精密磨削工艺预报软件的设计与开发
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摘要
磨削模型的多参数和磨削过程的复杂性决定了计算机仿真技术应用于磨削加工的重要性。本文依托国家863计划课题——特种材料(纳米结构陶瓷涂层)精密磨削及预报，研究开发了一个涵盖纳米结构陶瓷涂层材料、常规陶瓷材料和常规金属材料等加工对象的精密磨削加工工艺预报软件，该软件能方便地用于工程实际，指导生产，提高效率与精度，降低加工成本。本文的研究内容和研究成果对纳米结构材料的工业化应用及磨削工艺过程优化及智能控制等具有相当大的理论和实用价值。
本文首先在文献综述的基础上对计算机仿真技术在磨削领域的应用进行了初步的分析，提出了开发精密磨削工艺预报软件的出发点、主要研究目标、技术难点和解决方案等。
在分析磨削工艺、磨削模型及磨削工艺参数的特征的基础上，本文归纳并提取出了涵盖多种磨削工艺的可用于磨削工艺预报及优化的工艺预报输入参数，并且针对这些参数的有关特性，对之作了分类。
本文定义了软件的需求目的，对软件的整体结构作了规划设计，确定了软件的体系结构，提出了用于求解磨削工艺参数的专家系统方案以及基于效率和加工质量目标的最优工艺参数求解的参数优化策略，实现了任意模型的磨削工艺过程的预报及预报结果处理功能、预报模型参数求解专家系统、参数优化系统、预报工艺模型表达式识别与计算处理、建立了磨削工艺系统库、插值数据图表库、参数变量库、专家知识库、预报模型库等应用库体系。本文选用C++Builder6.0作为软件开发工具，初步建立起了基础的工具化的平台软件。
论文对软件进行了运行测试，结果表明，软件运行稳定，预报及优化结果与文献及实验结果具有良好的一致性，软件各功能模块运行准确可靠，配合协调。软件运行界面简洁美观、操作简单方便，已完全达到开发的预期目标。
Because of the multi-parameter of grinding models and the complicacy of grinding process, it is important for the computer simulation and prediction techniques to be applied to the field of grinding. This paper has studied and developed a precision grinding process prediction software involving the machining of nanostructured ceramic coatings, conventional ceramic and conventional metal etc. The software can be conveniently applied to engineering practice to guide production, improve efficiency and precision, reduce machining cost and so on. The study contents and results of this paper add considerable theoretic and practice value to the nano structured ceramic coatings in terms of industrial application.
Firstly, this paper puts forward the preliminary analysis for the application of computer simulation and prediction techniques in the field of grinding based on the literature reviews. The development goal of the software, the bottleneck and its of solution the software are presented in this paper.
Based on the analysis for the characteristics of grinding models and process parameters, the input parameters of precision process grinding are summed up and picked-up in this paper. They also are grouped according to their characteristics.
The requirement purpose of the software has been defined in this paper. The whole structure has also been layout. The scheme of expert system and the tactic of process parameter optimization according to the efficiency and machining quality are put forward in this paper. Many functions of the software have been achieved such as output of grinding process prediction and prediction results for the grinding models, the expert system for resolving the parameters of prediction models, process parameters optimization function, identification and computation of the expressions of models etc. The data-bases (DB) are also built such as grinding process system DB, interpolation data and chart DB, parameter variant DB, expert knowledge DB, prediction model DB and so on. C++Builder6.0 is selected as the development tool in this paper, and the software plat has been established initially.
The test for the soft is also run, and the stability and veracity of running are verified. All function module of the software can run accurately and reliably, and can work harmoniously. The software interfaces are compact and nice, and can operate simply and conveniently. The anticipate goal of development have already achieved.
本文首先在文献综述的基础上对计算机仿真技术在磨削领域的应用进行了初步的分析，提出了开发精密磨削工艺预报软件的出发点、主要研究目标、技术难点和解决方案等。
在分析磨削工艺、磨削模型及磨削工艺参数的特征的基础上，本文归纳并提取出了涵盖多种磨削工艺的可用于磨削工艺预报及优化的工艺预报输入参数，并且针对这些参数的有关特性，对之作了分类。
本文定义了软件的需求目的，对软件的整体结构作了规划设计，确定了软件的体系结构，提出了用于求解磨削工艺参数的专家系统方案以及基于效率和加工质量目标的最优工艺参数求解的参数优化策略，实现了任意模型的磨削工艺过程的预报及预报结果处理功能、预报模型参数求解专家系统、参数优化系统、预报工艺模型表达式识别与计算处理、建立了磨削工艺系统库、插值数据图表库、参数变量库、专家知识库、预报模型库等应用库体系。本文选用C++Builder6.0作为软件开发工具，初步建立起了基础的工具化的平台软件。
论文对软件进行了运行测试，结果表明，软件运行稳定，预报及优化结果与文献及实验结果具有良好的一致性，软件各功能模块运行准确可靠，配合协调。软件运行界面简洁美观、操作简单方便，已完全达到开发的预期目标。
Because of the multi-parameter of grinding models and the complicacy of grinding process, it is important for the computer simulation and prediction techniques to be applied to the field of grinding. This paper has studied and developed a precision grinding process prediction software involving the machining of nanostructured ceramic coatings, conventional ceramic and conventional metal etc. The software can be conveniently applied to engineering practice to guide production, improve efficiency and precision, reduce machining cost and so on. The study contents and results of this paper add considerable theoretic and practice value to the nano structured ceramic coatings in terms of industrial application.
Firstly, this paper puts forward the preliminary analysis for the application of computer simulation and prediction techniques in the field of grinding based on the literature reviews. The development goal of the software, the bottleneck and its of solution the software are presented in this paper.
Based on the analysis for the characteristics of grinding models and process parameters, the input parameters of precision process grinding are summed up and picked-up in this paper. They also are grouped according to their characteristics.
The requirement purpose of the software has been defined in this paper. The whole structure has also been layout. The scheme of expert system and the tactic of process parameter optimization according to the efficiency and machining quality are put forward in this paper. Many functions of the software have been achieved such as output of grinding process prediction and prediction results for the grinding models, the expert system for resolving the parameters of prediction models, process parameters optimization function, identification and computation of the expressions of models etc. The data-bases (DB) are also built such as grinding process system DB, interpolation data and chart DB, parameter variant DB, expert knowledge DB, prediction model DB and so on. C++Builder6.0 is selected as the development tool in this paper, and the software plat has been established initially.
The test for the soft is also run, and the stability and veracity of running are verified. All function module of the software can run accurately and reliably, and can work harmoniously. The software interfaces are compact and nice, and can operate simply and conveniently. The anticipate goal of development have already achieved.
引文
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[3] Jia K, Fischer T.E. Sliding wear of conventional and nanostructured cemented carbides. Wear, 1997,203-204:310-318
[4] 陈煌，林新华，曾毅等．热喷涂陶瓷涂层研究进展．硅酸盐学报，2002，Vol．30(2)235-239
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[7] 欧忠文，徐滨士，马士宁等．纳米表面工程中的纳米结构涂层组装．机械工程学报，2002，38(6)：5-10
[8] Stewart D A, Shipway P H, McCartney D G. Abrasive wear behaviour of conventional and nanocomposite HVOF-sprayed WC-Co coatings. Wear, 1999,225-229:789-798
[9] Zhang B, Liu X B, Deng Z H, et al. Grindiability comparison between conventional and nonstructured material coatings. Proceedings of the 5th International Conferenceon on Frontiers of Design and Manucfacturing (ICFDM'2002): 1-5
[10] 邓朝晖，张璧，孙宗禹．纳米结构金属陶瓷(n-WC／Co)涂层材料精密磨削的试验研究．湖南大学学报．2003．30(2)：35-40
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[23] Bifano T G., Dow T A, Scattergood R O. Ductile-regime grinding: A new technology for machining brittle materials. ASME., J. of Eng. for Ind.,1991,113:184-189
[24] Zhang B, Howes T D. Material-removal mechanisms in grinding ceramics. Annals of the CIRP, 1994,43(1):305-308
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[2] Jia K, Fischer T E. Abrasion resistance of nanostructured and conventional cemented carbides. Wear, 1996,200:201-214
[3] Jia K, Fischer T.E. Sliding wear of conventional and nanostructured cemented carbides. Wear, 1997,203-204:310-318
[4] 陈煌，林新华，曾毅等．热喷涂陶瓷涂层研究进展．硅酸盐学报，2002，Vol．30(2)235-239
[5] Wang Y, Jiang S, Wang M, et al. Abrasive wear characteristics of plasma sprayed nanostrucrured alumina/titania coatings. Wear, 2000,237:176-185
[6] Jordan E H, Gell M, Sohn Y H, et al. Fabrication and evaluation of plasma sprayed nanostructured alumina-titania coatings with superior properties. Materials Science and Engineering, A, 2001,301:80-89
[7] 欧忠文，徐滨士，马士宁等．纳米表面工程中的纳米结构涂层组装．机械工程学报，2002，38(6)：5-10
[8] Stewart D A, Shipway P H, McCartney D G. Abrasive wear behaviour of conventional and nanocomposite HVOF-sprayed WC-Co coatings. Wear, 1999,225-229:789-798
[9] Zhang B, Liu X B, Deng Z H, et al. Grindiability comparison between conventional and nonstructured material coatings. Proceedings of the 5th International Conferenceon on Frontiers of Design and Manucfacturing (ICFDM'2002): 1-5
[10] 邓朝晖，张璧，孙宗禹．纳米结构金属陶瓷(n-WC／Co)涂层材料精密磨削的试验研究．湖南大学学报．2003．30(2)：35-40
[11] Liu X B, Zhang B, Deng Z H. Grinding of nanostructured ceramic coatings: surface observations and material removal mechanisms.International Journal of Machine Tools & Manufacture, 2002,42(15): 1665-1676
[12] Deng Z H, Jin Q Y, Zhang B. Critical grinding condition models for predicting grinding cracks in nanostructured ceramic coatings. Key Engineering Material,2004,259—260: 273-277
[13] 邓朝晖，刘建，曹德芳等．纳米结构陶瓷涂层精密磨削的材料去除机理及磨削加工技术．金刚石与磨料磨具工程，2003，6(总138)：5-11
[14] 邓朝晖．纳米结构陶瓷涂层精密磨削机理及仿真预报技术的研究：[湖南大学博士学位论文]．长沙：湖南大学，2004，3
[15] 周曙光，关佳亮，徐中耀．陶瓷喷涂层精密镜面磨削技术的实验研究．金刚石与磨料磨具工程，2000，6(总120)：23-27
[16] Tan Y F, Martin P, Lescalier C, et al. Study on the ground surface quality of Cr_2O_3 coatings. Journal of Materials Processing technology, 2002,129:441-445
[17] Mamalis A G., Vaxevanidis N M. On the grinding of ceramic layer plasma-sparyed metal plates. In: 1st International Machining and Grinding Conference. Dearborn:Michigan, 1995,SME,MR-95-204
[18] 邓朝晖，张璧，孙宗禹等．陶瓷磨削中材料去除机理的研究进展．中国机械工程，2002，13(18)：1608-1611
[19] Malkin S , Hwang T W. Grinding mechanisms for ceramics. Annals of the CIRP, 1996,45(2): 569-580
[20] Zhang B. Surface integrity in machining hard-brittle materials. Journal of Japan Society for Abrasive Technology, 2003,47(3): 131-134
[21] Lawn B R. Fracture of brittle solids, 2nd Editions. Cambridge University Press,1993,249-306
[22] Kirchner H P. Damage.penetration at elongated machining grooves in hot-pressed Si_3N_4. J.Amer. Ceram.Soc.,1984,67:127-132
[23] Bifano T G., Dow T A, Scattergood R O. Ductile-regime grinding: A new technology for machining brittle materials. ASME., J. of Eng. for Ind.,1991,113:184-189
[24] Zhang B, Howes T D. Material-removal mechanisms in grinding ceramics. Annals of the CIRP, 1994,43(1):305-308
[25] Zhang B, Zheng X L, Tokura H,et al. Grinding Induced Damage in Ceramics. Journal of Materials Processing Technology, 132(2003):353-36
[26] Xu H H K, Jahanmir S, Ives L K. Material removal and damage formation mechanisms in grinding silicon nitride. J. Mater. Res., 1996,11: 1717-1724
[27] 王长琼，刘忠，华勇．工程结构陶瓷磨削力试验研究．金刚石与磨料磨具工程．1997．5(101)：18—20
[28] 贺永，董海，马勇等．工程陶瓷磨削力的研究现状与进展．金刚石与磨料磨具工程．2002．1(127)：40—43
[29] 仇君，梁式，庞庭阶．磨削力的灰色预测模型．广西大学学报．1997．22(2)：155—157
[30] 梁式．外圆切入磨削过程的计算机仿真．新技术工艺．1998，3：10—12
[31] 楼少敏．磨削加工实时检测及工艺参数智能选择的研究．新技术新工艺，2001，11：2—4
[32] 洪玉芳，程兆谦，朱聘和等．磨削系统加工过程的计算机仿真分析．机械制造．1999，4：15-17
[33] 王惠刚主编．计算机仿真原理及应用．第1版．长沙：国防科技大学出版社，1994：1—220
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