CN115577512A - Method for establishing centerless grinding ERWC carbon emission model based on grinding removal rate - Google Patents
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Abstract
The invention relates to a method for establishing a centerless grinding ERWC carbon emission model based on grinding removal rate, which comprises the steps of deeply analyzing centerless grinding carbon emission influence factors, calculating material removal energy consumption and grinding wheel abrasion carbon emission by using the grinding material removal rate based on a power signal, effectively avoiding the bias of the centerless grinding carbon emission calculated based on an empirical formula to reflect the actual condition, establishing the centerless grinding carbon emission model, and then comprehensively considering the influence of electric energy consumption, resource consumption and waste on the centerless grinding carbon emission based on the centerless grinding material removal rate model for monitoring the power signal to establish the centerless grinding ERWC carbon emission model; and finally, the established centerless grinding ERWC carbon emission model is used for experimental research of grinding processing of the plunger cores of the enterprise factories, and the influence of the rotating speed process parameters of the grinding wheel and the guide wheel on the centerless grinding carbon emission is deeply analyzed and researched.
Description
Technical Field
The invention relates to a method for establishing a centerless grinding ERWC carbon emission model, in particular to a method for establishing the centerless grinding ERWC carbon emission model based on grinding removal rate.
Background
In mechanical processing, grinding is an important processing mode and is widely applied to the fields of aerospace, automobiles, metallurgy and the like. Grinding refers to a mechanical processing method for removing redundant materials on a workpiece by using a grinding tool and an abrasive material, and is mainly divided into plane grinding, cylindrical grinding, inner circle grinding, centerless grinding, free grinding and ring end face grinding. The centerless grinding does not need clamping and positioning, but depends on the outer circle of the workpiece to position, in the machining process, the workpiece is supported by a supporting plate, a guide wheel and a grinding wheel rotate in the same direction, the guide wheel drives the workpiece to rotate, and the grinding wheel finishes material removal. Compared with other processing modes, the centerless grinding has low energy efficiency, the temperature generated in the processing process is higher, and a large amount of carbon emission is generated by using grinding fluid and dressing a grinding wheel, so that the centerless grinding is a processing mode with high energy consumption, high resource consumption and high emission.
At present, a great deal of research and experimental analysis is carried out on carbon emission in machining by scholars at home and abroad. 1. And establishing an empirical model of energy consumption of the machine tool in the machining process based on the cutting speed, the feed amount and the cutting depth. 2. Dividing the machine tool into different running states of no-load, preparation and processing, and fitting the energy consumption models of different stages of the machine tool according to experimental data. 3. The power of the non-cutting state was modeled and verified experimentally. 4. Analyzing the energy parameter characteristics of the machine tool in no-load operation, establishing a corresponding no-load energy parameter model, and providing a general energy consumption model of the numerical control machine tool. 5. The load loss exists in the machining process, and the main transmission system of the machine tool is taken as a research object to establish the main transmission of the machine tool considering the load lossA system time interval energy model. 6. Different subsystems of the numerical control machine tool are divided into a time-varying energy consumption unit and a time-invariant energy consumption unit, so that a multi-remote dynamic energy consumption modeling method of the numerical control machine tool is provided, and the effectiveness of the multi-remote dynamic energy consumption modeling method is verified by machining of a numerical control milling machine. The above studies mainly consider energy consumption during machine tool machining, but machining carbon emissions, in addition to the part generated by energy consumption, such as grinding fluid consumption, tool loss, etc., also cause carbon emissions, and therefore are considered when establishing a carbon emission model. 7. Influence factors of carbon emission in the numerical control milling process are analyzed, a data milling carbon emission model is established, and carbon emission generated in the data milling process is calculated quantitatively. 8. And comprehensively considering carbon emission caused by materials, energy, wastes and the like in the gear machining process, and establishing a carbon emission calculation model in the gear machining process. 9. Starting from the whole life cycle of typical parts of the machine tool, the carbon emission of a key link is analyzed, and a grinding energy consumption and carbon emission model is established from the perspective of three flows (material flow, energy flow and environmental emission flow). 10. The hobbing is taken as a research object, quantitative analysis is carried out on the material and energy consumption and the carbon emission characteristics in the hobbing process, and a carbon emission quantitative calculation model in the hobbing process is provided. 11. A micro-analysis-based modeling method for improving energy consumption and carbon emission is provided, and the effectiveness of the method is verified by taking milling as an example. 12. The effectiveness of the method is verified by examples by applying a digital twinning technique to the reduction of carbon emissions from numerical control machining. The main research of researchers in the above-mentioned research is milling, gear machining, and the like, and there are few studies on grinding, particularly, centerless grinding in grinding. 13. The method is characterized in that key influence factors influencing the emission of the centerless grinding carbon are found out by using a method of common physicochemical design, the influence of three aspects of energy, resources and wastes on the centerless grinding carbon emission is comprehensively considered, an ERWC carbon emission model is established, and the key factors influencing the carbon emission are analyzed. 14. An energy consumption model of the centerless grinder subsystem is established by utilizing a key diagram theory, and a low-carbon evaluation method in the grinding process of the centerless grinder is provided, so that the carbon emission in the centerless grinding process can be quantitatively calculated. The above researchIn the process of establishing the carbon emission model, the empirical formula is mostly directly adopted to calculate the material removal energy consumption in the processing process and other carbon emissions related to material removal. Because the centerless grinding process is complex, the processing technologies of most workpieces are different, and the processing characteristics of different machine tools are different, the empirical formula often cannot reflect the real situation of centerless grinding, and the calculation of the carbon emission generated in the centerless grinding process by the centerless grinding carbon emission model established based on the empirical formula is not accurate enough. Therefore, it is necessary to provide a carbon emission model that better reflects the actual machining conditions of centerless grinding. The grinding removal rate is a theoretical model established by considering the interaction between abrasive particles and a workpiece in the machining process and combining process parameters, and the material removal condition in the grinding machining process is effectively reflected. Ginger morning [16] The method for monitoring the material removal rate of the shaft parts on line by using the acoustic emission signals is provided, and the effectiveness of the method is proved through experiments. Late jade lun [17] Firstly, a model based on power signal grinding removal rate is provided, and the model can effectively improve grinding efficiency. 15. Another method for calculating the removal rate of the multi-abrasive-particle material is provided, and the effectiveness of the method is verified through experiments. At present, most of research on the removal rate of grinding is focused on improving the machining efficiency of grinding by using the removal rate of grinding, and no researcher uses the removal rate of grinding material in modeling of a centerless grinding carbon emission model.
Disclosure of Invention
The invention provides a method for establishing a centerless grinding carbon emission model based on a centerless grinding material removal rate model of a monitoring power signal. In the machining process of centerless grinding, the power signal can effectively reflect the change of the grinding force in the machining process, and further reflect the electric energy consumption condition of material removal in the machining process. The method determines the removal rate of the centerless grinding material by using the actual power signal generated in the centerless grinding process, calculates the carbon emission such as material removal energy consumption and the like in the centerless grinding by using the material removal rate, finally establishes the carbon emission model which can effectively reflect the real situation of the centerless grinding process, and improves the accuracy of the centerless grinding carbon emission model.
The technical scheme of the invention is as follows: a method for establishing a centerless grinding ERWC carbon emission model based on grinding removal rate comprises the steps of deeply analyzing centerless grinding carbon emission influence factors, calculating material removal energy consumption and grinding wheel abrasion carbon emission by using the grinding material removal rate based on a power signal, effectively avoiding the deviation of the centerless grinding carbon emission calculated based on an empirical formula to reflect the actual condition, establishing the centerless grinding carbon emission model, then comprehensively considering the electric energy consumption, resource consumption and the influence of wastes on the centerless grinding carbon emission based on the centerless grinding material removal rate model for monitoring the power signal, and establishing the centerless grinding ERWC carbon emission model; and finally, the established centerless grinding ERWC carbon emission model is used for experimental research of grinding processing of the plunger cores of the enterprise factories, and the influence of the rotating speed process parameters of the grinding wheel and the guide wheel on the centerless grinding carbon emission is deeply analyzed and researched.
Further, the centerless grinding carbon emission influence factor analysis comprises: before establishing a centerless grinding carbon emission model, analyzing factors influencing centerless grinding carbon emission to determine components of the centerless grinding carbon emission: 1) the energy consumption generated in the operation process of the auxiliary device and the numerical control device is basically consumed, 2) the no-load energy consumption generated by the grinding wheel and the guide wheel due to the frequency conversion effect in the operation process of the machine tool is determined by the characteristics of the numerical control machine tool, 3) the energy consumption generated in the material removing process, and 4) the additional energy consumption caused by the additional load on the motor generated by the grinding force in the material removing process of the guide wheel; in addition, in the centerless grinding process, grinding dust generated by grinding the workpiece, abrasion of the grinding wheel and consumption of lubricating liquid and grinding liquid are also important influence factors generated by carbon emission in the centerless grinding process, and by combining the analysis on the centerless grinding carbon emission influence factors, carbon emission generated in the centerless grinding process is determined from the three aspects of energy consumption, resource utilization and waste treatment.
Further, the method for establishing the centerless grinding carbon emission model includes the steps of firstly establishing the centerless grinding material removal rate model by monitoring the power signal, then establishing the centerless grinding carbon emission model according to the model, wherein the centerless grinding carbon emission model is established based on the power signal, establishing the centerless grinding power monitoring device by the power sensor and the oscilloscope element, establishing the grinding material removal rate model according to the measured power signal, after the grinding material removal rate model is established, using the model for calculating the material removal energy consumption carbon emission, the grinding wheel abrasion carbon emission, the grinding dust carbon emission and the like, and finally establishing the centerless grinding carbon emission model.
Further, the centerless grinding material removal rate model includes: the method comprises the steps of simplifying the plunge grinding process of centerless grinding, establishing a centerless grinding dynamics simplified model, deducing a grinding material removal rate general formula of four stages of centerless grinding based on the dynamics model, and establishing a grinding material removal rate model, wherein:
the workpiece is subjected to 7 acting forces in the grinding process, namely the gravity mg of the workpiece and the normal acting force F of the guide wheel to the workpiece cn And tangential frictional force F ct Normal force F of the pallet against the workpiece bn And tangential force F bt Normal acting force F of grinding wheel to workpiece gn And tangential friction force F gt The main grinding parameters of the centerless grinding plunge grinding process comprise the linear velocity v of a grinding wheel s Linear velocity v of workpiece w The numerical control system controls the feeding speed
The plunge grinding is realized by controlling the parameters;
simplifying the centerless grinding excircle plunge grinding dynamic model into three spring systems, namely the rigidity k of the grinding wheel s Workpiece stiffness k w And contact rigidity k of grinding wheel and workpiece a Equivalent stiffness k of the simplified model e Is composed of
In the formula: k is a radical of formula a -the equivalent stiffness, N/mm,
k a -the grinding wheel contact stiffness with the workpiece, N/mm,
k s -the stiffness of the grinding wheel, N/mm,
k w -the stiffness of the workpiece, N/mm,
the feeding speed of the grinding wheel is set according to a numerical control system in the grinding process
Feed, after contact with the workpiece, generates a grinding force which is divided into a normal grinding force and a tangential grinding force, wherein the normal grinding force F gn The elastic deformation delta generated is
In the formula: f gn -the normal grinding force, N,
delta-elastic deformation, mm,
in addition, the normal cutting force and the actual grinding feed rate
Has the following relationship
In the formula: k is a radical of c The grinding force coefficient is related to the grinding conditions,
a-depth of feed per revolution of the workpiece, mm,
n w -the rotational speed of the workpiece, r/s,
actual grinding feed rate
And theoretical feed rate
The difference between them is
In the formula:
-the numerical control system controls the feed speed, mm/s,
obtaining by combining the above formulas
Further, the method for establishing the centerless grinding ERWC carbon emission model deduces and establishes the centerless grinding ERWC carbon emission model based on the deduced centerless grinding material removal rate model from the respective components of energy, resources and wastes, and specifically comprises the following steps:
(1) Carbon emission of grinding energy consumption
The electric energy consumption in the grinding process is mainly related to grinding power, the grinding power in the grinding process is mainly divided into four aspects, namely grinding basic power, grinding no-load power, material removal power and grinding response power, and the grinding power model is
P＝P base +P e +P grinding +P r (3.1)
In the formula: p base -grinding the basic power, W,
P e -grinding the grinding wheel at a no-load power, W,
P grinding -the material removal power, W,
P r -the response power, W,
from the four aspects, respective power models are respectively established, and then corresponding electric energy consumption is obtained.
(1.1) energy consumption for Material removal
In the processing of centerless grinding, there is a gap between grinding power and grinding force
P grinding ＝k p F gt v s (3.2)
In the formula: k is a radical of p -the power factor is a function of the power,
F gt the tangential friction of the grinding wheel against the workpiece, N,
v s -the linear speed of the workpiece, m/s,
the relationship between the normal grinding force and the tangential grinding force is
F gn ＝AF gt (3.3)
In the formula: a is the proportional relation between the tangential grinding force and the normal grinding force, which is 1.5 to 3,
the general theoretical power model of each stage of plunge grinding based on grinding power signals is shown in the general formulas (2.3) and (2.6)
According to the formula, the centerless grinding power model has a plurality of unknown parameters, the time constant tau can be calculated according to the change rate of the grinding power signal, and the power signal is calculated by using a least square method; in order to reduce errors and improve the accuracy of the time constant tau, a semi-refining stage power signal with stable margin is selected as data for calculating the time constant tau, and k p ，k c Least square fitting solution is carried out on the power signals, the unknown parameters are calculated, and finally a power model of the whole grinding stage is obtained,
it is thus possible to obtain a material removal energy of
In the formula: e g -the energy consumption for material removal, W.s,
(1.2) grinding response energy consumption
The stress of the workpiece is balanced in the grinding process, and the force balance equation is
In the formula: mg-the weight of the workpiece itself, N,
F cn the normal force of the guide wheels on the workpiece, N,
F ct the tangential friction of the guide wheel to the workpiece, N,
F bn the normal force of the pallet on the workpiece, N,
F bt -the tangential force of the pallet on the workpiece, N,
theta, alpha, beta-geometric parameter angle, degree,
at the same time have
In the formula: f. of 1 -the coefficient of friction between the guide wheel and the workpiece,
f 2 coefficient of friction between pallet and workpiece, usually f 1 ＝0.2,f 2 ＝0.28，
From formulae (2.1) to (2.4) to F gt And F ct A relationship between them, order
Then
The grinding machine response power caused by grinding of the workpiece is
P r ＝F ct ν D (3.10)
In the formula: v is D -the linear speed of the guide wheels, m/s,
corresponding response energy consumption is
In the formula: e r -in response to the energy consumption, W.s,
(1.3) basic energy consumption
In the whole processing process of numerical control centerless grinding, an electric cabinet, a hydraulic system, a cooling system, a lubricating system and a lighting system are always operated, the power is basically kept unchanged in the whole processing process, the generated energy consumption is necessary for the normal operation of a grinding machine, and the sum of the power is called basic power P of the grinding machine base (ii) a The basic power of the grinding machine is basically unchanged in the grinding process, the basic power is directly measured by using a sensor, and the basic energy consumption is obtained by power integration
In the formula: e b The basic energy consumption, W.s,
(1.4) grinding No-load energy consumption
The machine tool has basic energy consumption and energy consumption generated by a grinding wheel motor and a guide wheel motor under the no-load state, the power of the grinding wheel motor and the power of the guide wheel motor change along with the respective rotating speed due to the frequency conversion function of a motor control system, and the power needs to be analyzed independently,
under the no-load state, the relation between the power of the main shaft and the rotating speed is
P in ＝P u0 +k 1 n+k 2 n 2 (3.13)
In the formula: p is in The power of the main shaft, W,
P u0 ，k 1 ，k 2 -a constant relating to the characteristics of the machine tool,
the centerless grinding mainly comprises two main shafts, namely a grinding wheel main shaft and a guide wheel main shaft, and the no-load energy consumption of the centerless grinding mainly needs to be considered, so that a relation formula between the grinding wheel main shaft and the guide wheel main shaft and the rotating speed is respectively established according to the formula
In the formula: p is S The no-load power of the grinding wheel spindle, W,
P D the no-load power of the guide wheel shaft, W,
n D -the rotational speed of the guide wheels, r/s,
n S -the rotational speed of the grinding wheel, r/s,
the power of the grinding wheel main shaft and the guide wheel main shaft at different rotating speeds is obtained through experiments,
according to the experimental value, linear fitting is carried out on the experimental value by a least square method to respectively obtain the calculation formulas of the power of the grinding wheel and the power of the guide wheel main shaft under different rotating speeds,
the calculation process is as follows:
order to
The partial derivatives of the three parameters in the formula are respectively calculated, so that
Three parameters P are obtained u0 ，k 1 ，k 2 The value of (A) is obtained, so that a no-load power formula of the grinding wheel spindle and the guide wheel spindle is obtained, and further the no-load power of the machine tool is obtained
P k ＝P S +P D (3.17)
Corresponding no-load energy consumption is
In the formula: e k The energy consumption in the idle load, W.s,
(1.5) Total electric energy consumption carbon emissions
By deriving the above calculations for the respective powers of the four aspects of the resulting grinding power, the total power in the grinding process is obtained from equation (3.1), and the corresponding electrical energy corresponds to a total energy consumption of (3.5), (3.11), (3.12) and (3.18)
E＝E b +E k +E g +E r (3.19)
In the formula: e-total energy consumption of electric energy consumption, W.s,
the total carbon emission of the electric energy consumption is
In the formula: c E The total carbon emission of the electrical energy consumption, g,
C ep the carbon emission corresponding to the consumed electric energy is g/(kW.h),
(2) Carbon emission from grinding wheel wear
In the grinding process, the abrasion of the grinding wheel can lead to the reduction of the available quantity of the grinding wheel and even the complete scrapping, the carbon emission generated in the part cannot be ignored and needs to be considered in a model,
obtaining the volume of the material removed from the workpiece according to a grinding material removal rate formula
In the formula: l-the length of the workpiece being ground, mm,
d W the diameter of the workpiece, mm,
ΔV W the volume of material removed from the workpiece, mm 3 ，
The wear ratio G of a grinding wheel refers to the volume of material removed from a workpiece corresponding to the wear per unit volume of the grinding wheel, and is usually
In the formula: Δ V S Amount of wear of grinding wheel, mm 3 ，
Thereby, the abrasion loss of the grinding wheel can be obtained, the abrasion loss conditions of the grinding wheel in different grinding stages,
the volume of the grinding wheel is
In the formula, B represents the width of the grinding wheel in mm,
d Smax the maximum diameter, mm,
d min the diameter of the minimum part of the grinding wheel, mm,
the grinding wheel can be used for grinding in the volume of
In the formula (d) Smin Is the minimum available diameter, mm,
in the life cycle of the grinding wheel, the volume of the finished grinding wheel is
V d ＝NBa d π(d Smax +d Smin )/2 (3.25)
In the formula: n-the number of times the grinding wheel can be dressed,
a d the depth of one time of dressing by the grinding wheel, mm,
carbon emission of grinding wheel dressing is
In the formula: c SD The carbon emission, g,
s d -the lead of the dressing of the grinding wheel,
P SD -the grinding wheel dressing power, W,
ρ S density of grinding wheel, kg/m 3 ，
Carbon emission of grinding wheel abrasion is
In the formula: c GWP The carbon emission in g/kg corresponding to the production of the grinding wheel,
C GWD processing the carbon emission of the waste grinding wheel in g/kg,
(3) Carbon emission of abrasive dust
In the centerless grinding process, a large amount of abrasive dust is generated by the contact of the grinding wheel and the workpiece, and the abrasive dust can not be recycled, so the influence of the abrasive dust on carbon emission needs to be considered,
the workpiece is ground by a volume of
The carbon emission amount generated by the abrasive dust is
C WA ＝ΔV W ρ W C WCD (3.29)
In the formula: rho W -density of swarf, kg/mm 3 ，
C WCD -carbon emission factor, g/kg,
(4) Carbon emission of lubricating fluid
In the centerless grinding process, lubricating fluid is required for a plurality of parts of a machine tool in order to reduce friction, the lubricating fluid is equivalent to a main shaft, and the carbon emission generated by the lubricating fluid is
In the formula: c L The carbon emission of the lubricating fluid, g,
t LO -working the lubricating fluid in one stepThe time, s,
t LA the interval time between two changes of the lubricating fluid, s,
C LP -treating the carbon emission, g/L, produced by 1L of lubricating fluid,
Q LA the total volume of lubricating fluid, L,
(5) Carbon emission of grinding fluid
During grinding, although the grinding fluid is recycled, the grinding fluid needs to be replaced and replenished periodically due to evaporation and adhesion to abrasive dust and workpieces, and the carbon emission corresponding to the consumption of the grinding fluid is considered
In the formula: t is t GFO -the time of use of the grinding fluid for one-time machining, s,
t GFA the interval time between the grinding fluid changes, s,
C GFP the carbon emission, g/L, required for producing grinding fluid,
C GFD the carbon emission, g/L, required for the treatment of the grinding fluid,
Q GFI -the total volume of grinding fluid to be treated, L,
(6) Total carbon emission
Comprehensively considering the carbon emission in the grinding process to obtain a model of the change of the total emission along with the time in the grinding process
C Grinding (t)＝C E (t)+C SA (t)+C WA (t)+C L (t)+C GF (t) (3.32)。
The beneficial effects of the invention are:
the invention establishes a centerless grinding removal rate carbon emission model based on the grinding removal rate, analyzes the theoretical model through experiments, and mainly obtains the following conclusion:
(1) The invention analyzes factors influencing the emission of centerless grinding carbon, provides a method for calculating the carbon emission of important components of the centerless grinding carbon emission, such as the abrasion loss of a grinding wheel, the amount of grinding chips, the energy consumption in the material removal process and the like by using the removal rate of the centerless grinding material, and establishes a model of the removal rate of the centerless grinding material based on a power signal.
(2) Starting from an ERWC carbon emission model, three aspects of electric energy consumption, resource consumption and waste treatment are comprehensively considered, calculation formulas of abrasion carbon emission of the grinding wheel, carbon emission of abrasive dust and carbon emission of material removal energy consumption are determined based on a centerless grinding material removal rate model, an equivalent carbon emission model in the centerless grinding machining process is established by combining calculation formulas of other factors influencing carbon emission, and then the carbon emission in the centerless grinding process can be predicted.
(3) The established centerless grinding ERWC carbon emission equivalent model is used for the grinding processing of the plunger core of an enterprise factory for experimental research, and the electric energy consumption and the abrasion of the grinding wheel which are main factors influencing the centerless grinding carbon emission can be obtained by analyzing the proportion of the carbon emission value of each influencing factor in the total carbon emission. Meanwhile, the influence of two process parameters of the rotating speed of the grinding wheel and the rotating speed of the guide wheel on the emission of the centerless grinding carbon is analyzed. The rotating speed of the guide wheel and the rotating speed of the grinding wheel mainly influence the total carbon emission by influencing the energy consumption of material removal. The emission of the total carbon in the centerless grinding is correspondingly increased along with the increase of the rotation speed of the grinding wheel. Compared with the grinding wheel, the rotating speed of the guide wheel is increased, and the total carbon emission of the centerless grinding is increased and then reduced. The experimental result accords with theoretical derivation, the accuracy of the model is verified, and a theoretical basis is provided for subsequent process optimization.
(4) The invention subsequently optimizes the parameters of the centerless grinding process based on the centerless grinding carbon emission model and by combining an intelligent algorithm, and reduces the carbon emission generated in the centerless grinding process on the premise of not reducing the processing quality.
Drawings
FIG. 1 is a diagram illustrating an analysis of centerless grinding carbon emission influencing factors;
FIG. 2 is a process diagram for establishing a centerless grinding carbon emission model based on power signals;
FIG. 3 is a centerless grinding force analysis graph;
FIG. 4 is a diagram of a centerless grinding cylindrical plunge grinding model;
FIG. 5 is a graph of centerless grinding of an exemplary workpiece;
FIG. 6 is a graph comparing the response force and the tangential grinding force;
FIG. 7 is a graph showing changes in the amount of wear of the grinding wheel;
FIG. 8 is a graph of actual power versus fit;
FIG. 9 is a graph of carbon emissions for different processing schemes;
FIG. 10 is a graph of carbon emission ratios of various influencing factors;
FIG. 11 is a graph illustrating the effect of guide wheel speed on carbon emissions for four types of energy consumption;
FIG. 12 is a graph of the effect of idler speed on electrical energy consumption carbon emissions and total carbon emissions;
FIG. 13 is a graph illustrating the effect of grinding wheel speed on carbon emissions for four types of energy consumption;
FIG. 14 is a graph of the effect of wheel speed on carbon emissions and total carbon emissions for power consumption.
Detailed Description
The invention is further described with reference to the following figures and examples.
A method of modeling centerless grinding carbon emissions based on a centerless grinding material removal rate model monitoring power signals, comprising:
1. centerless grinding carbon emission influence factor analysis
Before establishing the centerless grinding carbon emission model, it is necessary to analyze the factors affecting centerless grinding carbon emission in order to determine the components of centerless grinding carbon emission. As shown in fig. 1, the main raw materials and devices participating in the centerless grinding process include a centerless grinder, a workpiece, a lubricating fluid and a grinding fluid, wherein the centerless grinder mainly comprises a numerical control system, a servo system, a machine tool body, a guide wheel spindle, a grinding wheel spindle, an auxiliary device and the like. During the centerless grinding process, carbon emission generated by the operation of the centerless grinder is generated by consuming electric energy, and can be roughly divided into the following four parts: 1. the energy consumption generated in the operation process of auxiliary devices, numerical control devices and the like is essential for the operation of the machine tool and is basic energy consumption. 2. The no-load energy consumption of the grinding wheel and the guide wheel generated by the frequency conversion function in the running process of the machine tool is determined by the characteristics of the numerical control machine tool 3, and the energy consumption generated in the material removing process. 4. The additional energy consumption of the guide wheel due to the additional load on the motor during material removal due to grinding forces etc. In addition, in the centerless grinding process, abrasive dust generated by grinding the workpiece, abrasion of the grinding wheel, and consumption of lubricating fluid and grinding fluid are also important factors generated by carbon emission in the centerless grinding process. By combining the analysis of the centerless grinding carbon emission influence factors, the carbon emission (C) generated in the centerless grinding process is considered from the three aspects of energy consumption (E), resource utilization (R) and waste treatment (W), so that a centerless grinding ERWC carbon emission model is established.
As can be obtained from fig. 1 and the above analysis, the centerless grinding material removal process is a key link affecting centerless grinding carbon emission, and therefore, the research on the grinding material removal process is an important step for establishing a centerless grinding carbon emission calculation model. In the centerless grinding material removal process, the grinding material removal rate is an important parameter in the material removal process, so that the establishment of a grinding removal rate model is the key for solving the abrasion loss and the abrasive dust amount of the grinding wheel and the energy consumption in the material removal process. The grinding removal rate model is usually established according to a grinding force signal, but the grinding force signal is difficult to measure, and along with the development of an plunge grinding theory and a sensor technology, a power signal is also suitable for establishing the centerless grinding material removal rate model, so that the grinding material removal rate model is established by monitoring the power signal, and then the centerless grinding carbon emission model is established according to the model.
The process of establishing a centerless grinding carbon emission model based on the power signal is shown in FIG. 2. A centerless grinding power monitoring device is established through elements such as a power sensor and an oscilloscope, a grinding material removal rate model is established according to measured power signals, the model is used for calculating the carbon emission of material removal energy consumption, the carbon emission of abrasion of a grinding wheel, the carbon emission of abrasive dust and the like after the grinding material removal rate model is established, and finally the centerless grinding carbon emission model is established.
2. Centerless grinding material removal rate model
In the centerless grinding process, the grinding wheel is mainly responsible for grinding a workpiece, the guide wheel guides and controls the workpiece to move, the supporting plate is used for supporting the workpiece, the grinding wheel and the guide wheel rotate in the same direction, and the workpiece rotates in the direction opposite to that of the grinding wheel. The guide wheel and the supporting plate are combined to position the workpiece, and the center of the workpiece is not fixed during machining because the positioning surface of the workpiece is not in a standard cylindrical shape. The stress during centerless grinding is shown in fig. 3. The workpiece is subjected to 7 acting forces in the grinding process, namely the gravity mg of the workpiece and the normal acting force F of the guide wheel to the workpiece cn And tangential frictional force F ct Normal force F of the pallet against the workpiece bn And tangential force F bt Normal acting force F of grinding wheel to workpiece gn And tangential friction force F gt . The main grinding parameter of the centerless grinding cut-in grinding process is the linear velocity v of the grinding wheel s Linear velocity v of workpiece w The numerical control system controls the feeding speed
Plunge grinding is primarily achieved by control of these parameters.
To facilitate the study of grinding material removal rate models, the plunge grinding process can be simplified, reference [19-21]: [19] DAVID BARRENETXAA, JORGE ALVAREZ, JOSE IGNACIO MARQUINEZ, et al.Stablility analysis and optimization algorithms for the set-up of fed center grinding [ J ]. International Journal of Machine Tools & Manufacture: design, research and application,2014,8417-32; [20] yulun Chi, jiajiajian Gu, hailin li. Optimization of internal sampling using filtering of The air-sampling and The material removal model based on The power signal [ J ]. The International Journal of Advanced Manufacturing Technology,2019,105 (1-4); [21] chen Xun, allanson D.S., thomas A.et al.simulation of cycles for grinding between centers [ J ]. International Journal of Machine Tools and Manual, 1994,34 (5).
As shown in fig. 4, the model is simplified for centerless grinding.
The dynamic model of centerless grinding and cylindrical plunge grinding can be simplified into three bulletsSpring system, respectively grinding wheel stiffness k s Workpiece stiffness k w And the contact rigidity k of the grinding wheel and the workpiece a . Equivalent stiffness k of the simplified model e Is composed of
In the formula: k is a radical of formula a Equivalent stiffness, N/mm.
k a -the contact stiffness of the grinding wheel with the workpiece, N/mm.
k s -grinding wheel stiffness, N/mm.
k w -workpiece stiffness, N/mm.
The feeding speed of the grinding wheel is set according to a numerical control system in the grinding process
Feed, upon contact with the workpiece, generates grinding forces that can be resolved into normal and tangential grinding forces. Wherein the normal grinding force F gn An elastic deformation delta of
In the formula: f gn Normal grinding force, N.
Delta-elastic deformation, mm.
Furthermore, according to the literature [ Marsh E, morlein A, deakyne T, et al in-process measurement of form error and form in cylinder-joint grinding. Precis Eng,2008,32 (4): 348-352.]Normal cutting force and actual grinding feed rate
Has the following relationship
In the formula: k is a radical of formula c -grinding force coefficient, in relation to grinding conditions.
a is the feeding depth of the workpiece per revolution, mm.
n w -workpiece rotation speed, r/s.
By reference [ Chen X, rowe W B, mills B, et al. Analysis and Simulation of the processing.part III. Complex with Experiment [ J ]].International Journal of machine tools and manufacture,1996,36(8):897-906.]It can be known that the actual grinding feed rate
And theoretical feed rate
The difference between them is
In the formula:
-the numerical control system controls the feed speed, mm/s.
The simultaneous formation of the above formulas
For centerless grinding of a typical workpiece, as shown in fig. 5, four processes, rough grinding, semi-finish grinding, and finish grinding, are mainly performed.
Let n =1 be the rough grinding stage, n =2 be the semi-finish grinding stage, n =3 be the finish grinding stage, and n =4 be the finish grinding stage. The grinding time and the theoretical feed rate for each stage are shown in table 1 below.
TABLE 1 grinding feed stage time and feed rate
At the same time have
In the formula: τ — time constant.
Equation (2.5) is solved according to table 1. The general formula for obtaining the removal rate of the grinding material fed for the nth time is as follows
The method simplifies the plunge grinding process of the centerless grinding, establishes a centerless grinding dynamics simplified model, deduces a grinding material removal rate general formula of four stages of centerless grinding based on the dynamics model, and establishes a grinding material removal rate model. Next, the invention applies the grinding material removal rate model to the establishment of a specific carbon emission calculation model in the three aspects around the three aspects of energy, waste and resource which are provided above and influence the centerless grinding carbon emission, and further establishes a centerless grinding ERWC carbon emission model, so that the carbon emission model can reflect the centerless grinding process more accurately.
3. ERWC model establishment based on centerless grinding material removal rate
For the factors influencing the carbon emission in the centerless grinding process, the first section of the text has already been analyzed and mainly includes three aspects of energy, resources and wastes. In the aspect of energy, in the machining process of centerless grinding, the consumption of generated electric energy mainly comprises four parts, namely material removal energy consumption, grinding response energy consumption, basic energy consumption and grinding no-load energy consumption. In the aspect of resources, the resources consumed in the centerless grinding process are mainly a grinding wheel, a grinding fluid and a lubricating fluid. In terms of waste, the waste mainly generated in grinding is grinding dust and evaporated grinding fluid. The following text will derive and establish a centerless grinding ERWC carbon emission model based on the centerless grinding material removal rate model derived from the components of energy, resources and waste.
3.1 grinding energy consumption carbon emission
The electrical energy consumption during grinding is mainly related to the grinding power. In the grinding process, grinding power is mainly divided into four aspects, namely grinding basic power, grinding idle power, material removal power and grinding response power. The grinding power model is
P＝P base +P e +P grinding +P r (3.1)
In the formula: p base -grinding the basic power, W.
P e -grinding no load power, W.
P grinding -material removal power, W.
P r -response power, W.
From the four aspects, respective power models are respectively established, and then corresponding electric energy consumption is obtained.
3.11 energy consumption for Material removal
In the processing of centerless grinding, there is a gap between grinding power and grinding force
P grinding ＝k p F gt v s (3.2)
In the formula: k is a radical of p -a power coefficient.
F gt -the tangential friction of the grinding wheel against the workpiece, N.
v s -workpiece linear velocity, m/s.
The relationship between the normal grinding force and the tangential grinding force is
F gn ＝AF gt (3.3)
In the formula: a is the proportional relation between the tangential grinding force and the normal grinding force, and is generally 1.5-3, and is 2 in the text.
The general theoretical power model of each stage of plunge grinding based on grinding power signals is shown in the general formulas (2.3) and (2.6)
From the above equation, the centerless grinding power model has many unknown parameters. The time constant τ may be calculated from the rate of change of the grinding power signal, and the power signal is calculated using a least squares method. In order to reduce errors and improve the accuracy of the time constant tau, the semi-refining stage power signal with stable allowance can be selected as data for calculating the time constant tau. Furthermore, k p ，k c It needs to be solved by least squares fitting to the power signal. By calculating the unknown parameters, the power model of the whole grinding stage is finally obtained.
It is thus possible to obtain a material removal energy of
In the formula: e g Material removal energy, W.s.
3.12 grinding response energy consumption
In centerless grinding, the tangential grinding force of the guide wheels on the workpiece and the friction force between the wheel spindle and the guide wheel spindle and the bearing cause additional load on the motor and thus additional energy consumption during grinding of the workpiece, and this is called response energy consumption. Because the shaft and the bearing are well lubricated and the friction force is small, the extra load generated by the friction between the shaft and the bearing is not considered, and the extra load caused by the tangential grinding force of the guide wheel to the workpiece is only considered.
The stress of the workpiece is balanced in the grinding process, and the force balance equation is
In the formula: mg-the work piece's own weight, N.
F cn The normal force of the guide wheels on the workpiece, N.
F ct -the tangential friction of the guide wheel to the workpiece, N.
F bn -the normal force of the pallet against the workpiece, N.
F bt -the tangential force of the pallet on the workpiece, N.
Theta, alpha, beta-geometric parameter angles are shown in figure 3, (°).
At the same time have
In the formula: f. of 1 -coefficient of friction between guide wheel and workpiece.
f 2 -coefficient of friction between pallet and workpiece. In general f 1 ＝0.2,f 2 ＝0.28。
F is obtained from the formulae (2.1) to (2.4) gt And F ct A relationship between them, order
Then
FIG. 6 is F ct And F gt The change in the grinding process is compared with the graph, and the change trend of the two is consistent.
The grinding machine response power caused by grinding of the workpiece is
P r ＝F ct ν D (3.10)
In the formula: v is D -guide wheel linear speed, m/s.
Corresponding response energy consumption is
In the formula: e r -response energy consumption, W.s.
3.13 basic energy consumption
During the whole process of numerical control centerless grinding, some systems are in operation all the time, and the power is basically kept unchanged during the whole process, such as an electrical cabinet, a hydraulic system, a cooling system, a lubricating system and a lighting system. The energy consumption generated by these systems is necessary for the proper operation of the grinding machine, and the sum of the powers is called the basic power P of the grinding machine base . The basic power of the grinding machine is basically unchanged in the grinding process, and can be directly measured by using a sensor. The basic energy consumption can be obtained by power integration
In the formula: e b Basic energy consumption, W.s.
3.14 no-load grinding energy consumption
In a grinding cycle of the numerically controlled grinding machine, the machine tool is in a grinding state and has a plurality of times in an idle state, and the energy consumption generated in the part is not negligible and needs to be considered in a model. The machine tool has basic energy consumption and energy consumption generated by a grinding wheel motor and a guide wheel motor in an idle state, and the power of the grinding wheel motor and the power of the guide wheel motor change along with respective rotating speed due to the frequency conversion function of a motor control system, so that independent analysis is required.
According to the documents [ Shi Jinliang, liu Fei, xu Dijian, et al. Dension Model and Practical Method of Energy-saving in NC Machine Tool Tool [ J ]. China Mechanical Engineering,2009,20 (11): 1344-1346 (in China) [ good, liu Fei, permission, etc. ], the numerical control Machine Tool in no-load operation Energy-saving decision Model and Practical Method [ J ]. China Mechanical Engineering,2009,20 (11): 1344-1346 ], in no-load state, the relation between the main shaft power and the rotating speed is
P in ＝P u0 +k 1 n+k 2 n 2 (3.13)
In the formula: p is in Spindle power, W.
P u0 ，k 1 ，k 2 -constants related to machine characteristics.
The centerless grinding mainly comprises two main shafts, namely a grinding wheel main shaft and a guide wheel main shaft, and the no-load energy consumption of the main shafts needs to be considered, so that a relation formula of the grinding wheel main shaft and the guide wheel main shaft with the rotating speed is respectively established according to the formula.
In the formula: p is S -grinding spindle no-load power, W.
P D -idle power of the idler shaft, W.
n D -the rotation speed of the guide wheel, r/s.
n S -grinding wheel speed, r/s.
The power of the grinding wheel main shaft and the power of the guide wheel main shaft at different rotating speeds can be obtained through experiments.
According to the experimental value, linear fitting is carried out on the grinding wheel spindle and the guide wheel spindle through a least square method, and calculation formulas of the power of the grinding wheel spindle and the power of the guide wheel spindle under different rotating speeds can be obtained respectively.
The calculation process is as follows:
order to
The partial derivatives of the three parameters in the formula are respectively calculated, so that
Three parameters P can be obtained u0 ，k 1 ，k 2 The no-load power formula of the grinding wheel spindle and the guide wheel spindle can be obtained, and the no-load power of a machine tool can be further obtained as
P k ＝P S +P D (3.17)
Corresponding no-load energy consumption is
In the formula: e k -no-load energy consumption, W.s.
3.15 Total Power consumption carbon emissions
The total power in the grinding process can be derived from equation (3.1) by the above calculation of the individual powers of the four aspects which make up the grinding power. According to the formulas (3.5), (3.11), (3.12) and (3.18), the corresponding total energy consumption of the electric energy is
E＝E b +E k +E g +E r (3.19)
In the formula: e-total energy consumption, W.s.
The total carbon emission of the electric energy consumption is
In the formula: c E -total carbon emission of electrical energy consumption, g.
C ep The carbon emission corresponding to the consumed electric energy is g/(kW.h).
3.2 carbon emission from grinding wheel wear
In the grinding process, the abrasion of the grinding wheel can lead to the reduction of the available amount of the grinding wheel and even the complete scrapping. The carbon emissions produced in this section are not negligible and need to be considered in the model.
The volume of material removed from the workpiece can be derived from the above formula for the removal rate of abrasive material
In the formula: l is the length of the workpiece to be ground, mm.
d W -diameter of the workpiece, mm.
ΔV W The volume of material removed from the workpiece, mm 3 。
The wear ratio G of the grinding wheel refers to the volume of material removed from the workpiece corresponding to the wear per unit volume of the grinding wheel, and is usually
In the formula: Δ V S Abrasion loss of grinding wheel, mm 3 。
The amount of abrasion of the grinding wheel can be determined from this, and the amount of abrasion of the grinding wheel at different grinding stages is shown in fig. 7.
The volume of the grinding wheel is
In the formula, B represents the width of the grinding wheel in mm.
d Smax The maximum diameter of the grinding wheel that can be used, mm.
d min The minimum diameter of the grinding wheel, mm.
The grinding wheel can be used for grinding in the volume of
In the formula, d Smin Is the smallest available diameter of the grinding wheel, mm.
In the life cycle of the grinding wheel, the volume of the finished grinding wheel is
V d ＝NBa d π(d Smax +d Smin )/2 (3.25)
In the formula: n is the number of times the grinding wheel can be dressed.
a d -depth of one dressing by grinding wheel, mm.
Carbon emission of grinding wheel dressing is
In the formula: c SD Carbon emission, g, of grinding wheel dressing.
s d -dressing the lead with a grinding wheel.
P SD -grinding wheel dressing power, W.
ρ S Density of the grinding wheel, kg/m 3 。
Carbon emission of abrasion of grinding wheel
In the formula: c GWP The corresponding carbon emission of the produced grinding wheel is g/kg.
C GWD Processing the carbon emission of the waste grinding wheel in g/kg.
3.3 carbon emission of abrasive dust
In the centerless grinding process, a large amount of abrasive dust is generated by the contact of the grinding wheel and a workpiece, and the abrasive dust cannot be recycled, so that the influence of the abrasive dust on carbon emission needs to be considered.
The workpiece is ground by a volume of
The carbon emission amount due to the abrasive dust is
C WA ＝ΔV W ρ W C WCD (3.29)
In the formula：ρ W -density of swarf, kg/mm 3 。
C WCD -carbon emission factor, g/kg, resulting from the treatment of the swarf.
3.4 carbon emissions from lubricating fluids
In centerless grinding, lubricating fluid is required at many locations of the machine to reduce friction. The lubricating fluid is equivalent to a main shaft, and the carbon emission amount generated by the lubricating fluid is obtained
In the formula: c L -carbon emission of lubricating fluid, g.
t LO -one-pass working of the lubricating fluid, time of use, s.
t LA -the interval between two changes of the lubricating fluid, s.
C LP -carbon emissions, g/L, from processing 1L of lubricating fluid.
Q LA -total volume of lubricating fluid, L.
3.5 carbon emission of grinding fluid
In the grinding process, the grinding fluid is recycled, but the grinding fluid needs to be replaced and replenished periodically due to evaporation, adhesion to abrasive dust and a workpiece, and the like. The amount of carbon emissions in view of the consumption of grinding fluid is
In the formula: t is t GFO -one-time machining grinding fluid service time, s.
t GFA -interval time for grinding fluid change, s.
C GFP The carbon emission amount required by the production of the grinding fluid is g/L.
C GFD The carbon emission amount, g/L, required for processing the grinding fluid;
Q GFI -a processing millTotal paring fluid volume, L.
3.6 Total carbon emissions
From the above analysis, taking into account the carbon emissions during the grinding process, a model of the time-dependent change of the total emissions during the grinding process can be obtained as
C Grinding (t)＝C E (t)+C SA (t)+C WA (t)+C L (t)+C GF (t) (3.32)
4. Experiments and analyses
In order to verify the accuracy of the ERWC model, and use the ERWC model for guiding actual grinding and reducing carbon emission, the model is used in a grinding experiment of the plunger core. And establishing an ERWC model according to the collected power signals in the grinding process of the plunger core, and performing calculation analysis on the established model.
4.1 Experimental setup
The machine tool used in this experiment was a Kronos S250 model cylindrical grinder. 4 grinding wheels used for processing are of a same model and are of a Tyroiit/CS33A 120HH5 VK8/50 model, the diameter is 450mm, the width is 65mm, the granularity of the coarse grinding wheel is 320, and the granularity of the fine grinding wheel is 120. The rotating speed of the grinding wheel spindle is 1967r/s, the linear speed of the grinding wheel is 38m/s, and the linear speed of the guide wheel is 0.47m/s. The dressing mode is that the rough grinding is dressed by a diamond roller, the fine grinding wheel is dressed by a diamond butterfly, and the grinding wheel is dressed once after 35 workpieces are ground and processed. The processed workpiece is a plunger core, the model is HDP6 Piston is 10mm, the diameter is 10mm, and the material is 45 steel. The cooling liquid is the type of Jiashiduo Hysol water-based grinding fluid.
The power sensor is arranged on the machine tool electrical cabinet and is used for detecting the power of the grinding wheel spindle motor so as to obtain the grinding force in the grinding process of the grinding wheel. The sensor adopts a WB9128-1 three-phase power sensor, inputs phase voltage AC 57.7V-289V and line voltage AC 100V-500V, and data are collected and stored by using WinDaq software.
The machine tool is used for clamping 4 workpieces at one time, 2 workpieces are subjected to coarse grinding, and 2 workpieces are subjected to fine grinding. Through automatic unloader that goes up, adopt vacuum adsorption's mode to put the assigned position with the work piece on, use electromagnetic fixture to fix a position and press from both sides tightly, then the emery wheel fast feed carries out abrasive machining to the assigned position. After finishing the machining, the workpiece at the finish grinding position is taken off, and the workpiece at the rough grinding position is moved to the finish grinding position for the next finish grinding machining.
There are many carbon emission parameters in the centerless grinding carbon emission model identified in the second section, and specific values for each carbon emission parameter can be obtained according to literature [25], as shown in table 2.
TABLE 2 carbon emission parameter Table
To complete the modeling of centerless grinding carbon emissions, the model for material removal power and idle power presented in the above theoretical section will be fitted next herein by experimental and actual data.
4.2 Power model fitting
In order to calculate the no-load energy consumption of centerless grinding, the P of the grinding wheel and the guide wheel of the machine tool needs to be determined u0 ，k 1 ，k 2 And establishing an idle load power model by using the three parameters. The no-load power of the machine tool under the no-load condition of the grinding wheel and the guide wheel is respectively tested according to different rotating speeds of the centerless grinding machine, and the no-load power is shown in table 3.
TABLE 3 correspondence table of rotation speed and no-load power of grinding wheel spindle and guide wheel spindle
| Grinding wheel spindle rotating speed (r/s) | 22.7 | 26.7 | 40 | 53.3 | 60 | 66.7 |
| Machine tool no-load power (KW) | 3.126 | 3.193 | 3.312 | 3.394 | 3.462 | 3.585 |
| Rotating speed of guide wheel shaft (r/s) | 0.5 | 0.67 | 0.92 | 1.17 | 1.33 | 1.5 |
| Machine tool no-load power (KW) | 0.469 | 0.479 | 0.497 | 0.509 | 0.519 | 0.538 |
According to the data in Table 3, the corresponding parameters of no-load of the grinding wheel and guide wheel of the machine tool can be calculated according to the formulas (3.14) to (3.16) as
The correlation coefficient R of the grinding wheel model and the guide wheel model is calculated 2 0.9768 and 0.9869, respectively, correlation coefficient R 2 A closer to 1 indicates a better fit of the model, and therefore the resulting model coefficients are reliable. F corresponding to the grinding wheel model and the guide wheel model is 31.9373 and 10.4635 respectively, and the probability p corresponding to F is 0.002 and 0.0089 respectively.
Based on the power data of the actual process, the parameter τ, k in equation (3.4) can be calculated by the least square method p ，k c . Then obtaining a power model P according to the actual processing parameters, the rotating speed of the grinding wheel and the rotating speed of the guide wheel grinding The fitted curve and the actual power curve are shown in fig. 8.
The correlation coefficient R was calculated from the above Table 3 2 Therefore, the no-load power model established according to the experiment has higher accuracy; from the above fig. 11, it can be derived that the power curve fitted by the model conforms to the actual power curve. The material removal energy consumption and the grinding no-load energy consumption calculated according to the table 3 and the figure 8 basically accord with the actual energy consumption, and a good foundation is laid for accurate calculation of the carbon emission of the subsequent centerless grinding ERWC.
4.3 Experimental results and comparison.
After determining the carbon emission factor in the machine idle power characteristic, centerless grinding carbon emission model above, three different processing scenarios will be compared herein to explore the impact of feed and grinding time on centerless grinding carbon emission. The process parameters for each processing scheme are shown in table 4.
TABLE 4 different processing schemes
Total carbon emissions C of 3 schemes Grinding The curves are shown in fig. 9. By comprehensively comparing the maximum carbon emission values generated by the schemes at different stages, the feeding amount at the rough grinding stage is large, and the grinding time is longerLong, has a great influence on the final carbon emission, and the grinding time is long although the feed amount is small in the finish grinding stage, so the influence on the carbon emission is second only to the rough grinding stage. Compared with the rough grinding and the finish grinding, the semi-finish grinding stage and the finish grinding stage have the advantages that although the feeding amount is large, the grinding time is short, the grinding time is long, but the feeding amount is small, and therefore the two stages have small influence on the emission of centerless grinding carbon.
4.4 analysis of the results of the experiment
After comparing the results of the three different processing schemes, the invention analyzes the experimental results according to the process parameters of the first processing scheme, and discusses the influence of different factors on the emission of the centerless grinding carbon and the influence of two key process parameters, namely the rotating speed of the grinding wheel and the rotating speed of the guide wheel, on the emission of the centerless grinding carbon.
Fig. 10 shows the carbon emission of the centerless grinding, wherein the carbon emission of the electric energy consumption accounts for 31%, the carbon emission of the grinding wheel abrasion accounts for 65%, the carbon emission of the grinding dust and the grinding fluid respectively accounts for 2%, and the lubricating fluid accounts for 0.2%. It can be seen that power consumption and grinding wheel wear are the main factors affecting centerless grinding carbon emission, and other factors have less impact on centerless grinding carbon emission. In the machining process of centerless grinding, the energy consumption for removing grinding materials, the energy consumption for responding to grinding and the no-load energy consumption of a machine tool are all influenced by the rotating speed n of the grinding wheel s And the rotating speed n of the guide wheel D The effect of grinding wheel speed and guide wheel speed on centerless grinding carbon emissions will be discussed separately herein below.
By using the technological parameters of the scheme I and the data such as power signals in the centerless grinding process, the rotating speed n of the guide wheel can be obtained D Influence on carbon emission of all aspects in the centerless grinding process.
FIG. 11 is a graph of the effect of stator speed on four main carbon emissions in power consumption. Wherein (a) of FIG. 11 is the influence of the rotating speed of the guide wheel on the carbon emission of the material, it can be seen from the graph that the carbon emission of the material is reduced with the increase of the rotating speed of the guide wheel, and in this trend and equation (3.5), the energy consumption of the material removal and the rotating speed n of the workpiece are reduced w Negative correlation due to n w And n D In direct proportion, the energy consumption for removing materials is in accordance with the rotating speed n of the guide wheel D The theory of inverse proportionality is identical. In the centerless grinding process, the rotation of the workpiece is driven by the guide wheel, so that the linear velocity of the guide wheel is the same as that of the workpiece, and the rotating speed n of the workpiece is the same as that of the workpiece under the condition that the diameters of the workpiece and the guide wheel are not changed w And the rotating speed n of the guide wheel D Is in direct proportion. Thus, the energy consumption for material removal and the number of revolutions n of the guide wheel D And inversely, as the speed of the stator increases, the carbon emissions resulting from the energy consumption of material removal decrease. Fig. 11 (b) shows the influence of the guide wheel rotation speed on the idle carbon emission, and the idle carbon emission during centerless grinding increases as the guide wheel rotation speed increases. From the quadratic relation between the machine tool guide wheel shaft no-load power and the guide wheel rotating speed calculated above, it can be seen that the guide wheel shaft no-load power is continuously improved along with the continuous increase of the guide wheel rotating speed. According to the formula (3.18), the energy consumption of the machine tool is increased correspondingly when the idle power of the machine tool is increased, and the corresponding idle carbon emission is increased continuously, which is consistent with the trend reflected in the figure. Fig. 11 (c) is a graph showing the influence of the stator rotation speed on the response to the power consumption carbon emission, which increases as the stator rotation speed increases. Centerless grinding response F according to equation (3.7) gt And F ct Is in direct proportion to F ct And n w In inverse proportion, i.e. to stator speed n D In inverse proportion. Considering equations (2.3) and (3.11), the stator speed n D The proportional influence on the response energy consumption can offset the rotating speed n of the guide wheel D To F ct The inverse of (c) and therefore the conclusion can be drawn that carbon emissions increase in response to energy consumption, consistent with the increase in stator rpm, as reflected in the graph. As can be seen from (d) of fig. 11, the influence of the variation in the rotation speed of the stator on the basic energy consumption carbon emission is not large.
The effect of idler speed on carbon emissions and total carbon emissions for electrical power consumption is shown in fig. 12. Fig. 12 (a) shows the influence of the rotation speed of the stator on the carbon emission amount of power consumption, and it is seen that the carbon emission amount of power consumption increases after decreasing with the increase of the rotation speed of the stator, and the minimum value thereof occurs at the rotation speed of the stator of 4.39 r/s. Fig. 12 (b) shows the influence of the rotating speed of the guide wheel on the total carbon emission, and as shown in the figure, the total carbon emission and the electric energy consumption carbon emission have the same trend, the values thereof decrease and increase, and the minimum value still occurs when the rotating speed of the guide wheel is 4.39r/s, so that the influence of the rotating speed of the guide wheel on the centerless grinding carbon emission is mainly concentrated on the influence on the electric energy consumption carbon emission.
The final carbon emissions for different aspects for different idler wheel speeds at a wheel speed of 32.78r/s, according to the process parameters of scheme 1 above, are shown in table 5. It can be seen from the table that material removal carbon emissions and idling carbon consumption carbon emissions are the main components of the electrical energy consumption carbon emissions. As the rotating speed of the guide wheel is increased from 1r/s to 6r/s, the carbon emission removed by the material is reduced from 3.0843g to 0.5141g, and the reduction amplitude is large. At this time, the carbon emission of the idle energy consumption rises from 3.2698g to 3.8759g, and the rising amplitude is not large. The absolute numerical values of the basic energy consumption carbon emission and the response energy consumption carbon emission are not high, and the change is small along with the increase of the rotating speed of the guide wheel. Therefore, the carbon emission of the electric energy consumption is influenced most by the change of the rotating speed of the guide wheel, and the carbon emission is removed by the material.
TABLE 5 carbon emissions corresponding to different guide wheel rotation speeds
The effect of wheel speed on carbon emissions in various aspects of power consumption is shown in figure 13. Where (a) of fig. 13 is the influence of the grinding wheel rotation speed on the carbon emission removal of the material, it can be seen that as the grinding wheel rotation speed increases, the carbon emission removal of the material also increases. Fig. 13 (b) is a graph showing the influence of the grinding wheel rotation speed on the no-load energy consumption carbon emission, and the no-load energy consumption emission increases as the grinding wheel rotation speed increases. The no-load energy consumption comprises the no-load energy consumption of the grinding wheel shaft and the no-load energy consumption of the guide wheel shaft, a secondary relation between the grinding wheel rotating speed and the no-load energy consumption of the grinding wheel shaft is explained in section 3.14, and according to a calculated result, the no-load energy consumption of the grinding wheel is continuously increased along with the increase of the rotating speed in the effective rotating speed of the grinding wheel, which is consistent with the continuous increase of carbon emission along with the increase of the rotating speed of the grinding wheel in a figure. FIG. 13 (c) and FIG. 13 (d) are the effect of grinding wheel speed on carbon emissions in response to energy consumption and base energy consumption, respectivelyAnd (6) sounding. The carbon emission of the response energy consumption and the basic energy consumption is unchanged along with the increase of the rotation speed of the grinding wheel. Tangential grinding force F according to formulas (2.3) and (3.11) gt With the rotational speed n of the grinding wheel S There is no obvious relation, and the response energy consumption is in direct proportion to the tangential grinding force, so there is no obvious relation between the response energy consumption and the grinding wheel rotating speed. Likewise, there is no obvious relationship between the basic energy consumption and the grinding wheel speed, which follows n S The carbon emission of the basic energy consumption has no obvious change.
The effect of the wheel speed on the carbon emissions and total carbon emissions of the power consumption is shown in fig. 14. Fig. 14 (a) shows the influence of the grinding wheel rotation speed on the carbon emission in the power consumption, and fig. 14 (b) shows the influence of the grinding wheel rotation speed on the total carbon emission. It can be seen that within the allowable range of the grinding wheel rotating speed, the carbon emission of the electric energy consumption and the total carbon emission are continuously increased along with the increase of the grinding wheel rotating speed, and the difference between the carbon emission and the total carbon emission is not large under the conditions that the grinding wheel rotating speed is 20r/s and 70r/s respectively, so the influence of the grinding wheel rotating speed on the carbon emission of the centerless grinding is mainly focused on the influence on the electric energy consumption.
Similar to the rotating speed of the guide wheel, under the condition that the rotating speed of the guide wheel is 0.75r/s, the carbon emission in different aspects corresponding to different grinding wheel rotating speeds according to the process parameters of the scheme 1 is shown in the table 6. It can be seen from the table that as the wheel speed increases from 20r/s to 70r/s, the material removal carbon emissions rise from 2.5088g to 8.7810g, with a greater magnitude of rise. At this time, the carbon emission of the unloaded energy consumption rises from 3.1722g to 3.5880g, and the rising amplitude is not large. The absolute numerical values of the basic energy consumption carbon emission and the response energy consumption carbon emission are not high and do not change along with the increase of the rotating speed of the guide wheel. Therefore, the carbon emission of the electric energy consumption is most influenced by the change of the rotating speed of the grinding wheel, and the carbon emission is removed by the material.
TABLE 6 carbon emissions corresponding to different grinding wheel speeds
According to the grinding carbon emission model established above, the accuracy of the established grinding carbon emission model is verified through a grinding processing experiment of the plunger core and by combining a power signal in a processing process. Through analyzing the experimental result, the influence condition of the rotating speed of the grinding wheel and the rotating speed of the guide wheel on the emission of the centerless grinding carbon is explored.
Claims (5)
1. A method for establishing a centerless grinding ERWC carbon emission model based on grinding removal rate is characterized by comprising the following steps: firstly, deeply analyzing centerless grinding carbon emission influence factors, calculating material removal energy consumption and grinding wheel abrasion carbon emission by using a grinding material removal rate based on a power signal, effectively avoiding the deviation of centerless grinding carbon emission calculated based on an empirical formula to reflect the actual condition, establishing a centerless grinding carbon emission model, then, comprehensively considering the influence of electric energy consumption, resource consumption and waste on centerless grinding carbon emission based on the centerless grinding material removal rate model for monitoring the power signal, and establishing a centerless grinding ERWC carbon emission model; and finally, the established centerless grinding ERWC carbon emission model is used for experimental research of grinding processing of the plunger cores of the enterprise factories, and the influence of the rotating speed process parameters of the grinding wheel and the guide wheel on the centerless grinding carbon emission is deeply analyzed and researched.
2. The method of establishing a centerless grinding ERWC carbon emission model based on grinding removal rate of claim 1, wherein: the centerless grinding carbon emission influence factor analysis comprises the following steps: before establishing a centerless grinding carbon emission model, analyzing factors influencing centerless grinding carbon emission to determine components of the centerless grinding carbon emission: 1) the energy consumption generated in the operation process of the auxiliary device and the numerical control device is basically consumed, 2) the no-load energy consumption generated by the grinding wheel and the guide wheel due to the frequency conversion effect in the operation process of the machine tool is determined by the characteristics of the numerical control machine tool, 3) the energy consumption generated in the material removing process, and 4) the additional energy consumption caused by the additional load on the motor generated by the grinding force in the material removing process of the guide wheel; in addition, in the centerless grinding process, grinding dust generated by workpiece grinding, abrasion of a grinding wheel and consumption of lubricating liquid and grinding liquid are also important influence factors generated by carbon emission in the centerless grinding process, and by combining the analysis on the centerless grinding carbon emission influence factors, carbon emission generated in the centerless grinding processing process is determined from the three aspects of energy consumption, resource utilization and waste treatment.
3. The method for establishing a centerless grinding ERWC carbon emission model based on grinding removal rate as claimed in claim 1, wherein: the method for establishing the centerless grinding carbon emission model comprises the steps of firstly establishing the centerless grinding material removal rate model by monitoring a power signal, then establishing the centerless grinding carbon emission model according to the model, wherein the centerless grinding carbon emission model is established based on the power signal, establishing the centerless grinding power monitoring device by a power sensor and an oscilloscope element, establishing the grinding material removal rate model according to the measured power signal, after the grinding material removal rate model is established, using the model for calculating the material removal energy consumption carbon emission, the grinding wheel abrasion carbon emission, the grinding dust carbon emission and the like, and finally establishing the centerless grinding carbon emission model.
4. The method for establishing a centerless grinding ERWC carbon emission model based on grinding removal rate as claimed in claim 3, wherein: the centerless grinding material removal rate model comprises: the method comprises the steps of simplifying the plunge grinding process of centerless grinding, establishing a centerless grinding dynamics simplified model, deducing a grinding material removal rate general formula of four stages of centerless grinding based on the dynamics model, and establishing a grinding material removal rate model, wherein:
the workpiece is subjected to 7 acting forces in the grinding process, namely the gravity mg of the workpiece and the normal acting force F of the guide wheel to the workpiece cn And tangential friction force F ct Normal force F of the pallet against the workpiece bn And tangential force F bt Normal acting force F of grinding wheel to workpiece gn And tangential friction force F gt The main grinding parameters of the centerless grinding plunge grinding process comprise the linear velocity v of a grinding wheel s Linear velocity v of workpiece w The numerical control system controls the feeding speed
Plunge grinding through theseRealizing parameter control;
simplifying the centerless grinding excircle plunge grinding dynamic model into three spring systems, namely the rigidity k of the grinding wheel s Workpiece stiffness k w And contact rigidity k of grinding wheel and workpiece a The equivalent stiffness k of the simplified model e Is composed of
In the formula: k is a radical of a -the equivalent stiffness, N/mm,
k a -the contact stiffness of the grinding wheel with the workpiece, N/mm,
k s -the rigidity of the grinding wheel, N/mm,
k w -the stiffness of the workpiece, N/mm,
the feeding speed of the grinding wheel is set according to a numerical control system in the grinding process
Feed, after contact with the workpiece, generates a grinding force which is divided into a normal grinding force and a tangential grinding force, wherein the normal grinding force F gn The elastic deformation delta generated is
In the formula: f gn The normal grinding force, N,
delta-elastic deformation, mm,
in addition, the normal cutting force and the actual grinding feed rate
Has the following relationship
In the formula: k is a radical of c The grinding force coefficient is related to the grinding conditions,
a is the feeding depth of the workpiece under each rotation, mm,
n w -the rotational speed of the workpiece, r/s,
actual grinding feed rate
And theoretical feed rate
The difference between them is
In the formula:
-the numerical control system controls the feed speed, mm/s,
obtaining by combining the above formulas
5. The method of establishing a centerless grinding ERWC carbon emission model based on grinding removal rate of claim 1, wherein: the method for establishing the centerless grinding ERWC carbon emission model deduces and establishes the centerless grinding ERWC carbon emission model based on the deduced centerless grinding material removal rate model from the respective components of energy, resources and wastes, and specifically comprises the following steps:
(1) Carbon emission of grinding energy consumption
The electric energy consumption in the grinding process is mainly related to grinding power, the grinding power in the grinding process is mainly divided into four aspects, namely grinding basic power, grinding no-load power, material removal power and grinding response power, and the grinding power model is
P＝P base +P e +P grinding +P r (3.1)
In the formula: p base -grinding the basic power, W,
P e -grinding of the empty load power, W,
P grinding -the material removal power, W,
P r -the response power, W,
from the four aspects, respective power models are respectively established, and then corresponding electric energy consumption is obtained.
(1.1) energy consumption for Material removal
In the processing of centerless grinding, there is a gap between grinding power and grinding force
P grinding ＝k p F gt v s (3.2)
In the formula: k is a radical of p -the power factor is such that,
F gt the tangential friction of the grinding wheel against the workpiece, N,
v s -the linear velocity of the workpiece, m/s,
the relationship between the normal grinding force and the tangential grinding force is
F gn ＝AF gt (3.3)
In the formula: a, taking 1.5 to 3 as the proportional relation between the tangential grinding force and the normal grinding force,
the general theoretical power model of each stage of plunge grinding based on grinding power signals is shown in the general formulas (2.3) and (2.6)
According to the formula, the centerless grinding power model has a plurality of unknown parameters, the time constant tau can be calculated according to the change rate of the grinding power signal, and the power signal is calculated by using a least square method; in order to reduce the error in the process,improving accuracy of time constant tau, selecting power signal of semi-fine grinding stage with stable allowance as data for calculating time constant tau, and k p ，k c Least square fitting solution is carried out on the power signals, the unknown parameters are calculated, and finally a power model of the whole grinding stage is obtained,
it is thus possible to obtain a material removal energy of
In the formula: e g The energy consumption for material removal, W · s,
(1.2) grinding response energy consumption
The stress of the workpiece is balanced in the grinding process, and the force balance equation is
In the formula: mg-the self-weight of the workpiece, N,
F cn the normal force of the guide wheels on the workpiece, N,
F ct the tangential friction of the guide wheel against the workpiece, N,
F bn the normal force of the pallet against the workpiece, N,
F bt -the tangential force of the pallet on the workpiece, N,
theta, alpha, beta-geometric parameter angle, degree,
at the same time have
In the formula: f. of 1 -the coefficient of friction between the guide wheel and the workpiece,
f 2 coefficient of friction between pallet and workpiece, usually f 1 ＝0.2,f 2 ＝0.28，
From formulae (2.1) to (2.4) to F gt And F ct A relationship between them, order
Then the
The response power of the grinding machine caused by grinding the workpiece is
P r ＝F ct ν D (3.10)
In the formula: v is D -the linear speed of the guide wheels, m/s,
corresponding response energy consumption is
In the formula: e r -in response to the energy consumption, W.s,
(1.3) basic energy consumption
In the whole processing process of numerical control centerless grinding, an electrical cabinet, a hydraulic system, a cooling system, a lubricating system and a lighting system are always in operation, the power is basically kept unchanged in the whole processing process, the generated energy consumption is necessary for the normal operation of a grinding machine, and the sum of the power is called basic power P of the grinding machine base (ii) a The basic power of the grinding machine is basically unchanged in the grinding process, the basic power is directly measured by using a sensor, and the basic energy consumption is obtained by power integration
In the formula: e b The basic energy consumption, W.s,
(1.4) grinding no-load energy consumption
The machine tool has basic energy consumption and energy consumption generated by a grinding wheel motor and a guide wheel motor under the no-load state, the power of the grinding wheel motor and the power of the guide wheel motor change along with the respective rotating speed due to the frequency conversion function of a motor control system, and the power needs to be analyzed independently,
under no-load state, the relation between the power of the main shaft and the rotating speed is
P in ＝P u0 +k 1 n+k 2 n 2 (3.13)
In the formula: p in The power of the main shaft, W,
P u0 ，k 1 ，k 2 -a constant relating to the characteristics of the machine tool,
the centerless grinding mainly comprises two main shafts, namely a grinding wheel main shaft and a guide wheel main shaft, and the no-load energy consumption of the main shafts needs to be considered, so that a relation formula between the grinding wheel main shaft and the guide wheel main shaft and the rotating speed is respectively established according to the formula
In the formula: p is S The no-load power of the grinding wheel spindle, W,
P D the no-load power of the guide wheel shaft, W,
n D -the rotational speed of the guide wheels, r/s,
n S -the rotational speed of the grinding wheel, r/s,
the power of the grinding wheel main shaft and the guide wheel main shaft at different rotating speeds is obtained through experiments,
according to the experimental value, linear fitting is carried out on the experimental value by a least square method to respectively obtain calculation formulas of the power of the grinding wheel and the main shaft of the guide wheel at different rotating speeds,
the calculation process is as follows:
order to
The partial derivatives of the three parameters in the formula are respectively calculated, so that
Three parameters P are obtained u0 ，k 1 ，k 2 The value of (A) is obtained, so that a no-load power formula of the grinding wheel spindle and the guide wheel spindle is obtained, and further the no-load power of the machine tool is obtained
P k ＝P S +P D (3.17)
Corresponding no-load energy consumption is
In the formula: e k -the energy consumption in no-load, W.s,
(1.5) Total Electrical energy consumption carbon emissions
By deriving the above calculations for the respective powers of the four aspects of the resulting grinding power, the total power in the grinding process is obtained from equation (3.1), and the corresponding electrical energy corresponds to a total energy consumption of (3.5), (3.11), (3.12) and (3.18)
E＝E b +E k +E g +E r (3.19)
In the formula: e-total energy consumption of electric energy consumption, W.s,
the total carbon emission of the electric energy consumption is
In the formula: c E The total carbon emission of the electrical energy consumption, g,
C ep the carbon emission corresponding to the consumption of electric energy, g/(kW. H),
(2) Carbon emission from abrasion of grinding wheel
In the grinding process, the abrasion of the grinding wheel can lead to the reduction of the available amount of the grinding wheel and even the complete abandonment of the grinding wheel, the carbon emission generated in the part is not negligible and needs to be considered in a model,
obtaining the volume of the material removed from the workpiece according to a grinding material removal rate formula
In the formula: l-the length of the workpiece being ground, mm,
d W the diameter of the workpiece, mm,
ΔV W the volume of material removed from the workpiece, mm 3 ，
The wear ratio G of a grinding wheel refers to the volume of material removed from a workpiece corresponding to the wear per unit volume of the grinding wheel, and is usually
In the formula: Δ V S Amount of wear of grinding wheel, mm 3 ，
Thereby, the abrasion loss of the grinding wheel can be obtained, the abrasion loss conditions of the grinding wheel in different grinding stages,
the volume of the grinding wheel is
In the formula, B represents the width of the grinding wheel in mm,
d Smax the maximum diameter, mm,
d min the diameter of the minimum part of the grinding wheel, mm,
the grinding wheel can be used for grinding in the volume of
In the formula (I), the compound is shown in the specification,d Smin is the minimum available diameter, mm,
in the life cycle of the grinding wheel, the volume of the finished grinding wheel is
V d ＝NBa d π(d Smax +d Smin )/2 (3.25)
In the formula: n is the number of times that the grinding wheel can be dressed,
a d the depth of the grinding wheel dressing once is mm,
carbon emission of grinding wheel dressing is
In the formula: c SD The carbon emission, g,
s d -the dressing lead of the grinding wheel,
P SD -the grinding wheel dressing power, W,
ρ S density of grinding wheel, kg/m 3 ，
Carbon emission of abrasion of grinding wheel
In the formula: c GWP The carbon emission in g/kg corresponding to the production of the grinding wheel,
C GWD processing the carbon emission of the waste grinding wheel in g/kg,
(3) Carbon emission of abrasive dust
In the centerless grinding process, a large amount of abrasive dust is generated by the contact of the grinding wheel and the workpiece, and the abrasive dust can not be recycled, so the influence of the abrasive dust on carbon emission needs to be considered,
the workpiece is ground by a volume of
The carbon emission amount generated by the abrasive dust is
C WA ＝ΔV W ρ W C WCD (3.29)
In the formula: ρ is a unit of a gradient W -density of swarf, kg/mm 3 ，
C WCD -carbon emission factor, g/kg, produced by the treatment of the swarf,
(4) Carbon emission of lubricating fluid
In the centerless grinding process, lubricating fluid is required for a plurality of parts of a machine tool in order to reduce friction, the lubricating fluid is equivalent to a main shaft, and the carbon emission generated by the lubricating fluid is
In the formula: c L The carbon emission of the lubricating fluid, g,
t LO the time of use of the one-time processing lubricating fluid, s,
t LA the interval time between two changes of the lubricating fluid, s,
C LP -treating the carbon emission, g/L, produced by 1L of lubricating fluid,
Q LA the total volume of lubricating fluid, L,
(5) Carbon emission of grinding fluid
During grinding, although the grinding fluid is recycled, the grinding fluid needs to be replaced and replenished periodically due to evaporation and adhesion to abrasive dust and workpieces, and the carbon emission corresponding to the consumption of the grinding fluid is considered
In the formula: t is t GFO The service time of the grinding fluid for one-time processing, s,
t GFA the interval time between the grinding fluid changes, s,
C GFP -production millThe carbon emission required for the cutting fluid, g/L,
C GFD the carbon emission, g/L, required for the treatment of the grinding fluid,
Q GFI -the total volume of grinding fluid, L,
(6) Total carbon emission
Comprehensively considering the carbon emission of each item in the grinding process to obtain a model of the change of the total emission with time in the grinding process as
C Grinding (t)＝C E (t)+C SA (t)+C WA (t)+C L (t)+C GF (t) (3.32)。
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