考虑质量和能耗的陶瓷抛光工艺参数仿真与优化

发布时间：2018-09-08 14:14

【摘要】：在整个瓷砖抛光生产线中陶瓷抛光机是最重要的加工设备,瓷砖经过抛光加工后表面具有平整光亮的特点。瓷砖抛光的质量主要取决于抛光机工艺参数的制定,然而生产过程中普遍存在由于工艺参数设置不当造成漏抛、返抛的现象。同时陶瓷抛光机是高能耗设备,占据了30%-40%的抛光生产线电力成本,而传统陶瓷抛光机工艺参数的制定大多建立在改善瓷砖表面加工质量和提高抛光的生产效率等问题上,缺乏能源消耗过程的考虑,导致能源损耗大、利用率低。节能降耗一直是陶瓷生产企业关注的焦点,工艺参数是控制生产质量和能耗的关键,基于参数的优化寻求满足抛光质量最好与能耗最小的节能方式不仅可为陶瓷企业节省成本提高收益,更为我国节能减排事业提供切实的技术基础。本文以新型摆动式陶瓷抛光机为原型,针对瓷砖抛光过程中质量与能耗的相互关系展开研究,建立了以瓷砖进给速度、磨头角速度、磨头压强以及横梁摆动频率为控制变量的抛光质量模型与加工能耗模型,然后基于上述模型分别构建质量最优的单目标与既考虑质量又考虑能耗的多目标工艺参数优化模型,并使用遗传算法对其进行优化,以分析两目标之间存在的差异与联系。本文主要研究内容如下：1.介绍了陶瓷抛光机的主要组成部件以及其工作原理,包括瓷砖输送部件、横梁摆动部件、磨头组件。接着分析了磨块的材料特性,介绍不同粒度号与组织号的磨块在抛光过程的作用和特点。2.从抛光机的加工机理出发,构建了磨块上任一点的运动学方程；基于压痕断裂力学理论研究了不同粒度号与磨粒垂直方向磨削深度之间的关系,以适应磨粒在一定压强下压入砖面的实际情况。结合运动学方程和磨削深度理论建立了以瓷砖表面高度方差为评价指标的质量模型；利用MATLAB软件对模型进行仿真分析,探讨了不同运动参数对磨削质量的影响规律。3.根据压痕断裂力学理论,分析了磨粒在不同压强下对瓷砖产生横向裂纹的特征尺寸,计算出磨粒加工过程中砖面去除的体积；根据脆性材料去除机理研究产生单位去除体积所需的能耗,结合前面建立运动方程与单位体积能耗建立以瓷砖表面能耗总和为评价指标的能耗模型。同样地,通过MATLAB软件进行仿真实验,分析抛光工艺参数对抛光能耗的影响规律。4.为实现抛光质量和能耗达到可控的目标,在满足高效磨削条件的同时,以磨削参数为变量分别构建以抛磨质量最好的单目标和以质量、能耗最优的多目标优化模型,应用遗传算法进行优化并对得到的解集对比分析,为实际生产加工提供指导意义。
[Abstract]:Ceramic polishing machine is the most important processing equipment in the whole ceramic tile polishing production line. The quality of ceramic tile polishing mainly depends on the formulation of polishing machine technological parameters. However, the phenomenon of leakage and backcasting is common in the production process due to improper setting of process parameters. At the same time, ceramic polishing machine is a high energy consumption equipment, which accounts for 30% to 40% of the power cost of polishing production line. However, most of the process parameters of traditional ceramic polishing machine are based on improving the quality of ceramic tile surface processing and improving the production efficiency of polishing. Lack of energy consumption process, leading to high energy consumption, low efficiency. Energy saving and consumption reduction have always been the focus of attention of ceramic manufacturing enterprises. Process parameters are the key to control production quality and energy consumption. The optimization based on parameters can not only save the cost and increase the income of ceramic enterprises, but also provide a practical technical basis for the cause of energy saving and emission reduction in China to find a way to meet the best polishing quality and minimum energy consumption. In this paper, a new type of swinging ceramic polishing machine is used as the prototype, aiming at the relationship between quality and energy consumption in the process of ceramic tile polishing, the feed speed of ceramic tile and the angular velocity of grinding head are established. The polishing quality model and the processing energy consumption model which are controlled by the pressure of the grinding head and the swing frequency of the beam are presented. Based on the above models, the optimization models of single objective and multi-objective process parameters considering both quality and energy consumption are constructed, respectively. Genetic algorithm is used to optimize it to analyze the difference and relationship between the two objectives. The main contents of this paper are as follows: 1. This paper introduces the main components of ceramic polishing machine and its working principle, including ceramic tile conveying parts, beam swinging parts and grinding head components. Then, the material characteristics of grinding block are analyzed, and the function and characteristics of grinding block with different particle size number and microstructure number in polishing process are introduced. Based on the machining mechanism of the polishing machine, the kinematics equation of any point on the grinding block is constructed, and the relationship between the different particle sizes and the grinding depth in the vertical direction is studied based on the theory of indentation fracture mechanics. In order to adapt to wear particles under a certain pressure into the actual situation of brick surface. Combined with kinematics equation and grinding depth theory, a quality model based on the variance of ceramic tile surface height is established, and the simulation analysis of the model is carried out by using MATLAB software, and the influence of different motion parameters on grinding quality is discussed. According to the theory of indentation fracture mechanics, the characteristic size of transverse crack produced by abrasive particles on ceramic tile under different pressures is analyzed, and the volume of tile surface removal in the process of abrasive grain processing is calculated. According to the mechanism of brittleness material removal, the energy consumption needed to produce unit removal volume is studied. The energy consumption model based on the total energy consumption of ceramic tile surface is established in combination with the former motion equation and the energy consumption per unit volume. Similarly, the influence of polishing process parameters on polishing energy consumption is analyzed by simulation experiments with MATLAB software. In order to achieve the goal of controllable polishing quality and energy consumption, a multi-objective optimization model with the best polishing quality and the best energy consumption is constructed by taking grinding parameters as variables while satisfying the conditions of high efficiency grinding. Genetic algorithm is used to optimize and analyze the solution set, which provides guidance for practical production and processing.
【学位授予单位】：广东工业大学
【学位级别】：硕士
【学位授予年份】：2015
【分类号】：TQ174.627

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