摘要
模具是各类产品生产的主要工艺装备,是衡量一个国家工业化程度的重要指标,而铣削加工是最常用的高生产率模具加工的方法之一,但在当前工厂的数控铣削加工中,还存在许多问题。本论文主要针对数控铣削加工过程中影响表面加工质量的各因素来展开研究。
本文首先针对数控铣削加工过程中的主轴转速、进给量、切削深度等几个主要铣削参数进行研究,在Wintec My-80加工中心上加工Cr12模具钢实验工件,用最新研制的YDX-Ⅲ9702型压电式铣削测量仪在线测出大量铣削力数据;然后建立铣削力模型,分析铣削力对工件表面质量的影响程度。
其次,针对数控铣削加工过程中的横切、纵切和45°切等三种切削路径进行研究,应用扫描电子显微镜对刀具磨损进行观察,分析刀具磨损对表面质量的影响,为现场加工曲面提供依据。
用正交设计法设计实验,在研究单个因素的基础上对几个主要参数的交互作用影响进行研究,通过实验分析它们在加工过程中对表面质量的综合作用并结合具体工况,为现场加工提供参数参考值。
最后,综合以上三个实验的研究与分析,应用最新的参数优化方法——遗传算法,建立数学模型,并结合实验数据进行修正,最后建立参数数据库,为现场加工提供参数选择依据。
Mold is the primary technics equipment of all sorts of production, and it is an important target that weighs the extent of one country's industrialization. Meanwhile, milling is one of the most efficient mold cutting methods, and has got wide applications in various manufacturing industries, but there are still a lot of technical problems in NC milling process left to solve. The thesis mainly focuses on the factors influencing the surface quality of numerical control milling. The main achievements of this thesis are as follows:
Aiming at several key process parameters including spindle speed, feed rate and cutting deepness, experiments were designed, and which were carried out on a Wintec MV-80 machining center by cutting a Cr12 steel part. The cutting force is detected online by a piezoelectricity measure instrument called YDX—Ⅲ9702. By analyzing the experiment data, establishing the model of cutting force, and analyzing the influence to the surface quality.
Aiming at three kind of routes including transverse cutting, lengthways cutting and 45°cutting, experiments were designed. Then using Scanning Electron Microscope S-3500N to observe the wear of tools and analyzing the influence to the surface quality. Whereby, the theoretical basis for rational selection of process parameters can be provided.
Special experiments were designed in orthogonal design method. Based on the research of every single parameter, the relationship between them was discussed, so that some regulation of their combined effect on the surface quality could be found. Then reference values of common process parameters were provided according to different conditions.
Synthetizing the last three experiments'researching and analyzing, a new method of optimization based on Genetic Algorithm(GA) was proposed, then establishing and correcting the math model. In the end, a parameter database was established, which can provide selection parametres for the fieldwork.
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