自由曲面高速铣削工艺规划与自主决策技术
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摘要
高速加工技术经过几十年发展,以其独有的技术特点,广泛应用于各个领域。目前,高速加工设备越来越受到企业青睐,在某些行业的产品生产中具有不可替代作用,如模具制造、航空航天产品制造等。实际生产加工中,工件的自由曲面越来越多,对表面质量和加工效率要求越来越高。高速加工技术的使用经验较少;工艺理论研究相对不足;高速加工工艺的智能决策技术水平还不高;工艺的制定多依赖于实际生产经验的积累,效率较低,受生产地点限制。为解决以上问题,最大限度的发挥高速加工的优势,对自由曲面高速加工的工艺规划和自主决策技术进行深入研究已经势在必行。
高速加工切削参数的研究是高速加工工艺自主决策的前提条件,也是高速加工工艺参数自主决策的判断基础和依据,决策理论和方法是自主决策的必备条件。本文在对国内外自由曲面高速加工的工艺技术和自主决策技术的研究现状与发展趋势进行分析的基础上,以自由曲面的高速铣削工艺为核心,以实现工件材料高速铣削的工艺自主决策为目标,进行了深入研究。主要研究内容、采用方法和结论如下:
(1)在典型工件材料高速切削试验基础上,对高速铣削的切削参数及其交互影响项与表面粗糙度间的关系进行了研究。针对试验室试验、随机数据和生产数据的数据特点,采用了不同的试验和数据处理办法,并进行了对比分析。利用试验数据,对相关切削参数进行了回归分析,获得相应公式;深入讨论了各工艺参数对表面粗糙度的影响,并对切削参数间的交互作用对表面粗糙度的影响进行了分析。
研究了球头铣刀高速铣削倾角变化对表面质量的影响规律。分析表明,在试验参数范围内,铣刀倾角对表面粗糙度的影响最显著,影响规律为:当倾角由0度开始到25度变大,表面粗糙度由急剧变坏到急剧变好;讨论分析了最差切削倾角的形成原因,并进行了确定。
(2)对切削参数进行了规划,讨论了曲面加工中的相关约束条件。对轴负载力和轴加速度与进给速度的关系进行了分析;对轴约束下的高速加工S曲线进给进行了速度规划;根据环形铣刀的可铣充分条件,推导了球头铣刀可铣充分条件;本文用等价圆弧拟合工件表面曲线,并推导得到球头铣刀三轴铣削自由曲面的径向进给公式,对于曲率变化大的的情况,如一些拐角,根据待加工曲面上曲线与球头铣刀刀心间的几何关系,用等距线的矢量方程来描述其生成的轨迹,提出了精确的径向进给确定方法。
(3)对高速加工中刀具的寿命进行了估计。根据相对Miner理论,在已知其他刀具寿命,且与当前刀具相似、负载相似的基础上,对当前刀具寿命进行了确定。在当前高速切削刀具寿命数据较少的情况下,可以避免加工中途换刀,提高刀具使用效率,减少刀具寿命试验,具有很强实用性;针对相对Miner理论使用的前提条件,本文根据刀具材料自身属性和刀具的形状特点,对刀具间的相似性进行判定;利用粗糙集理论中的容差关系,对缺失数据进行补足或舍弃,可以尽量的减少有限的刀具属性数据缺失带来的不利影响。
提出了一种工件材料连续属性离散方法。针对数据处理中工件材料的连续属性需要离散化处理问题,本文对影响灰色绝对关联度的数据离散区间进行了分析,结合灰熵定义,对连续数据区间的均衡度进行了确定。在此基础上,提出了一种多阶段的基于灰色绝对关联度和灰熵的动态离散方法,可以在不破坏数据间分类能力基础上,对连续属性进行离散;结合灰色绝对关联度的关于空缺值的定理,以及粗糙集的属性约简办法,对不完备信息的工件材料属性进行了约简,并获得唯一的属性相对约简组合。
(4)对高速加工工艺参数的自主决策方法进行了研究,提出了三种适用于自由曲面高速精加工工艺自主决策的方法。对于几个给定的工艺方案优选情况,采用了改进的层次分析法进行决策判断,并根据高速铣削中生产规律,重新给出确定权重的方法,提高了使用精度;对于已知切削参数与表面粗擦度的回归关系的情况,应用数学规划的方法进行了切削参数优化;对于切削参数未知的给定材料切削,本文考虑了切削环境的影响,首先以最近邻算法,对以材料可切削性和以刀具规格为代表的切削环境进行相似度计算,并获得相似范例,进而采用最小二乘支持向量机算法,进行范例推理的工艺自主决策。
HSM(High Speed Milling)has been wildly used in many fields after decades years of development. It is more and more important to enterprise and has irreplaceable function on some product manufacturing, such as dies and aviation products.Workpieces have more and more free form surfaces. The quality and efficiency of workpieces is reguired more and more highly.The operation experience of HSM is relatively less.The research on theory of HSM process is a relative shortage.The intelligent decision technology of HSM process is not high.Its process planning depends on experiences and is limited by working environment. Therefore, it is necessary to study on HSM process planning of free-form furface and autonomous decision technology.
The research on HSM parameters is a precondition and of HSM process planning .The decision theorires and methods are essential conditions. On the base of analysis on research status and development of HSM process planning and autonomous decision, this paper has further researched on the HSM process and autonomous decision technology .The main research contents and methods include:
(1) On the basis of tests of HSM typical materials, this paper researched on the relationship between milling parameters and surface roughness. Using the different test methods to fit different milling conditions.By using test datas, the milling parameters were made regression analysis, some formulas were got, the influence of single parameters on surface roughness was discussed, and the influence of interaction items on surface roughness was analysised.
The influence law of ball end mill pitch angle was researched. The test indicated that the influence of ball end mill pitch angle on roughness is obvious in test. The influence law is that the roughness largen quckly at first,then becomes smaller quickly in the range of pitch angle from 0 degree to 25 degree.The forming reason of the poorest pitch angle was discussed and formula was determined.
(2)The HSM parameters were planned, and the relative constraints of HSM free form surface were discussed in this paper. The relationship between the axis force,aixis acceleration and feed velocity was analysised.The S curve feed velocity was planned under the axis constraints.The sufficient milling conditions of ball end mill were derivated according to the sufficient milling conditions of ring mill cutter. By using equicalent arc to fit the curve on workpiece surface, the radial feed formulas were got which three axis constant scallop height milling free form surface with ball end mill.According to the offset curve vector equation and the geometry relationship between the workpiece surface and tool path, this paper has given a more precise method which getting the radial feed when using equivalent arc is not suitable. For instance, there are some corners or curves with rapid currage change.
(3)The tool life was determined in HSM. On the basis of having known the tool and load is similar with another, this paper determinded the tool life according to the relative Miner theory. In the condition of lack of tool life datas, it could avoid tool changing during cutting, increase the use efficiency, decrease the times of tool life test,and is practical.The similarity between tools was evaluated according to the material attributes and shape characteristics of tools. To fill or forsake the missing datas could decrease the unfavorable influence by using tolerance relation of rough set theory.
A discrete method of continous attributes of workpiece material was proposed. This paper analysis the interval of data discretization about the grey absolute incidence degree ,give a determinding method of banlance of contimuous data interval with grey entropy and propose a dynamic multi-stage discrete method of continuous attributes based on absolute degree of grey incidence and balance degree of grey entropy. It can keep the classification ability.With the theorem of grey absolute incidence degree, the incomplete attributes are reduced, and the result is unique.
(4)This paper researched on the autonomous decision of HSM parameters,and has proposed three methods to meet different conditions of HSM free form surface.In the condition of several given process plan optimal selection,AHP is a good decision method.According to machining laws of HSM, a new method of measuring weights was given,and has good effect. In the condition of known cutting formula,the cutting parameters is optimized by using mathematical programming.In the condition of unknown cutting formula, similarity which is about materials machinability and tool spectfication was calculate firstly considering cutting environment. Then the similar case was get, At last the process decision was done based on CBR by using LS-SVM.
高速加工切削参数的研究是高速加工工艺自主决策的前提条件,也是高速加工工艺参数自主决策的判断基础和依据,决策理论和方法是自主决策的必备条件。本文在对国内外自由曲面高速加工的工艺技术和自主决策技术的研究现状与发展趋势进行分析的基础上,以自由曲面的高速铣削工艺为核心,以实现工件材料高速铣削的工艺自主决策为目标,进行了深入研究。主要研究内容、采用方法和结论如下:
(1)在典型工件材料高速切削试验基础上,对高速铣削的切削参数及其交互影响项与表面粗糙度间的关系进行了研究。针对试验室试验、随机数据和生产数据的数据特点,采用了不同的试验和数据处理办法,并进行了对比分析。利用试验数据,对相关切削参数进行了回归分析,获得相应公式;深入讨论了各工艺参数对表面粗糙度的影响,并对切削参数间的交互作用对表面粗糙度的影响进行了分析。
研究了球头铣刀高速铣削倾角变化对表面质量的影响规律。分析表明,在试验参数范围内,铣刀倾角对表面粗糙度的影响最显著,影响规律为:当倾角由0度开始到25度变大,表面粗糙度由急剧变坏到急剧变好;讨论分析了最差切削倾角的形成原因,并进行了确定。
(2)对切削参数进行了规划,讨论了曲面加工中的相关约束条件。对轴负载力和轴加速度与进给速度的关系进行了分析;对轴约束下的高速加工S曲线进给进行了速度规划;根据环形铣刀的可铣充分条件,推导了球头铣刀可铣充分条件;本文用等价圆弧拟合工件表面曲线,并推导得到球头铣刀三轴铣削自由曲面的径向进给公式,对于曲率变化大的的情况,如一些拐角,根据待加工曲面上曲线与球头铣刀刀心间的几何关系,用等距线的矢量方程来描述其生成的轨迹,提出了精确的径向进给确定方法。
(3)对高速加工中刀具的寿命进行了估计。根据相对Miner理论,在已知其他刀具寿命,且与当前刀具相似、负载相似的基础上,对当前刀具寿命进行了确定。在当前高速切削刀具寿命数据较少的情况下,可以避免加工中途换刀,提高刀具使用效率,减少刀具寿命试验,具有很强实用性;针对相对Miner理论使用的前提条件,本文根据刀具材料自身属性和刀具的形状特点,对刀具间的相似性进行判定;利用粗糙集理论中的容差关系,对缺失数据进行补足或舍弃,可以尽量的减少有限的刀具属性数据缺失带来的不利影响。
提出了一种工件材料连续属性离散方法。针对数据处理中工件材料的连续属性需要离散化处理问题,本文对影响灰色绝对关联度的数据离散区间进行了分析,结合灰熵定义,对连续数据区间的均衡度进行了确定。在此基础上,提出了一种多阶段的基于灰色绝对关联度和灰熵的动态离散方法,可以在不破坏数据间分类能力基础上,对连续属性进行离散;结合灰色绝对关联度的关于空缺值的定理,以及粗糙集的属性约简办法,对不完备信息的工件材料属性进行了约简,并获得唯一的属性相对约简组合。
(4)对高速加工工艺参数的自主决策方法进行了研究,提出了三种适用于自由曲面高速精加工工艺自主决策的方法。对于几个给定的工艺方案优选情况,采用了改进的层次分析法进行决策判断,并根据高速铣削中生产规律,重新给出确定权重的方法,提高了使用精度;对于已知切削参数与表面粗擦度的回归关系的情况,应用数学规划的方法进行了切削参数优化;对于切削参数未知的给定材料切削,本文考虑了切削环境的影响,首先以最近邻算法,对以材料可切削性和以刀具规格为代表的切削环境进行相似度计算,并获得相似范例,进而采用最小二乘支持向量机算法,进行范例推理的工艺自主决策。
HSM(High Speed Milling)has been wildly used in many fields after decades years of development. It is more and more important to enterprise and has irreplaceable function on some product manufacturing, such as dies and aviation products.Workpieces have more and more free form surfaces. The quality and efficiency of workpieces is reguired more and more highly.The operation experience of HSM is relatively less.The research on theory of HSM process is a relative shortage.The intelligent decision technology of HSM process is not high.Its process planning depends on experiences and is limited by working environment. Therefore, it is necessary to study on HSM process planning of free-form furface and autonomous decision technology.
The research on HSM parameters is a precondition and of HSM process planning .The decision theorires and methods are essential conditions. On the base of analysis on research status and development of HSM process planning and autonomous decision, this paper has further researched on the HSM process and autonomous decision technology .The main research contents and methods include:
(1) On the basis of tests of HSM typical materials, this paper researched on the relationship between milling parameters and surface roughness. Using the different test methods to fit different milling conditions.By using test datas, the milling parameters were made regression analysis, some formulas were got, the influence of single parameters on surface roughness was discussed, and the influence of interaction items on surface roughness was analysised.
The influence law of ball end mill pitch angle was researched. The test indicated that the influence of ball end mill pitch angle on roughness is obvious in test. The influence law is that the roughness largen quckly at first,then becomes smaller quickly in the range of pitch angle from 0 degree to 25 degree.The forming reason of the poorest pitch angle was discussed and formula was determined.
(2)The HSM parameters were planned, and the relative constraints of HSM free form surface were discussed in this paper. The relationship between the axis force,aixis acceleration and feed velocity was analysised.The S curve feed velocity was planned under the axis constraints.The sufficient milling conditions of ball end mill were derivated according to the sufficient milling conditions of ring mill cutter. By using equicalent arc to fit the curve on workpiece surface, the radial feed formulas were got which three axis constant scallop height milling free form surface with ball end mill.According to the offset curve vector equation and the geometry relationship between the workpiece surface and tool path, this paper has given a more precise method which getting the radial feed when using equivalent arc is not suitable. For instance, there are some corners or curves with rapid currage change.
(3)The tool life was determined in HSM. On the basis of having known the tool and load is similar with another, this paper determinded the tool life according to the relative Miner theory. In the condition of lack of tool life datas, it could avoid tool changing during cutting, increase the use efficiency, decrease the times of tool life test,and is practical.The similarity between tools was evaluated according to the material attributes and shape characteristics of tools. To fill or forsake the missing datas could decrease the unfavorable influence by using tolerance relation of rough set theory.
A discrete method of continous attributes of workpiece material was proposed. This paper analysis the interval of data discretization about the grey absolute incidence degree ,give a determinding method of banlance of contimuous data interval with grey entropy and propose a dynamic multi-stage discrete method of continuous attributes based on absolute degree of grey incidence and balance degree of grey entropy. It can keep the classification ability.With the theorem of grey absolute incidence degree, the incomplete attributes are reduced, and the result is unique.
(4)This paper researched on the autonomous decision of HSM parameters,and has proposed three methods to meet different conditions of HSM free form surface.In the condition of several given process plan optimal selection,AHP is a good decision method.According to machining laws of HSM, a new method of measuring weights was given,and has good effect. In the condition of known cutting formula,the cutting parameters is optimized by using mathematical programming.In the condition of unknown cutting formula, similarity which is about materials machinability and tool spectfication was calculate firstly considering cutting environment. Then the similar case was get, At last the process decision was done based on CBR by using LS-SVM.
引文
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