CN114781081A - Cutter configuration method considering cutter service life - Google Patents

Cutter configuration method considering cutter service life Download PDF

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CN114781081A
CN114781081A CN202210373140.8A CN202210373140A CN114781081A CN 114781081 A CN114781081 A CN 114781081A CN 202210373140 A CN202210373140 A CN 202210373140A CN 114781081 A CN114781081 A CN 114781081A
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tool
cutter
task
changing
tools
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黎展滔
肖志晓
彭乘风
陈庆新
毛宁
徐国宁
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Guangdong University of Technology
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    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F30/00—Computer-aided design [CAD]
    • G06F30/10—Geometric CAD
    • G06F30/17—Mechanical parametric or variational design
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F30/00—Computer-aided design [CAD]
    • G06F30/20—Design optimisation, verification or simulation
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F2111/00—Details relating to CAD techniques
    • G06F2111/04—Constraint-based CAD
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F2119/00—Details relating to the type or aim of the analysis or the optimisation
    • G06F2119/02—Reliability analysis or reliability optimisation; Failure analysis, e.g. worst case scenario performance, failure mode and effects analysis [FMEA]

Abstract

A cutter configuration method considering cutter service life relates to the technical field of cutter configuration, and comprises the following steps: according to historical data, arranging basic information required by tool configuration; randomly generating a task sequence and task processing working hours, and initializing the state of the tool magazine to be null; determining the constraint of the solved problem and constructing a solved model; carrying out cutter configuration; starting machining, stopping the machine when the tool in the tool magazine cannot meet the next machining task, and making a tool changing decision until the task in the task sequence is finished; and calculating the total cost of stopping, using the new cutter and changing the cutter, and outputting a cutter configuration result. The invention has the beneficial effects that: the cost of using new knives, the cost of downtime and the cost of tool changing time are comprehensively considered, so that the number of the new knives used in the machining process is reduced, the utilization rate of the knives is improved, the tool changing time is improved, the production efficiency is improved, and the more practical tool configuration in the production and manufacturing process can be dealt with.

Description

Cutter configuration method considering cutter service life
Technical Field
The invention belongs to the technical field of cutter configuration, and particularly relates to a cutter configuration method considering the service life of a cutter.
Background
Since the market demand is transformed to the market of buyers, high product differentiation and large-scale customization become important challenges for the manufacturing industry, and the original large-batch production mode is gradually replaced by a multi-variety and small-batch production mode. The current trend in manufacturing is to widely use flexible manufacturing systems that are capable of manufacturing a variety of high quality products at high speeds and in production planning, attempt to organize production as efficiently as possible. When the product category becomes so large that the number of tools required to process a series of jobs exceeds the magazine capacity of the flexible manufacturing machine, the tools must be replaced. Generally, to produce different parts on a flexible manufacturing machine, the number of tools required for all parts is greater than the magazine capacity. In this case, the research on the problem of tool configuration becomes a key ring for improving the production efficiency.
From the literature and patents investigated at present, the tool layout problem under current investigation has been modeled with constraints such as tool size, machine tool setup time, tool capacity, tool life, etc. The number of machine tool stoppages, the number of tool changes, the minimum completion period and the like also cost a tool configuration research objective. Some scholars consider tool placement, job sequencing, machine assignment, etc. At present, mature operation methods comprise a KTNS algorithm, a genetic algorithm, a dynamic programming algorithm and the like. However, the following problems still exist in summarizing the prior art:
the most researches omit the cutter switching caused by the service life exhaustion of the cutter; secondly, a small part of research is focused on the problem of tool configuration of a single tool type; and thirdly, the changed cutter is not considered to be reused. In these studied approaches, either the tool usage rate is too low or the number of new tools used is too high, which often makes the tool configuration impractical.
The cutter configuration problem considering the service life of the cutter is an NP-Hard problem, and along with the increase of the number of types of the cutters, the number of tasks and the capacity of a tool magazine of a machine tool, a lot of difficulties are brought to the problem solving. The cutter configuration problem is an important research subject in a metal manufacturing machining center, the main targets of reducing the cost of a new cutter and the cutter changing time and the downtime are mainly achieved, the cutter configuration problem is very important in scenes such as high-precision machining, punctual manufacturing, automatic workshops and the like, and the cutter configuration problem has a great application prospect in solving the problem.
Disclosure of Invention
The invention aims to provide a cutter configuration method considering the service life of a cutter aiming at the problems of the current cutter configuration, which can solve the cutter configuration problems of cutter service life consideration, multiple cutter types and cutter reuse after replacement and better meet the requirements of actual production.
In order to achieve the purpose, the technical scheme adopted by the invention is as follows: a method of tool configuration taking into account tool life, comprising the steps of:
step 1, arranging basic information required by tool configuration according to historical data, and converting the downtime and the tool changing time into cost;
step 2, randomly generating a task sequence and task processing working hours, and initializing the state of the tool magazine to be null;
step 3, determining the constraint of the solution problem, and constructing a solution model;
step 4, tool configuration is carried out by adopting a greedy strategy, and from the 0 th task, the tool types required by the tasks are judged and added into the tool magazine until the tool positions of the tool magazine are filled;
step 5, starting machining, stopping the machine until the tool in the tool magazine cannot meet the next machining task, and making a tool changing decision;
step 6, determining the length of a task sequence to be processed covered by the tool changing during the shutdown according to a decision index of the average processing cost of a single task, and solving specific information of tool changing and making a tool changing decision;
step 7, starting the machining again, and performing the step 6 until the tool in the tool magazine cannot meet the machining of the next task until the machining of the task in the task sequence is finished;
and 8, calculating the total cost of stopping, using the new cutter and changing the cutter, and outputting a cutter configuration result.
The basic information required by the tool configuration in the step 1 comprises tool types, initial service lives of the tools, tool magazine capacity, downtime, new tool cost and tool changing time.
The constraint for solving the problem in the step 3 at least comprises the following steps:
(1) the loading quantity of the cutters at the cutter positions is restricted, and at most one cutter position can be loaded with one cutter;
(2) the service lives of the cutters before and after the processing task are restricted, and the service life of the cutter after processing cannot be longer than that of the cutter before processing before the cutter is stopped for changing;
(3) the tool life of the processing task is restricted, and the residual life of the tool of the processing task is more than or equal to the life required by the task;
(4) the number of the tools required by the task is restricted, and only one tool is required for processing one task.
The specific method of the step 6 comprises the following steps:
(1) acquiring cutter information in a cutter library and used cutter information on a temporary storage area cutter rest, solving the maximum task number which can be machined by changing the cutter at this time by adopting a greedy strategy, and determining a search range;
(2) traversing the processing requirements of tasks in the search range, taking the optimal average cost of the single task for tool changing at this time as a decision target, and solving specific information for tool changing;
(3) and (3) taking the solution result in the step (2) as a tool changing basis, stopping the machine and making a tool changing decision.
The method for solving the specific information of tool changing in the step (2) comprises the following steps:
firstly, solving the removal priority of the cutters in the cutter magazine and the priority of the cutters in the cutter magazine in the cutter changing process;
solving the tool changing information according to the removal priority and the loading priority, and calculating the tool changing cost in the search;
and thirdly, comparing the average processing cost of the single task in the search range, and taking the optimal decision target as the basis for tool changing.
The specific method for solving the removal priority of the cutters in the tool magazine in the step (I) is as follows: acquiring the information of the cutters which reach the scrapped state in the cutter base, listing the cutters in a removal list, and setting the removal priority as 1; acquiring the information of the tools which are not scrapped in the tool magazine but are not needed by the subsequent tasks, listing the tools in a removal list, and setting the removal priority as 2; and obtaining the information of the tools which are not scrapped in the tool magazine and are needed by the follow-up tasks, listing the tools in a removal list, and calculating the removal information of the tools.
The specific method for solving the priority of the tools needing to be loaded in the tool magazine in the tool changing process comprises the following steps: confirming used cutter information which can be inserted in the cutter changing process according to the cutter information of the cutter rest, and listing the cutters in an insertion list; and confirming new tools needed to be used by the remaining tasks, and listing the tools in an insertion list.
The specific method for calculating the removal priority of the cutter required by the unrepaired subsequent task in the tool magazine comprises the following steps: the priority is 3+ the next tool serial number/task number.
The beneficial effects of the invention are: the invention provides a cutter configuration method considering the service life of a cutter, which has the following advantages:
1. the method carries out tool changing decision according to the average processing cost of a single task, and the method mainly considers the influence of inserting a new tool or inserting a used tool processing task on the cost during tool changing decision, and is more suitable for actual production and manufacturing;
2. the optimization target in the invention comprehensively considers the cost of using new cutters, the cost of stopping time and the cost of cutter changing time, thus reducing the number of the new cutters used in the processing process and improving the utilization rate of the cutters on one hand, improving the cutter changing time and the production efficiency on the other hand, and being capable of dealing with the cutter configuration in the more practical production and manufacturing process.
Drawings
FIG. 1 is a schematic view of a main flow of a tool arranging method according to the present invention;
FIG. 2 is a schematic diagram of an initial decision process of the tool configuration method of the present invention;
FIG. 3 is a schematic diagram of a shutdown tool changing process of the tool configuration method of the present invention;
FIG. 4 is a graph of the average total cost variation for the tool configuration method (ACSTP) of the present invention versus the existing KTNS algorithm for tool scrapping parameter variation at a fixed cost parameter ratio;
FIG. 5 is a graph of average total cost change when the cost parameter ratio changes for a fixed tool reject parameter.
Detailed Description
The present invention is further described in detail with reference to the drawings and examples, but the invention is not limited thereto.
The invention is mainly applied to the cutter configuration problem considering the service life of the cutter, and the problems can be specifically described as follows: in a certain production unit of an enterprise production manufacturing system, the production task is known and fixed, and the processing requirement of each task is known and determined; the tool slot position of the numerical control machine tool magazine of the production unit is fixed; the service life of the tool is known and determined; each task only uses one cutter, and the task processing process cannot be interrupted; before the task processing, if the required cutter is not in the tool magazine or the service life of the cutter in the tool magazine does not meet the task processing requirement, the machine must be stopped to replace the cutter; the cost of downtime includes: the preparation time of stopping the machine, the number of used new cutters and the number of changed cutters; it is ultimately determined which tools are required to be loaded into the tool magazine and which tools are required to be removed from the magazine at each shutdown, and which tools are used for machining for that task, to achieve the optimum replacement cost.
The cutter configuration problem is a complex combination optimization problem, wherein the main factors restricting the problem solving are as follows: the length of a task sequence, the type of the cutter, the number of cutter positions of a tool magazine, and the problem of cutter configuration considering the service life of the cutter are commonly researched for a single cutter type, the reuse of the replaced cutter, a single optimization target and the like; the tool configuration problem considering the tool life has important characteristics of a dynamic planning problem, a subsequent decision making process depends on the current tool magazine state, the combination of a task sequence to be processed and the like, and at present, no solution which can be directly applied to the problem exists, so the invention provides a solution method considering the tool life and the average tool changing cost of a unit task, and the following method is further detailed.
Examples
The specific process and the symbols of the relevant variables appearing in the process are as follows:
Figure BDA0003589360470000051
wherein, the first and the second end of the pipe are connected with each other,
1，xi，j(r) is a variable between 0 and 1, and if the ith tool position before the processing of the (r) th task is loaded with a jth tool, xi，j(r) 1, otherwise xi，j(r)＝0；
2，yi，j(r) is a variable between 0 and 1, and if the ith tool position after the processing of the r task is loaded with a j-th tool, yi，j(r) 1, otherwise yi，j(r)＝0；
3，ui，j(r) is a decision variable in the processing process, if the j type cutter of the ith cutter position is selected and the r task is processed, ui，j(r)＝arOtherwise ui，j(r)＝0；
4，vi，j(r) is a tool configuration decision variable, and v is the value of the tool position if the tool position is not subjected to configuration changei，jIf the number (r) is 0 and j cutter tools are placed in the positions without cutter tools, the cutter tool is
Figure BDA0003589360470000061
If the j type tool is taken off and no tool is loaded, then
Figure BDA0003589360470000062
When the j1 type tool is removed and the j2 type tool is loaded, the tool is removed
Figure BDA0003589360470000063
The invention provides a cutter configuration method considering the service life of a cutter, which is described by combining the concrete implementation steps with the attached figures 1-3 of the specification:
step 1, sorting out variable information related to cutter configuration according to enterprise historical data, wherein a cutter position set of a tool magazine is Q, a cutter type set is K, an initial service life set H of a cutter and shutdown cost C0New tool cost C1Cost of tool change C2；
Step 2, randomly generating a machining task sequence T and a task machining working hour TT, initializing a tool magazine state X (r) ═ O, wherein O is a zero matrix and represents that the initial tool magazine state is empty;
step 3, determining the constraint of solving the problem, which at least comprises the following steps:
the tool position tools are restricted in loading quantity, and one tool position can only load one tool at most:
Figure BDA0003589360470000064
the service life of the cutter before and after the processing task is restricted, before the machine is stopped for cutter changing, the service life of the cutter after processing can not be longer than that of the cutter before processing:
Figure BDA0003589360470000065
tool life constraints of the machining task, the remaining life of the machining task tool is greater than or equal to the required life of the task:
Figure BDA0003589360470000066
the quantity of the tools required by a task is restricted, and only one tool is required for processing one task:
Figure BDA0003589360470000067
step 4, performing initial decision, namely performing cutter configuration by adopting a greedy strategy, and enabling r' to be 0;
step 4.1, judging whether the cutter of the tool magazine can meet the processing of the r ' th task, if so, making r ' ═ r ' +1, and repeating the step 4.1; if not, judging whether the tool magazine has a tool position, if so, loading a T (r') type tool, otherwise, jumping to the step 5;
step 5, starting machining, judging whether a tool meeting the machining requirement of the r-th task exists in the tool magazine, if so, selecting the tool to machine the r-th task, enabling r to be r +1, and repeating the step 5; otherwise, stopping the machine, and making a tool changing decision;
step 6, determining the length of a task sequence to be processed covered by the tool changing during the shutdown according to a decision index of the optimal average processing cost (ACSTP) of a single task;
and 6.1, acquiring the cutter information X (r) in the cutter warehouse and the used cutter information on the temporary storage region cutter rest. Solving the maximum task number which can be machined by changing the tool at this time by using a greedy strategy and determining a search range by using r ═ r 'X' (r) ═ O;
step 6.1.1, judging whether the cutter of the X '(r) can process the r' th task, if yes, making r '═ r' +1, and repeating the step 6.1; if not, judging whether a tool magazine has a tool position, if so, loading a T (r ') type tool, otherwise, determining the search range as [ r, r' ], and jumping to the step 6.2;
step 6.2, traversing the processing requirements of the tasks in the search range, taking the optimal average processing cost of the single task for tool changing at this time as a decision target, and solving specific information of tool changing;
step 6.2.1, solving the removal priority of the cutters in the tool magazine, acquiring the information of the cutters in the tool magazine reaching the scrapped state, listing the cutters in a removal list, and setting the removal priority to be 1; acquiring the information of the tools which are not scrapped in the tool magazine but are not needed by the subsequent tasks, listing the tools in a removal list, and setting the removal priority as 2; acquiring the information of the tools which are not scrapped and are required by the follow-up tasks in the tool magazine, listing the tools in a removal list, and calculating the removal information of the tools;
step 6.2.2, solving the information of the tools which need to be inserted for the tool changing at this time, confirming the information of the used tools which can be inserted for the tool changing at this time according to the information of the tools of the tool rest, and listing the tools in an insertion list; confirming new tools needed to be used by the remaining tasks, and listing the tools in an insertion list;
in the tool changing decision at this stage, the inserted tools are calculated according to task requirements, that is, the tools in the insertion list need to be loaded into a tool magazine to meet the task requirements, so that the insertion list does not need to define the priority; the reason why the removal priority is calculated is that the total number of tools in the magazine is greater than or equal to the number of inserted tools, so the removal priority is defined as: and determining that the tools in the tool magazine are removed according to the priority in the tool changing process so as to ensure that the inserted tools can be completely loaded into the tool magazine.
Step 6.2.3, according to the removal list, inserting the list to solve the tool changing information, and calculating the tool changing cost in the search;
6.2.4, comparing the average processing cost of a single task in the search range, and taking an optimal decision target as the tool changing basis;
step 6.3, taking the result obtained by the step 6.2 as a tool changing basis, stopping the machine, and making a tool changing decision;
step 7, starting the machining again, and performing the step 5 until the tool in the tool magazine cannot meet the machining of the next task until the task in the task sequence is finished;
and 8, calculating the total cost of stopping, using a new cutter and changing the cutter, and outputting a cutter configuration result.
Simulation experiment:
setting simulation parameters:
Figure BDA0003589360470000081
the experimental results are as follows:
in fig. 4, an average total cost change chart of two algorithms when the tool scrapping parameter is changed under a fixed cost parameter ratio is shown, and it can be seen from fig. 4 that the ACSTP algorithm of the invention is obviously superior to the KTNS algorithm when the tool scrapping parameter is 0.45. We show in fig. 5 that the average total cost variation of the two algorithms when the cost parameter ratio varies under a fixed tool rejection parameter, and it can be seen from fig. 5 that the acptp algorithm is also significantly better than the KTNS algorithm when the cost parameter ratio is 0.2, and the average total cost increase under the KTNS algorithm is greater than that of the acptp algorithm as the tool rejection coefficient increases.
The above embodiments are only intended to illustrate the technical solution of the present invention and not to limit the same, and it should be understood by those skilled in the art that the modifications and equivalents of the embodiments of the present invention can be made with reference to the above embodiments, and any modifications and equivalents without departing from the spirit and scope of the present invention are within the scope of the claims of the appended patent application.

Claims (8)

1. A method of configuring a tool with consideration of tool life, comprising the steps of:
step 1, arranging basic information required by tool configuration according to historical data, and converting the downtime and the tool changing time into cost;
step 2, randomly generating a task sequence and task processing working hours, and initializing the state of the tool magazine to be null;
step 3, determining the constraint of the solved problem and constructing a solved model;
step 4, tool configuration is carried out by adopting a greedy strategy, and from the 0 th task, the tool types required by the tasks are judged and added into the tool magazine until the tool positions of the tool magazine are filled;
step 5, starting machining, stopping the machine when the tool in the tool magazine cannot meet the next machining task, and making a tool changing decision;
step 6, determining the length of a task sequence to be processed covered by the tool changing during the shutdown according to a decision index of the average processing cost of a single task, and solving specific information of tool changing and making a tool changing decision;
step 7, starting the machining again, and performing step 6 until the tool in the tool magazine cannot meet the machining of the next task until the machining of the task in the task sequence is finished;
and 8, calculating the total cost of stopping, using the new cutter and changing the cutter, and outputting a cutter configuration result.
2. The method for configuring tools with consideration of tool life according to claim 1, wherein the basic information required for tool configuration in step 1 includes tool type, initial service life of tool, tool magazine capacity, downtime, new tool cost, tool change time.
3. The tool configuration method considering tool life according to claim 1, wherein the constraint of solving the problem in step 3 at least comprises:
(1) the tool position tools are restricted in loading quantity, and only one tool can be loaded at most in one tool position;
(2) the service lives of the cutters before and after the processing task are restricted, and the service life of the cutter after processing cannot be longer than that of the cutter before processing before the cutter is stopped for changing;
(3) limiting the service life of a tool of the processing task, wherein the residual service life of the tool of the processing task is more than or equal to the service life required by the task;
(4) the number of the tools required by the task is restricted, and only one tool is required for processing one task.
4. The tool configuration method considering tool life according to claim 1, wherein the specific method of step 6 is as follows:
(1) acquiring cutter information in a cutter library and used cutter information on a temporary storage area cutter rest, solving the maximum task number which can be machined by changing the cutter at this time by adopting a greedy strategy, and determining a search range;
(2) traversing the processing requirements of tasks in the search range, taking the optimal average cost of the single task for tool changing at this time as a decision-making target, and solving specific information of tool changing;
(3) and (3) taking the solving result in the step (2) as a tool changing basis, stopping the machine and making a tool changing decision.
5. The tool arrangement method taking into account the tool life as claimed in claim 4, wherein the method for solving the specific information of tool changing in step (2) is as follows:
solving the removal priority of the cutters in the cutter storage in the cutter changing process, wherein the priority of the cutters in the cutter storage needs to be loaded;
solving the tool changing information according to the removal priority and the loading priority, and calculating the tool changing cost in the search;
and thirdly, comparing the average processing cost of the single task in the search range, and taking the optimal decision target as the basis for tool changing.
6. The tool configuration method considering tool life according to claim 5, wherein the specific method for solving the removal priority of the tools in the tool magazine in the step (i) is as follows: acquiring the information of the cutters which reach the scrapped state in the cutter base, listing the cutters in a removal list, and setting the removal priority as 1; acquiring the information of the tools which are not scrapped in the tool magazine but are not needed by the subsequent tasks, listing the tools in a removal list, and setting the removal priority as 2; and acquiring the information of the tools which are not scrapped in the tool magazine and are required by the subsequent tasks, listing the tools in a removal list, and calculating the removal priority of the tools.
7. The method for configuring the tool with consideration of the tool life according to claim 5, wherein the specific method for solving the priority of the tool to be loaded in the tool magazine in the tool changing process at this time in the step (i) is as follows: confirming the used cutter information which can be inserted by the cutter changing at this time according to the cutter information of the cutter rest, and listing the cutters in an insertion list; new tools needed to be used for the remaining tasks are confirmed and such tools are listed in the insertion list.
8. The method for configuring tools with consideration of tool life according to claim 6, wherein the specific method for calculating the removal priority of the tools required for the non-scrapped subsequent tasks in the tool magazine is as follows:
the priority is 3+ the next tool serial number/task number.
CN202210373140.8A 2022-04-11 2022-04-11 Cutter configuration method considering cutter service life Pending CN114781081A (en)

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