
dFtw＝μ(dFrw)＝μ(Eh·VB)dS＝ΔKtw·dS (3)
where σ is the resilient surface contact stress, E is the modulus of elasticity, d is the material's resilience, and h is the thickness of the cutting layer.
A milling force model can be obtained that takes into account tool wear:
Figure BDA0002656364330000042
Figure BDA0002656364330000043
namely, it is
Figure BDA0002656364330000044
Figure BDA0002656364330000045
Wherein it can be seen that Δ Krw、ΔKrwAre related to flank wear VB.
Step three, dividing the power consumption of the milling process of the machine tool into idle cutting power consumption, cutting power consumption and extra load auxiliary power consumption generated along with cutting, and respectively carrying out modeling prediction on the three types of power consumption so as to calculate and predict the total power consumption of the milling process of the machine tool considering the cutter abrasion; the prediction model is as follows:
Ptotal＝Paircutting+Pcutting+Padd (8)
wherein, PtotalRepresenting the total power consumption of the milling process, PaircuttingIndicating the power consumption of the undercut during the milling process, PcuttingRepresents the cutting power consumption during milling, PaddRepresenting additional load-assisted energy consumption with cutting during the milling process.
Step four, establishing a cutting power consumption model considering the milling process of the tool abrasion machine tool:
Figure BDA0002656364330000051
namely, it is
Figure BDA0002656364330000052
Wherein r is the radius of the tool, n is the rotational speed of the machine tool spindle, and f is the feed speed.
The milling power consumption model is as follows:
Figure BDA0002656364330000053
wherein
Figure BDA0002656364330000054
In order to average the energy consumption for cutting,
Figure BDA0002656364330000055
n is the number of teeth of the tool
And step five, establishing a blank cutting power consumption model of the milling process of the machine tool, namely measuring blank cutting power consumption of the machine tool in a non-cutting state at different rotating speeds, and fitting the obtained data. Establishing a free-cutting power consumption model:
Paircutting＝f(n) (12)
wherein n is the rotation speed of the main shaft of the machine tool.
Step six, establishing an additional load power consumption model of milling:
the fitting showed from the data that:
Figure BDA0002656364330000056
wherein C is0The coefficients obtained by the experiment.
Step seven, considering the power consumption model establishment of the machine tool milling process considering the cutter abrasion:
Figure BDA0002656364330000057
in the embodiment, milling and slotting are taken as an example, and the material is high-temperature alloy GH 4169; the flat-bottom end mill with the cutter diameter of 10mm has the rotating speed of 400rpm and the feed amount per tooth of 0.03mm/r and 0.04 mm/r. And adopting a VMC-850 numerical control machining center for machining.
The modeling method of the power consumption model of the machine tool milling process considering the cutter abrasion comprises the following specific steps:
step one, a traditional milling force model without considering tool wear is introduced:
Figure BDA0002656364330000061
wherein Kte、Kre、KaeExpressing the cutting edge force coefficient of the tool, Ktc、Krc、KacRepresenting the cutting force coefficient of the tool, dS representing the cutting edge infinitesimal length, dz representing the axial cutting depth infinitesimal length, StIndicating the feed per tooth and psi the radial dip angle of the cutting edge element.
Step two, introducing a milling force abrasion coefficient delta K related to abrasiontw、ΔKrwEstablishing a milling force model:
dFrw＝σ·VB·dS＝Eh·VB·dS＝ΔKrw·dS (2)
dFtw＝μ(dFrw)＝μ(Eh·VB)dS＝ΔKtw·dS (3)
where σ is the resilient surface contact stress, E is the modulus of elasticity, d is the material's resilience, and h is the thickness of the cutting layer.
A milling force model can be obtained that takes into account tool wear:
Figure BDA0002656364330000062
Figure BDA0002656364330000063
namely, it is
Figure BDA0002656364330000064
Figure BDA0002656364330000065
Wherein it can be seen that Δ Krw、ΔKrwAre related to flank wear VB.
Step three, dividing the power consumption of the milling process of the machine tool into idle cutting power consumption, cutting power consumption and extra load auxiliary power consumption generated along with cutting, and respectively carrying out modeling prediction on the three types of power consumption so as to calculate and predict the total power consumption of the milling process of the machine tool considering the cutter abrasion; the prediction model is as follows:
Ptotal＝Paircutting+Pcutting+Padd (8)
wherein, PtotalRepresenting the total power consumption of the milling process, PaircuttingIndicating the power consumption of the undercut during the milling process, PcuttingRepresents the cutting power consumption during milling, PaddRepresenting additional load-assisted energy consumption with cutting during the milling process.
Step four, establishing a cutting power consumption model considering the milling process of the tool abrasion machine tool:
Figure BDA0002656364330000071
namely, it is
Figure BDA0002656364330000072
Wherein r is the radius of the tool, n is the rotational speed of the machine tool spindle, and f is the feed speed.
The milling power consumption model is as follows:
Figure BDA0002656364330000073
wherein
Figure BDA0002656364330000074
In order to average the energy consumption for cutting,
Figure BDA0002656364330000075
n is the number of teeth of the tool
And step five, establishing a blank cutting power consumption model of the milling process of the machine tool, namely measuring blank cutting power consumption of the machine tool in a non-cutting state at different rotating speeds, and fitting the obtained data. Establishing a free-cutting power consumption model:
Paircutting＝f(n) (12)
wherein n is the rotation speed of the main shaft of the machine tool.
Step six, establishing an additional load auxiliary power consumption model of milling:
the fitting showed from the data that:
Figure BDA0002656364330000076
wherein C is0The coefficients obtained by the experiment.
Step seven, considering the power consumption model establishment of the machine tool milling process considering the cutter abrasion:
Figure BDA0002656364330000077
application examples. The slotting machining of the high-temperature alloy GH4165 material is carried out on a VMC-850 numerical control machining center, the milling slotting is taken as an example, a flat-bottom end mill with the cutter diameter of 10mm is adopted, the rotating speed is 400rpm, the feeding amount of each tooth is 0.03mm/r and 0.04mm/r, and the milling process is verified by adopting the method.
(1) A conventional milling force model is cited that does not take into account tool wear:
according to the first step, the traditional milling force modeling without considering tool wear is carried out, and the cutting force model is as follows:
dFt(ψ，z)＝KtedS+KtcStsinψdz
dFr(ψ，z)＝KredS+KrcStsinψdz
dFa(ψ，z)＝KaedS+KacStsinψdz
according to the data obtained by milling groove milling experiment, K can be obtainedte＝73.08、Kre＝106.47、Ktc＝4169.1、Krc＝1074.9。
(2) Establishing a milling force model considering tool wear:
Figure BDA0002656364330000081
Figure BDA0002656364330000082
calibrating to obtain delta K according to data obtained by experimenttw＝0.6929VB-35.338，ΔKrw＝0.8272VB+1.5063。
(3) Establishing a cutting power consumption model considering the milling process of the tool wear machine tool:
according to the cutting force model, calculating an instantaneous cutting energy consumption model of milling
Figure BDA0002656364330000083
Wherein r is the radius of the tool, n is the rotational speed of the machine tool spindle, and f is the feed speed.
(4) Establishing a free cutting power consumption model of the milling process of the machine tool:
establishing a free-cutting power consumption model according to the fifth step, respectively measuring the power at different rotating speeds under the non-cutting state of the machine tool, and fitting to calculate the free-cutting power consumption model:
Paircutting＝0.00004x2+0.0656x+873.26
(5) establishing an additional load auxiliary power consumption model of milling:
and (5) establishing an additional load auxiliary power consumption model of milling according to the sixth step, wherein the additional load power consumption model is calculated as follows:
Figure BDA0002656364330000084
(6) establishing a total power consumption prediction model:
Figure BDA0002656364330000085
the method has the advantages that the accuracy obtained by predicting the power consumption of the numerical control machine tool in the milling process is higher, the method is more suitable for actual processing conditions, and compared with a power consumption model without considering the cutter abrasion, the prediction accuracy is obviously improved when the cutter abrasion is larger.
TABLE 1 comparison of Power consumption errors for different processing parameters
Figure BDA0002656364330000091

Claims (1)

1. The power consumption modeling method of the machine tool milling process considering tool abrasion is characterized by comprising the following steps of:
step one, a traditional milling force model is introduced, and the model does not consider tool abrasion;
dFt(ψ，z)＝KtedS+KtcSt sinψdz
dFr(ψ，z)＝KredS+KrcSt sinψdz
dFa(ψ，z)＝KaedS+KacSt sinψdz
wherein dFt、dFr、dFaRespectively tangential, radial and axial cutting forces, K, acting on the height dz infinitesimalte、Kre、KaeExpressing the cutting edge force coefficient of the tool, Ktc、Krc、KacRepresenting the cutting force coefficient of the tool, dS representing the cutting edge infinitesimal length, dz representing the axial cutting depth infinitesimal length, StThe feed per tooth is expressed, psi represents the radial immersion angle of the cutting edge infinitesimal;
step two, introducing a milling force abrasion coefficient delta K related to abrasiontw、ΔKrwAnd obtaining a milling force model considering tool wear:
Figure FDA0002656364320000011
Figure FDA0002656364320000012
wherein
Figure FDA0002656364320000013
The tangential and radial cutting forces acting on the height dz infinitesimal after the cutter is worn are considered;
step three, dividing the power consumption of the milling process of the machine tool into idle cutting power consumption, cutting power consumption and extra load auxiliary power consumption generated along with cutting, and respectively carrying out modeling prediction on the three types of power consumption so as to calculate and predict the total power consumption of the milling process of the machine tool considering the cutter abrasion; the prediction model is as follows:
Ptotal＝Paircutting+Pcutting+Padd
wherein, PtotalRepresenting the total power consumption of the milling process, PaircuttingIndicating the power consumption of the undercut during the milling process, PcuttingRepresents the cutting power consumption during milling, PaddRepresents the additional load auxiliary energy consumption accompanying cutting in the milling process;
step four, establishing a cutting power consumption model considering the milling process of the tool abrasion machine tool:
Figure FDA0002656364320000014
where r is the radius of the tool, n is the rotational speed of the machine spindle, f is the feed rate, Pcutting wCutting power to account for tool wear;
the milling power consumption model is as follows:
Figure FDA0002656364320000021
wherein
Figure FDA0002656364320000022
In order to average the power consumption of the cutting,
Figure FDA0002656364320000025
n is the number of teeth of the tool
Step five, establishing a free cutting power consumption model of the milling process of the machine tool, namely measuring the free cutting power consumption of the machine tool in a non-cutting state at different rotating speeds, fitting the obtained data, and establishing the free cutting power consumption model:
Paircutting＝f(n)
wherein n is the machine tool spindle speed, and f (n) is a unitary quadratic function expressed as n;
step six, establishing an additional load power consumption model of milling:
the fitting showed from the data that:
Figure FDA0002656364320000023
wherein C is0、C1The coefficients obtained for the experiment;
step seven, considering the power consumption model of the milling process of the machine tool with the cutter abrasion as follows:
Figure FDA0002656364320000024
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CN114714419A (en) * 2022-04-18 2022-07-08 青岛锐智智能装备科技有限公司 Chicken middle wing cutting device and cutting method thereof

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