CN113601265B - Method for estimating energy consumption ratio of front tool face and rear tool face of cutter in machining - Google Patents
Method for estimating energy consumption ratio of front tool face and rear tool face of cutter in machining Download PDFInfo
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- CN113601265B CN113601265B CN202111022146.2A CN202111022146A CN113601265B CN 113601265 B CN113601265 B CN 113601265B CN 202111022146 A CN202111022146 A CN 202111022146A CN 113601265 B CN113601265 B CN 113601265B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
- B23Q17/00—Arrangements for observing, indicating or measuring on machine tools
- B23Q17/09—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool
- B23Q17/0952—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool during machining
- B23Q17/0957—Detection of tool breakage
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
- B23Q17/00—Arrangements for observing, indicating or measuring on machine tools
- B23Q17/09—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool
- B23Q17/0952—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool during machining
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- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
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Abstract
The invention discloses a method for estimating the energy consumption ratio of front and rear tool faces of a tool in machining, which comprises the steps of firstly setting working conditions to be analyzed, constructing a plurality of cutting tests according to the working conditions, and acquiring an energy consumption data array; and then constructing an energy consumption difference value array, calculating the energy consumption of the rear tool face under the working condition by fitting the relation between the energy consumption difference value and the cutting parameter, and finally calculating to obtain the energy consumption ratio of the rear tool face and the energy consumption ratio of the front tool face. The invention has the obvious effects that the proportion of the energy consumption of the front cutter face and the energy consumption of the rear cutter face of the cutter can be quantized, so that the energy consumption of the front cutter face and the rear cutter face of the cutter in the cutting process can be reflected visually, and important digital basis is provided for energy consumption separation in the machining process, optimization and optimization design of the cutter, cutter wear state analysis, cutter changing decision and the like.
Description
Technical Field
The invention relates to energy consumption in a machining process or machine tool, in particular to an evaluation method of the energy consumption ratio of front and rear tool faces of a tool.
Background
The machining amount is wide, and the huge energy consumption is accompanied. Analyzing and determining the energy consumption ratio in the machining process (the separation from the energy consumption is a problem in nature) has great significance for design, decision, optimization and the like related to energy saving.
Energy consumption separation in the machining process can be developed along two dimensions of time and space, physical components of a machining system and a machine tool are researched and analyzed in the spatial dimension, such as a cooling system, a main transmission system, a feeding system, a tool changing mechanism, a chip removal mechanism and the like, and energy consumption of each component is determined through ways of measurement, modeling and the like; in the time dimension, researches are carried out on energy consumption of a processing system or a machine tool in time periods of standby, starting, idle running, feeding, cutting and the like, and researches are also carried out on energy consumption separation of an energy transmission path (time sequence), for example, the energy consumption of a main transmission system of the machine tool is separated into energy consumption of a frequency converter, energy consumption of a motor, energy consumption of a mechanical transmission chain, energy consumption of a main shaft and the like. These studies are valuable and many of the results of the studies have been put to practical use.
However, at present, the energy entering the cutting area is generally processed as a whole without further separation, and the common practice is to use the output energy of the machine tool spindle as the input energy of the cutting area. The energy problem of the cutting area mainly relates to the energy consumption of the cutter in the process of removing the machining allowance of the workpiece, the energy consumption of the cutting area is separated, on one hand, the theoretical significance is provided for further clarifying the energy consumption constitution, and on the other hand, the practical significance is provided for the cutter optimization and optimization design, the cutter abrasion state analysis and cutter changing decision, the cutting amount optimization and the like.
Disclosure of Invention
Aiming at the problem of separation of energy consumption of a cutting area, the invention provides a method for separating the energy consumption of the cutting area into the energy consumption of a front cutter face and the energy consumption of a rear cutter face of a cutter, namely the energy consumption ratio of the front cutter face and the rear cutter face of the cutter can be determined; the method can particularly support tool optimization and optimization design, tool wear state analysis, tool changing decision and the like. The main technical scheme adopted is as follows:
a method for estimating the energy consumption ratio of front and rear tool faces of a tool in machining is characterized by comprising the following steps:
step one, setting the working condition (v) to be analyzedcg，apg，fg) Wherein v iscgIs cutting speed, apgFor the amount of cuttinggIs the feed amount;
step two, sequentially constructing a plurality of cutting tests according to the working condition, wherein the cutting test adopts the condition of (v)cg，apg，fi) Wherein:
i＝1，2，3…，n；
fi＝f1，f2，…，fn；
n≥6；
fi＝f1*i；
fg∈fi；
step three, performing a cutting test according to the setting, and recording a corresponding energy consumption data array E;
E＝(E1，E2，…，En)；
analysis of the operating conditions (v)cg，apg，fg) Corresponding energy consumption data is Eg，Eg∈Ei；
Step four, constructing an energy consumption difference array delta E;
ΔE＝(ΔE2，ΔE3，…，ΔEn)＝((E2-E1)，(E3-E2)，…，(En-En-1))；
step five, fitting delta EiAnd fiThe relationship of (1);
ΔEi＝G(fi)；
step six, calculating the energy consumption E of the rear cutter face under the working conditionb；
Eb＝E1-ΔE1＝E1-G(f1)；
Seventhly, calculating the energy consumption of the rear cutter face to c% and the energy consumption of the front cutter face to 1-c% under the working condition;
c％＝Eb/Eg×100％＝(E1-G(f1))/Eg×100％。
Detailed Description
The present invention is further illustrated by the following examples.
Example 1:
a method for estimating the energy consumption ratio of front and rear tool faces of a tool in machining comprises the following steps:
step one, setting the working condition (v) to be analyzedcg，apg，fg) Wherein v iscgIs the cutting speed, apgFor the amount of cuttinggIs the feed amount;
step two, constructing a plurality of cutting tests in sequence according to the working condition, wherein the cutting test adopts the condition of (v)cg，apg，fi) Wherein:
i＝1，2，3…，n；
fi＝f1，f2，…，fn；
n≥6；
fi＝f1*i；
fg∈fi；
step three, performing a cutting test according to the setting, and recording a corresponding energy consumption data array E;
E＝(E1，E2，…，En)；
analysis of the operating conditions (v)cg，apg，fg) Corresponding energy consumption data is Eg，Eg∈Ei；
Step four, constructing an energy consumption difference array delta E;
ΔE＝(ΔE2，ΔE3，…，ΔEn)＝((E2-E1)，(E3-E2)，…，(En-En-1))；
step five, fitting delta EiAnd fiThe relationship of (1);
ΔEi＝G(fi)；
sixthly, calculating the energy consumption E of the rear cutter face under the working conditionb；
Eb＝E1-ΔE1＝E1-G(f1)；
Seventhly, calculating the energy consumption of the rear cutter face to c% and the energy consumption of the front cutter face to 1-c% under the working condition;
c％＝Eb/Eg×100％＝(E1-G(f1))/Eg×100％。
example 2:
a method for estimating the energy consumption ratio of front and rear tool faces of a tool in machining is carried out according to the following steps:
step one, setting the working condition (v) to be analyzedcg，apg，fg) Wherein v iscgIs the cutting speed, apgFor carrying the amount of the knife fgIs the feed amount;
step two, constructing a plurality of cutting tests in sequence according to the working condition, wherein the cutting test adopts the condition of (v)cg，apg，fi) Wherein:
i＝1，2，3…，n；
fi＝f1，f2，…，fn；
n≥6；
fi＝f1*i；
fg∈fi；
fngreater than the maximum feed used by the tool;
the sequence of feed amounts fiCarrying out assignment construction under the conditions of considering the obtuse radius of the cutting edge of the cutter, the existence of negative chamfer and the range of feed amount;
step three, using the main cutting force FiRecording a corresponding main cutting force array F as energy consumption data;
F＝(F1，F2，…，Fn)；
analysis of the operating conditions (v)cg，apg，fg) Corresponding main cutting force of Fg，Fg∈Fi；
Step four, constructing a main cutting force difference value array delta F;
ΔF＝(ΔF2，ΔF3，…，ΔFn)＝((F2-F1)，(F3-F2)，…，(Fn-Fn-1))；
step five, fitting delta FiAnd fiThe relationship of (1);
ΔFi＝G(fi)＝Kfi bwherein:
k is a fitting coefficient, b is a fitting index, and the fitting index is obtained according to the measured main cutting force and the corresponding feed amount;
sixthly, calculating the main cutting force F of the rear cutter face under the working conditionb；
Fb＝F1-ΔF1＝F1-G(f1)＝F1-Kf1 b
Seventhly, calculating the energy consumption of the rear cutter face to c% and the energy consumption of the front cutter face to 1-c% under the working condition;
c％＝(F1-Kf1 b)/Fg×100％；
said main cutting force FiThe method can be measured or calculated according to the following formula:
wherein:
CFcis a coefficient related to a machining material, machining conditions and the like, and is obtained through a cutting experiment or by looking up a tool manual;
KFcobtaining the correction coefficient through a cutting experiment or by checking a tool manual;
XFcis apgThe index of (a) is obtained by cutting experiments or by looking up a tool manual;
YFcis fiObtained by cutting experiments or by looking up tool manuals;
nFcis v iscgObtained by cutting experiments or by looking up tool manuals.
Similarly, in step three, the energy J consumed by the machine tool spindle, the power W consumed by the machine tool spindle, the current a consumed by the machine tool spindle, or other data having a linear relationship with the main cutting force may be equal to the energy consumption data, and the subsequent steps may be performed.
Example 3:
based on the method of example 2, the following is described by taking an empirical formula of the excircle longitudinal turning index as an example. According to the manual of machining technology, turning 45 steel excircle longitudinally with carbide turning tool, taking CFc＝2650，KFc＝1.0，XFc＝1.0、YFc＝0.75、nFc＝-0.15；
At cutting speed v of the tool to be analyzedcg＝60m/min，apg＝2mm，fgThe energy consumption ratio of the front and rear cutter faces is 0.4 mm/r.
Construction of the feed quantity sequence fi＝0.1，0.2，0.3，0.4，0.5，0.6；
According to the formula
The calculated main cutting force array F is:
F＝(F1，F2，…，F6)＝(509.98，857.68，1162.50，1442.44，1705.22，1955.09)；
the main cutting force difference array Δ F constructed from the main cutting force array F is:
ΔF＝(ΔF2，ΔF3，…，ΔF6)＝(347.70，304.82，279.94，262.78，249.87)；
according to the formula Δ Fi＝G(fi)＝Kfi bThe formula constructed is:
ΔFi＝G(fi)＝Kfi b＝5.363·fi -0.300；
under the working condition, the energy consumption of the rear cutter face accounts for c% as follows:
c％＝(F1-Kf1 b)/Fg×100％＝(509.98-5.363·0.1-0.300)/1442.44×100％＝5.81％；
the energy consumption of the rake face is 1-c percent to 94.19 percent.
Theoretical basis: according to the cutting deformation theory, the metal material generates shearing deformation under the extrusion action of a cutter, and is divided into a first deformation area, a second deformation area and a third deformation area according to different deformation positions. The I deformation zone is a zone where the material generates shear slip deformation under the extrusion of a rake face and chips are generated; the second deformation area is formed by violent friction and further deformation of the chips under the pushing action of the front tool face, so that the chips are separated from the base material; the III deformation zone occurs between the flank face and the machined surface and is the deformation of the machined surface by the pressing and rubbing action of the flank face. From the origin of the forces of material deformation, the first deformation zone and the second deformation zone II can be classified as one type, both caused by the rake face, and the third deformation zone as another type, caused by the flank face. From the view of the usefulness or not of doing work, the function of doing work of the rake face is to make the material generate shearing slip to form the chip and further to separate the chip from the material matrix, and the part of work is useful and unavoidable; the flank work is to press and rub the machined surface, so that the machined surface generates phenomena of elastic-plastic deformation, work hardening, frictional heat and the like, and the work is useless and is expected to be as small as possible or even zero. Based on this, it is reasonable to divide the cutting zone energy consumption into rake face energy consumption and flank face energy consumption.
The energy consumption of the flank face is mainly used for resisting the elastic-plastic deformation of a workpiece caused by the flank face and the friction between the flank face and a processed surface, and the size of the flank face is related to the size of a contact surface, the geometrical form of the contact surface, the friction coefficient between a cutter and a material, the clearance angle of the cutter, the abrasion damage state of the flank face, the performance of the cutter material and the performance of a tool material and the like. Among the three factors of the cutting amount, the back bite amount apDirectly influencing the contact area and the contact state of the rear cutter face and the workpiece; cutting speed vcThe contact area of the rear cutter face and the workpiece is hardly influenced, but the cutting temperature, the boundary stress distribution and the like are changed due to different cutting speeds, so that the contact state of the rear cutter face and the workpiece is influenced; for most machining situations, the feed amount f does not affect the contact area between the flank face and the workpiece, and the influence on the friction state is very small (for less machining situations, such as grooving, cutting-off and the like on a lathe, the change of the feed amount can obviously change the actual clearance angle of the tool, so that the contact state between the flank face of the tool and the workpiece is changedAnd, therefore, the present method is expected to have a large error when applied to such situations). Therefore, it is considered that changing the feed amount does not affect the energy consumption of the flank face at a given cutting speed and back-bite. Considering that there are theoretically infinite possible sequences when constructing the feed amount sequence, and the energy consumption of the front and back tool surfaces calculated by different sequences is different; meanwhile, because the cutting force index empirical formula is obtained through a cutting experiment, factors and levels adopted in the experimental process have obvious influence on the coefficients and indexes in the formula, and when the feed amount sequence in the method is greatly different from the feed amount level selected in the cutting experiment, the difference between the presumed energy consumption of the front and rear tool faces and the real situation is possibly large. Therefore, based on a practical principle, the construction of the feed sequence needs to consider the factors of the blunt radius of the cutting edge of the cutter, the existence of negative chamfer, the rationality of the feed range and the like, and the following is a reference feed sequence construction method: f. of1Is the minimum feed amount, but cannot be too small, and can normally cut, according to the handbook of Metal cutting, when the obtuse radius of the cutting edge is rnWhen it is necessary to make f1≥3rn(ii) a For having a width of bγ1When the negative chamfering is carried out, if low carbon steel, stainless steel, gray cast iron and the like are processed, f is determined1≥2bγ1If it is medium carbon steel, alloy structural steel, etc., f is set to1＝1.25～3.3bγ1If the cutting impact load is large, f should be made1＝0.5～0.7bγ1；fnIs the maximum feed, should be greater than the maximum feed used by the tool, and may be based on tool material, workpiece material, vcg、apgChecking a cutting amount manual under known conditions to obtain the cutting amount, wherein the checked value is usually a range and is selected to be larger as much as possible, fnAnd can also be given directly by experienced workers.
Has the advantages that: by adopting the technical scheme of the invention, the ratio of the energy consumption of the front cutter face and the energy consumption of the rear cutter face of the cutter can be quantized, so that the energy consumption of the front cutter face and the rear cutter face of the cutter in the cutting process can be visually reflected, and important digital basis is provided for the optimization and optimization design of the cutter, the abrasion state analysis of the cutter, the cutter changing decision and the like.
Finally, it should be noted that the above-mentioned description is only a preferred embodiment of the present invention, and those skilled in the art can make various similar representations without departing from the spirit and scope of the present invention.
Claims (3)
1. A method for estimating the energy consumption ratio of front and rear tool faces of a tool in machining is characterized by comprising the following steps:
step one, setting the working condition (v) to be analyzedcg，apg，fg) Wherein v iscgIs the cutting speed, apgFor the amount of cuttinggIs the feed amount;
step two, constructing a plurality of cutting tests in sequence according to the working condition, wherein the cutting test adopts the condition of (v)cg，apg，fi) Wherein:
i＝1，2，3…，n；
fi＝f1，f2，…，fn；
n≥6；
fi＝f1*i；
fg∈fi；
step three, performing a cutting test according to the setting, and recording a corresponding energy consumption data array E;
E＝(E1，E2，…，En)；
analysis of the operating conditions (v)cg，apg，fg) Corresponding energy consumption data is Eg，Eg∈Ei；
Step four, constructing an energy consumption difference array delta E;
ΔE＝(ΔE2，ΔE3，…，ΔEn)＝((E2-E1)，(E3-E2)，…，(En-En-1))；
step five, fitting delta EiAnd fiThe relationship of (1);
ΔEi＝G(fi)＝Kfi bwherein:
k is a fitting coefficient, b is a fitting index, and the fitting index is obtained according to the measured energy consumption data and the corresponding feeding amount;
sixthly, calculating the energy consumption E of the rear cutter face under the working conditionb；
Eb＝E1-ΔE1＝E1-G(f1)；
Seventhly, calculating the energy consumption of the rear cutter face to c% and the energy consumption of the front cutter face to 1-c% under the working condition;
c％＝Eb/Eg×100％＝(E1-G(f1))/Eg×100％；
in the third step, the main cutting force F is adjustediEquivalent to said energy consumption data, to said main cutting force FiOn the basis, carrying out the subsequent steps; said main cutting force FiOr obtained through trial test or calculated by the following formula;
wherein:
CFcis a coefficient related to a machining material, machining conditions and the like, and is obtained through a cutting experiment or by looking up a tool manual;
XFcobtaining the correction coefficient through a cutting experiment or by checking a tool manual;
XFcthe index of apg is obtained through cutting experiments or by looking up a tool manual;
YFcis fiThe index of (a) is obtained by cutting experiments or by looking up a tool manual;
nFcis v iscgObtained by cutting experiments or by looking up tool manuals.
2. The method for estimating the rake face energy consumption ratio of the tool in machining according to claim 1, wherein: and in the third step, the main cutting force, the energy consumed by the main shaft of the machine tool, the power consumed by the main shaft of the machine tool or the current consumed by the main shaft of the machine tool is equal to the energy consumption data, and the subsequent steps are carried out.
3. The method for estimating the rake face energy consumption ratio of the tool in machining according to claim 1 or 2, characterized in that: the sequence of feed amounts fiAnd (4) carrying out assignment construction under the conditions of considering the obtuse radius of the cutting edge of the cutter, the existence of negative chamfer and the feed amount range.
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