柴油发动机缸体切削参数优化与切削数据库研究
发布时间：2018-08-02 16:33
【摘要】：随着现代制造技术的发展,汽车工业受到越来越多的关注,已成为衡量一个国家工业发展水平的重要标志之一。发动机是汽车的核心部件,而缸体作为汽车发动机最重要的零件之一,其制造工艺对整车的性能影响重大。切削参数是制造工艺的核心,切削参数优化对改善产品质量,降低加工成本,提高生产效率有重要意义。涵盖主要切削信息的切削数据库管理系统,是实现切削数据信息化集成管理,工厂车间无纸化办公的重要途径。本文围绕柴油发动机缸体用合金铸铁的铣削加工过程,针对不同加工要求开展切削参数的优化研究,并以优化后的切削参数为基础,开发切削数据库。主要研究工作如下:(1)分析缸体粗加工过程中刀具磨损的情况,以降低刀具磨损和提高加工效率为目标优化切削参数。设计涂层硬质合金铣刀铣削合金铸铁的预实验,分析不同参数组合下刀具后刀面平均磨损量随金属去除体积的变化趋势,确定正交试验方案;利用扫描电镜和能量扩散谱仪(SEM-EDS)设备观察刀具磨损,得出氧化磨损、硬质点磨损、粘结磨损和扩散磨损是合金铸铁铣削过程中的主要磨损形式;根据正交实验结果,得到恒金属去除体积为30000mm3情况下刀具后刀面平均磨损量的预测模型;利用优化算法NSGA-Ⅱ对刀具磨损和加工时间进行多目标优化并验证预测模型和优化结果的准确性。(2)建立了缸体结合面球头铣削三维表面形貌预测模型,并利用广义回归拟合得到基于最小三维轮廓算术平均偏差Sba的最优每齿进给量fz与径向切削深度ae比值。根据加工过程中的刀具轨迹,构造出基于MATLAB软件的三维仿真模型;根据仿真模型,利用响应曲面法设计仿真试验,得出球头铣削表面的三维轮廓算术平均偏差只与每齿进给量和径向切削深度有关,并随着二者的变化成正相关变化趋势的结论;在每齿进给量与径向切削深度不同乘积条件下利用广义回归拟合得到关于两者的比值(fz/ae)预测模型;结合数学原理推导出归一化乘积/比值预测函数,以最小Sba为目标,得到最优比值,指导生产。(3)结合缸体加工的实际情况和最优切削参数,设计并开发了切削数据库及其管理系统。在缸体的加工工艺系统分析和切削数据库需求分析的基础上,确定切削数据库及其管理系统的管理对象和管理模式,完成切削数据库的搭建及相应管理系统软件的开发。通过对系统的调试,验证切削信息管理、用户管理等主要操作的可行性,为实现生产企业的切削信息数字化管理提供帮助。本研究针对缸体不同加工方式下不同生产目标进行的切削参数优化可以为企业加工工艺的制定提供参考,所开发的切削数据库及其管理系统对企业信息化内部控制有重要作用。
[Abstract]:With the development of modern manufacturing technology, the automobile industry has received more and more attention, and has become one of the important signs to measure the level of industrial development in a country. Engine is the core component of a car, and the cylinder body is one of the most important parts of the automobile engine. Its manufacturing process has a great influence on the performance of the whole vehicle. The cutting parameters are made. At the core of the process, the optimization of cutting parameters is of great significance for improving the quality of the products, reducing the cost of processing and improving the production efficiency. The cutting database management system covering the main cutting information is an important way to realize the integrated management of the information of the cutting data and the paperless office in the factory workshop. This paper is based on the alloy cast iron of the diesel engine cylinder. In the milling process, the cutting parameters are optimized for different processing requirements, and the cutting database is developed on the basis of the optimized cutting parameters. The main research work is as follows: (1) the analysis of tool wear in the rough machining process of the cylinder body is analyzed, and the cutting parameters are optimized in order to reduce the tool wear loss and improve the machining efficiency. The pre experiment of milling alloy cast iron with coated carbide milling cutter is carried out. The orthogonal test scheme is determined by analyzing the changing trend of the average wear amount of the cutter surface with the metal removal volume under different parameters. The wear loss of the tool is observed by scanning electron microscope and energy diffusion spectrometer (SEM-EDS), and the oxidation wear, hard point wear, bond wear and wear are obtained. Diffusion wear is the main wear form in the milling process of alloy cast iron. According to the orthogonal experimental results, the prediction model of the average wear of the tool face is obtained under the condition of the constant metal removal volume of 30000mm3. The optimization algorithm NSGA- II is used to optimize the tool wear and processing time and to verify the prediction model and the optimization results. (2) a three-dimensional surface morphology prediction model for ball head milling of cylinder head is established, and the ratio of optimal feed per tooth per tooth FZ to radial cutting depth based on the minimum 3D contour arithmetic mean deviation Sba is obtained by generalized regression fitting. A three-dimensional simulation model based on MATLAB software is constructed according to the tool track of the machining process. According to the simulation model, the simulation experiment is designed by the response surface method. It is concluded that the arithmetic mean deviation of the three-dimensional contour of the ball milling surface is only related to the feed and radial cutting depth of each tooth, and with the change of the two is the conclusion of the positive correlation, and the generalized return is used under the different product conditions of the feed per tooth and the radial cutting depth. The ratio (fz/ae) prediction model of the two is obtained, and the normalized product / ratio prediction function is derived by combining the mathematical principle. The optimal ratio is obtained with the minimum Sba as the target. (3) the cutting database and its management system are designed and developed in combination with the actual situation and the optimal cutting parameters of the cylinder body processing. On the basis of the analysis of the process system and the requirement analysis of the cutting database, the management object and management mode of the cutting database and its management system are determined. The construction of the cutting database and the development of the corresponding management system software are completed. The feasibility of the main operation, such as the cutting information management, the user management and so on, is verified by the debugging of the system. The cutting information digital management of production enterprises is helpful. The optimization of cutting parameters for different production targets in different processing modes of cylinder can provide reference for the formulation of enterprise processing technology. The developed cutting database and its management system play an important role in the internal control of enterprise's information and interest.
【学位授予单位】：山东大学
【学位级别】：硕士
【学位授予年份】：2017
【分类号】：TG506.7;U464.172
[Abstract]:With the development of modern manufacturing technology, the automobile industry has received more and more attention, and has become one of the important signs to measure the level of industrial development in a country. Engine is the core component of a car, and the cylinder body is one of the most important parts of the automobile engine. Its manufacturing process has a great influence on the performance of the whole vehicle. The cutting parameters are made. At the core of the process, the optimization of cutting parameters is of great significance for improving the quality of the products, reducing the cost of processing and improving the production efficiency. The cutting database management system covering the main cutting information is an important way to realize the integrated management of the information of the cutting data and the paperless office in the factory workshop. This paper is based on the alloy cast iron of the diesel engine cylinder. In the milling process, the cutting parameters are optimized for different processing requirements, and the cutting database is developed on the basis of the optimized cutting parameters. The main research work is as follows: (1) the analysis of tool wear in the rough machining process of the cylinder body is analyzed, and the cutting parameters are optimized in order to reduce the tool wear loss and improve the machining efficiency. The pre experiment of milling alloy cast iron with coated carbide milling cutter is carried out. The orthogonal test scheme is determined by analyzing the changing trend of the average wear amount of the cutter surface with the metal removal volume under different parameters. The wear loss of the tool is observed by scanning electron microscope and energy diffusion spectrometer (SEM-EDS), and the oxidation wear, hard point wear, bond wear and wear are obtained. Diffusion wear is the main wear form in the milling process of alloy cast iron. According to the orthogonal experimental results, the prediction model of the average wear of the tool face is obtained under the condition of the constant metal removal volume of 30000mm3. The optimization algorithm NSGA- II is used to optimize the tool wear and processing time and to verify the prediction model and the optimization results. (2) a three-dimensional surface morphology prediction model for ball head milling of cylinder head is established, and the ratio of optimal feed per tooth per tooth FZ to radial cutting depth based on the minimum 3D contour arithmetic mean deviation Sba is obtained by generalized regression fitting. A three-dimensional simulation model based on MATLAB software is constructed according to the tool track of the machining process. According to the simulation model, the simulation experiment is designed by the response surface method. It is concluded that the arithmetic mean deviation of the three-dimensional contour of the ball milling surface is only related to the feed and radial cutting depth of each tooth, and with the change of the two is the conclusion of the positive correlation, and the generalized return is used under the different product conditions of the feed per tooth and the radial cutting depth. The ratio (fz/ae) prediction model of the two is obtained, and the normalized product / ratio prediction function is derived by combining the mathematical principle. The optimal ratio is obtained with the minimum Sba as the target. (3) the cutting database and its management system are designed and developed in combination with the actual situation and the optimal cutting parameters of the cylinder body processing. On the basis of the analysis of the process system and the requirement analysis of the cutting database, the management object and management mode of the cutting database and its management system are determined. The construction of the cutting database and the development of the corresponding management system software are completed. The feasibility of the main operation, such as the cutting information management, the user management and so on, is verified by the debugging of the system. The cutting information digital management of production enterprises is helpful. The optimization of cutting parameters for different production targets in different processing modes of cylinder can provide reference for the formulation of enterprise processing technology. The developed cutting database and its management system play an important role in the internal control of enterprise's information and interest.
【学位授予单位】：山东大学
【学位级别】：硕士
【学位授予年份】：2017
【分类号】：TG506.7;U464.172
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