【摘要】：隨著現(xiàn)代制造技術(shù)的發(fā)展,汽車工業(yè)受到越來越多的關(guān)注,已成為衡量一個(gè)國家工業(yè)發(fā)展水平的重要標(biāo)志之一。發(fā)動機(jī)是汽車的核心部件,而缸體作為汽車發(fā)動機(jī)最重要的零件之一,其制造工藝對整車的性能影響重大。切削參數(shù)是制造工藝的核心,切削參數(shù)優(yōu)化對改善產(chǎn)品質(zhì)量,降低加工成本,提高生產(chǎn)效率有重要意義。涵蓋主要切削信息的切削數(shù)據(jù)庫管理系統(tǒng),是實(shí)現(xiàn)切削數(shù)據(jù)信息化集成管理,工廠車間無紙化辦公的重要途徑。本文圍繞柴油發(fā)動機(jī)缸體用合金鑄鐵的銑削加工過程,針對不同加工要求開展切削參數(shù)的優(yōu)化研究,并以優(yōu)化后的切削參數(shù)為基礎(chǔ),開發(fā)切削數(shù)據(jù)庫。主要研究工作如下:(1)分析缸體粗加工過程中刀具磨損的情況,以降低刀具磨損和提高加工效率為目標(biāo)優(yōu)化切削參數(shù)。設(shè)計(jì)涂層硬質(zhì)合金銑刀銑削合金鑄鐵的預(yù)實(shí)驗(yàn),分析不同參數(shù)組合下刀具后刀面平均磨損量隨金屬去除體積的變化趨勢,確定正交試驗(yàn)方案;利用掃描電鏡和能量擴(kuò)散譜儀(SEM-EDS)設(shè)備觀察刀具磨損,得出氧化磨損、硬質(zhì)點(diǎn)磨損、粘結(jié)磨損和擴(kuò)散磨損是合金鑄鐵銑削過程中的主要磨損形式;根據(jù)正交實(shí)驗(yàn)結(jié)果,得到恒金屬去除體積為30000mm3情況下刀具后刀面平均磨損量的預(yù)測模型;利用優(yōu)化算法NSGA-Ⅱ?qū)Φ毒吣p和加工時(shí)間進(jìn)行多目標(biāo)優(yōu)化并驗(yàn)證預(yù)測模型和優(yōu)化結(jié)果的準(zhǔn)確性。(2)建立了缸體結(jié)合面球頭銑削三維表面形貌預(yù)測模型,并利用廣義回歸擬合得到基于最小三維輪廓算術(shù)平均偏差Sba的最優(yōu)每齒進(jìn)給量fz與徑向切削深度ae比值。根據(jù)加工過程中的刀具軌跡,構(gòu)造出基于MATLAB軟件的三維仿真模型;根據(jù)仿真模型,利用響應(yīng)曲面法設(shè)計(jì)仿真試驗(yàn),得出球頭銑削表面的三維輪廓算術(shù)平均偏差只與每齒進(jìn)給量和徑向切削深度有關(guān),并隨著二者的變化成正相關(guān)變化趨勢的結(jié)論;在每齒進(jìn)給量與徑向切削深度不同乘積條件下利用廣義回歸擬合得到關(guān)于兩者的比值(fz/ae)預(yù)測模型;結(jié)合數(shù)學(xué)原理推導(dǎo)出歸一化乘積/比值預(yù)測函數(shù),以最小Sba為目標(biāo),得到最優(yōu)比值,指導(dǎo)生產(chǎn)。(3)結(jié)合缸體加工的實(shí)際情況和最優(yōu)切削參數(shù),設(shè)計(jì)并開發(fā)了切削數(shù)據(jù)庫及其管理系統(tǒng)。在缸體的加工工藝系統(tǒng)分析和切削數(shù)據(jù)庫需求分析的基礎(chǔ)上,確定切削數(shù)據(jù)庫及其管理系統(tǒng)的管理對象和管理模式,完成切削數(shù)據(jù)庫的搭建及相應(yīng)管理系統(tǒng)軟件的開發(fā)。通過對系統(tǒng)的調(diào)試,驗(yàn)證切削信息管理、用戶管理等主要操作的可行性,為實(shí)現(xiàn)生產(chǎn)企業(yè)的切削信息數(shù)字化管理提供幫助。本研究針對缸體不同加工方式下不同生產(chǎn)目標(biāo)進(jìn)行的切削參數(shù)優(yōu)化可以為企業(yè)加工工藝的制定提供參考,所開發(fā)的切削數(shù)據(jù)庫及其管理系統(tǒng)對企業(yè)信息化內(nèi)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.
【學(xué)位授予單位】：山東大學(xué)
【學(xué)位級別】：碩士
【學(xué)位授予年份】：2017
【分類號】：TG506.7;U464.172

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本文編號：2160027