【摘要】：模具被普遍的應(yīng)用于汽車產(chǎn)業(yè)、手機(jī)產(chǎn)業(yè)和航空航天產(chǎn)業(yè)等領(lǐng)域,因此模具的數(shù)控加工精度是一個(gè)重要研究對(duì)象。由于產(chǎn)品零件的形狀變化萬千,使得模具的形狀千差萬別,特別是模具有較多拐角時(shí),增加了加工難度。這些角度不同的銳角、鈍角等內(nèi)外過渡連接,使得銑削加工過程中,刀具產(chǎn)生的銑削力波動(dòng)增大造成工件震顫、加工效率降低等問題。本文針對(duì)平面拐角銑削加工效率和銑削力問題進(jìn)行了研究。首先,查閱了國內(nèi)外研究現(xiàn)狀,拐角處優(yōu)化加工有三種方式:(1)數(shù)控系統(tǒng)控制方面,利用數(shù)控系統(tǒng)的自身的控制方式如運(yùn)動(dòng)軌跡插補(bǔ)特性、速度前瞻預(yù)處理、加減速運(yùn)動(dòng)控制等方面;(2)刀具軌跡方面,考慮的是最優(yōu)路徑、走刀優(yōu)化等;(3)工藝參數(shù)方面,主要考慮進(jìn)給速度、切削深度和主軸轉(zhuǎn)速等參數(shù)。比較三種方式優(yōu)缺點(diǎn),本文采用工藝參數(shù)方面。其次,剖析了銑削平面拐角時(shí)銑刀與工件的位置參數(shù)關(guān)系,得出銑削過程中刀刃真實(shí)軌跡,經(jīng)分析其真實(shí)軌跡給出了平面拐角銑削加工過程中相應(yīng)參變量的數(shù)學(xué)表達(dá)式。針對(duì)典型性的模具型腔拐角,使用平面幾何理論對(duì)銑削加工過程中銑刀與工件不同階段的接觸情況進(jìn)行了分析,得出了銑刀與工件瞬時(shí)接觸角的變化趨勢(shì),并根據(jù)瞬時(shí)接觸角度的變動(dòng)求解拐角加工過程中的刀刃瞬時(shí)銑削面積,以此建立了計(jì)算刀刃瞬時(shí)銑削面積的公式。再次,使用仿真軟件DEFORM-3D,對(duì)設(shè)計(jì)的對(duì)比參數(shù)方案進(jìn)行了模擬仿真,獲得了銑削載荷曲線,針對(duì)曲線的波動(dòng)情況,選用統(tǒng)計(jì)分析的方法,在MATLAB中使用“3σ”原則剔除了仿真結(jié)果中的異常數(shù)據(jù),保證了仿真數(shù)據(jù)的可靠性。通過對(duì)銑削力、銑刀扭矩與進(jìn)給量、銑刀轉(zhuǎn)速的函數(shù)關(guān)系進(jìn)行推導(dǎo),將指數(shù)公式轉(zhuǎn)化為線性公式,為數(shù)據(jù)分析提供了依據(jù)。通過MATLAB軟件,對(duì)仿真結(jié)果數(shù)據(jù)進(jìn)行了回歸分析,得到了銑削力和銑削扭矩的預(yù)測模型,并且通過對(duì)數(shù)據(jù)線性相關(guān)性和線性擬合度的分析,考證了數(shù)據(jù)的可靠性。最后,詳細(xì)介紹了粒子群算法(POS)的基本理論、形式和設(shè)計(jì)流程,根據(jù)算法基本形式推導(dǎo)出了優(yōu)化目標(biāo)的函數(shù)和約束條件的數(shù)學(xué)模型,根據(jù)基本流程在MATLAB軟件中編制了優(yōu)化程序,迭代運(yùn)算結(jié)果顯示拐角銑削優(yōu)化后銑削參數(shù)設(shè)置比經(jīng)驗(yàn)參數(shù)設(shè)置加工時(shí)間節(jié)省了54.75%與58.20%。
[Abstract]:Mould is widely used in automobile industry, mobile phone industry, aerospace industry and other fields, so the NC machining accuracy of die is an important research object. Because of the thousands of changes in the shape of the product parts, the shape of the die is very different, especially when the die has more corners, it increases the difficulty of machining. The internal and external transition connections of these angles, such as sharp angle, obtuse angle and so on, make the milling force fluctuation produced by the cutting tool cause the workpiece trembling and the machining efficiency decrease in the milling process. In this paper, the machining efficiency and milling force of plane corner milling are studied. First of all, after consulting the research status at home and abroad, there are three ways to optimize machining at the corner: (1) in the control aspect of NC system, the control mode of NC system, such as the interpolation characteristic of motion trajectory, speed prospective preprocessing, acceleration and deceleration motion control, etc. (2) in the aspect of tool path, the optimal path is considered, and the optimization of tool walking is considered. (3) in terms of process parameters, feed speed, cutting depth and spindle speed are mainly considered. The advantages and disadvantages of the three methods are compared, and the process parameters are adopted in this paper. Secondly, the relationship between the position parameters of milling cutter and workpiece when milling plane corner is analyzed, and the real trajectory of cutter edge in milling process is obtained, and the mathematical expression of the corresponding parameter variables in the process of plane corner milling is given by analyzing its real trajectory. Aiming at the typical corner of die cavity, the contact between milling cutter and workpiece in different stages is analyzed by using plane geometry theory, and the changing trend of instantaneous contact angle between milling cutter and workpiece is obtained, and the instantaneous milling area of cutting edge in the process of corner machining is solved according to the change of instantaneous contact angle, and the formula for calculating the instantaneous milling area of cutter edge is established. Thirdly, the simulation software DEFORM-3D, is used to simulate the designed comparative parameter scheme, and the milling load curve is obtained. according to the fluctuation of the curve, the statistical analysis method is selected, and the abnormal data in the simulation results are eliminated by using the "3 蟽" principle in MATLAB to ensure the reliability of the simulation data. Through the derivation of the functional relationship between milling force, milling cutter torque and feed rate and milling cutter speed, the exponential formula is transformed into a linear formula, which provides a basis for data analysis. Through MATLAB software, the regression analysis of the simulation data is carried out, and the prediction model of milling force and milling torque is obtained, and the reliability of the data is verified by analyzing the linear correlation and linear fitting degree of the data. Finally, the basic theory, form and design flow of particle swarm optimization algorithm (POS) are introduced in detail. According to the basic form of the algorithm, the mathematical model of optimization objective function and constraint conditions is deduced. According to the basic flow, the optimization program is compiled in MATLAB software. The iterative operation results show that the machining time of milling parameters after corner milling optimization is 54.75% and 58.20% less than that of empirical parameter setting.
【學(xué)位授予單位】：西安建筑科技大學(xué)
【學(xué)位級(jí)別】：碩士
【學(xué)位授予年份】：2017
【分類號(hào)】：TG547

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