【摘要】：隨著計(jì)算機(jī)技術(shù)在花崗巖銑削加工中的應(yīng)用,使得花崗巖雕刻制品在實(shí)際生活中已得到了大量的應(yīng)用,同時(shí)也具有著更廣闊的應(yīng)用前景。目前花崗巖加工機(jī)械設(shè)備技術(shù)已比較成熟,但刀具的使用效能成為了困擾花崗巖銑削加工的難題,其加工工藝參數(shù)一直使用經(jīng)驗(yàn)的工藝參數(shù),不適當(dāng)?shù)募庸すに噮?shù)經(jīng)常導(dǎo)致刀具磨損,甚至斷裂,縮短刀具使用壽命。而銑削力是影響刀具使用效能的關(guān)鍵因素,同時(shí)刀具的磨損也對(duì)加工效能有較大的影響。目前在花崗巖加工領(lǐng)域針對(duì)金剛石鋸片的研究成果較多,為實(shí)際加工提供了參考和依據(jù),但對(duì)花崗巖銑削加工刀具的研究較少,阻礙了花崗巖銑削技術(shù)的迅速發(fā)展和應(yīng)用。因此,本文針對(duì)花崗巖銑削加工刀具加工效能關(guān)鍵因素進(jìn)行了系統(tǒng)研究,所做的工作主要包括：(1)從壓痕斷裂理論入手,通過(guò)分析尖銳壓頭擠壓花崗巖的接觸應(yīng)力及裂紋形成過(guò)程,研究花崗巖銑削加工的機(jī)理。運(yùn)用ANSYS/LS-DYNA軟件進(jìn)行壓痕仿真,模擬了金剛石顆粒在壓入花崗巖時(shí)裂紋的產(chǎn)生及應(yīng)力狀態(tài),通過(guò)不同進(jìn)給速度的加載,獲得了花崗巖和金剛石的最大應(yīng)力,得出當(dāng)切入深度一定時(shí),金剛石的最大應(yīng)力隨進(jìn)給速度的增加而增大。并利用尖銳壓頭進(jìn)行了壓痕實(shí)驗(yàn),通過(guò)顯微照片進(jìn)一步對(duì)裂紋的構(gòu)成和特征做了進(jìn)一步描述和分析。(2)根據(jù)建立的加工模型,分析金剛石顆粒銑削花崗巖的幾何學(xué)參數(shù),推導(dǎo)了花崗巖銑削加工中工件與刀具相互作用弧長(zhǎng)、平均切削厚度的理論公式。從切削前后切削體積相等入手,微觀上分析了單顆粒金剛石的受力情況,理論上建立了相關(guān)的特征因素的計(jì)算公式。主要包括銑刀單位長(zhǎng)度靜態(tài)有效磨粒數(shù)N1、單位面積靜態(tài)有效磨粒數(shù)Ns和動(dòng)態(tài)有效磨粒數(shù)Nd。同時(shí)進(jìn)行了系統(tǒng)的公式推導(dǎo),從宏觀理論上分析了一般銑削條件下的銑刀受力的情況,并結(jié)合實(shí)際花崗巖雕刻中的典型加工,建立了花崗巖雕刻的加工模型,推導(dǎo)花崗巖雕刻中銑削力公式。分析結(jié)果表明花崗巖銑削加工中銑削力大小與加工參數(shù)切削深度成比例增大,與進(jìn)給速度成接近1/2的指數(shù)增長(zhǎng),與主軸轉(zhuǎn)速成接近1/2的指數(shù)遞減。(3)為了對(duì)理論分析結(jié)果進(jìn)一步驗(yàn)證,同時(shí)為后續(xù)的預(yù)測(cè)分析提供建模樣本數(shù)據(jù),搭建了花崗巖銑削力在線檢測(cè)的硬件系統(tǒng),并利用VC++6.0軟件開(kāi)發(fā)了對(duì)應(yīng)的檢測(cè)系統(tǒng)軟件,實(shí)現(xiàn)對(duì)加工過(guò)程中銑削力的動(dòng)態(tài)檢測(cè)。(4)在搭建的檢測(cè)實(shí)驗(yàn)臺(tái)上進(jìn)行了花崗巖銑削力的實(shí)驗(yàn),完成了金剛石銑刀加工花崗巖的單因素實(shí)驗(yàn)、正交實(shí)驗(yàn)和刀具斷裂實(shí)驗(yàn)。重點(diǎn)考察加工工藝參數(shù)主軸轉(zhuǎn)速n (r/min)、進(jìn)給速度vf(mm/min)和切削深度αp (mm)對(duì)銑削力的影響。單因素實(shí)驗(yàn)測(cè)量出對(duì)應(yīng)加工工藝參數(shù)下的100組實(shí)驗(yàn)樣本；做正交實(shí)驗(yàn)并測(cè)量出對(duì)應(yīng)加工工藝參數(shù)下的9組實(shí)驗(yàn)樣本；做金剛石銑刀斷裂實(shí)驗(yàn)并測(cè)出金剛石銑刀斷裂時(shí)所受的最大銑削力,獲得刀具斷裂的臨界銑削力。根據(jù)實(shí)驗(yàn)數(shù)據(jù)進(jìn)行了相關(guān)分析,同時(shí)獲得的實(shí)驗(yàn)數(shù)據(jù)也為后續(xù)的神經(jīng)網(wǎng)絡(luò)建模和驗(yàn)證提供了樣本數(shù)據(jù)。(5)分別采用BP神經(jīng)網(wǎng)絡(luò)和RBF神經(jīng)網(wǎng)絡(luò)對(duì)花崗巖雕刻過(guò)程中的銑削力建立了預(yù)測(cè)模型,通過(guò)對(duì)MATLAB神經(jīng)網(wǎng)絡(luò)工具箱中相關(guān)函數(shù)的調(diào)用實(shí)現(xiàn)了網(wǎng)絡(luò)設(shè)計(jì)、權(quán)值初始化和網(wǎng)絡(luò)訓(xùn)練以及仿真等,通過(guò)實(shí)驗(yàn)數(shù)據(jù)驗(yàn)證了預(yù)測(cè)模型的可行性,使模型能夠根據(jù)不同的加工參數(shù)比較準(zhǔn)確的預(yù)測(cè)銑削力。并根據(jù)實(shí)驗(yàn)數(shù)據(jù)對(duì)兩種神經(jīng)網(wǎng)絡(luò)的預(yù)測(cè)準(zhǔn)確性做了比較。結(jié)果表明,利用BP神經(jīng)網(wǎng)絡(luò)預(yù)測(cè)的銑削力雖然能夠保證其預(yù)測(cè)值的平均誤差低于6%,但單體誤差的波動(dòng)較大,且與銑削力的理論計(jì)算值的平均誤差較大；相比之下,利用RBF神經(jīng)網(wǎng)絡(luò)的預(yù)測(cè)模型預(yù)測(cè)的銑削力不僅平均誤差低于BP神經(jīng)網(wǎng)絡(luò),而且單體誤差波動(dòng)比較穩(wěn)定,與銑削力的實(shí)驗(yàn)值平均誤差為2.5173%,相比BP神經(jīng)網(wǎng)絡(luò)誤差更小,更接近實(shí)際情況,切實(shí)可行,能根據(jù)加工工藝參數(shù)更準(zhǔn)確的預(yù)測(cè)出花崗巖雕刻加工中金剛石銑刀的銑削力。(6)針對(duì)花崗巖加工中銑刀表面磨損情況進(jìn)行了分析。從銑刀的磨損量和銑刀表面微觀的磨損形式進(jìn)行了研究。分析銑刀磨損量與加工工藝參數(shù)：主軸轉(zhuǎn)速n(r/min)、進(jìn)給速度vf (mm/min)和切削深度αp (mm)間的影響關(guān)系和規(guī)律；對(duì)銑刀表面微觀形態(tài)進(jìn)行觀察分析研究其主要的磨損形式和對(duì)刀具壽命的影響。結(jié)合刀具的磨損情況,進(jìn)行了新型刀具的探索實(shí)驗(yàn),將等離子熱噴涂技術(shù)引入到花崗巖加工刀具的制備中,并對(duì)制備的刀具進(jìn)行了相關(guān)的刀具磨損實(shí)驗(yàn),并對(duì)實(shí)驗(yàn)結(jié)果給出了較詳細(xì)的分析。本文最后結(jié)合RBF神經(jīng)網(wǎng)絡(luò)預(yù)測(cè)模型、刀具斷裂實(shí)驗(yàn)結(jié)果和刀具磨損分析,給出了花崗巖銑削加工過(guò)程中提高刀具加工效能,優(yōu)選加工工藝參數(shù)的步驟,該方法在保證刀具可靠加工的情況下,通過(guò)優(yōu)選加工參數(shù)提高材料去除率,從加工效率和刀具兩方面降低產(chǎn)品成本,通過(guò)石材企業(yè)的實(shí)際應(yīng)用驗(yàn)證了該方法的可行性。并給出了具體的應(yīng)用實(shí)例,為花崗巖銑削加工中工藝參數(shù)的選擇提供了參考的方法和依據(jù)。通過(guò)優(yōu)選加工參數(shù),對(duì)花崗巖銑削加工中降低生產(chǎn)成本、提高加工效率具有一定的指導(dǎo)意義。
[Abstract]:With the application of computer technology in the process of granite surface cutting, the granite carving product has been widely used in the actual life, and has a wider application prospect. At present, the technology of the granite processing and mechanical equipment has been relatively mature, but the use efficiency of the tool has become a difficult problem for the processing of the granite of the granite, the processing process parameters of the tool have been using the process parameters of the experience, and the improper machining process parameters often cause the tool to wear and even break, And the service life of the cutter is shortened. The cutting force is a key factor that affects the efficiency of the tool, and the wear of the tool has a great effect on the processing efficiency. At present, the research results of the diamond saw blade in the field of granite processing are much more, and the reference and the basis for the actual processing are provided. However, the research on the granite cutting and processing tool is less, and the rapid development and application of the granite cutting technology are hindered. In this paper, a systematic study on the key factors of the machining efficiency of the cutting tool for granite is carried out. The main work is as follows: (1) from the theory of indentation fracture, the contact stress and the crack formation process of the granite are analyzed by the analysis of the sharp pressure head. In this paper, the mechanism of granite cutting and processing is studied. By using the software of ANSYS/ LS-DYNA to simulate the indentation, the generation and stress state of the crack during the press-in of the granite by the diamond particles are simulated, the maximum stress of the granite and the diamond is obtained through the loading of different feeding speeds, and when the cut-in depth is fixed, The maximum stress of the diamond increases with the increase in the feed rate. The formation and characteristics of the crack were further described and analyzed by the micrographs. (2) According to the established machining model, the geometric parameters of the diamond particles and the granite are analyzed, and the theoretical formula of the interaction arc length and the average cutting thickness of the workpiece and the tool in the granite cutting process is derived. Starting from the cutting volume before and after cutting, the stress condition of single-grain diamond is analyzed, and the relevant characteristic factors are theoretically established. The static and effective abrasive grain number N1, the static effective abrasive grain number Ns and the dynamic effective abrasive grain number Nd of the unit area are mainly included, and the formula derivation of the system is also carried out, Combining with the typical processing in the granite carving, the processing model of the granite carving is established, and the formula of the cutting force in the granite carving is derived. The results show that the size of the cutting force of the granite in the cutting process is increased in proportion to the cutting depth of the machining parameter, and the index with the feeding speed close to 1/2 is increased, and the index with the rotation speed of the main shaft is close to 1/2 is decreased. and (3) in order to further verify the theoretical analysis result, the data is provided for subsequent prediction analysis, a hardware system for on-line detection of the granite cutting force is built, and a corresponding detection system software is developed by using the VC ++ 6.0, And the dynamic detection of the cutting force in the machining process is realized. (4) The experiment of granite shearing force was carried out on the built-up test bench, and the single-factor experiment, the orthogonal experiment and the tool fracture experiment of the diamond cutter-processed granite were completed. The influence of the spindle speed n (r/ min), the feeding speed vf (mm/ min) and the cutting depth (p (mm) on the cutting force of the machining process parameters is mainly studied. a single-factor experiment is used to measure 100 groups of experimental samples corresponding to the processing process parameters, And the critical cutting force of the tool fracture is obtained. The relevant analysis is carried out according to the experimental data, and the obtained experimental data also provides the sample data for subsequent neural network modeling and verification. and (5) using the BP neural network and the RBF neural network to set up a prediction model for the cutting force in the granite carving process, and the network design, the weight initialization and the network training and the simulation are realized through the call of the related functions in the MATLAB neural network toolbox, The feasibility of the prediction model is verified by the experimental data, so that the model can accurately predict the cutting force according to different machining parameters. And the prediction accuracy of the two neural networks is compared according to the experimental data. The results show that the average error of the predicted value is lower than 6% by using the BP neural network, but the fluctuation of the monomer error is large, and the average error of the theoretical calculation value of the cutting force is large; in contrast, The prediction model of the RBF neural network not only has the average error lower than that of the BP neural network, but also the fluctuation of the monomer error is relatively stable, the average error of the experimental value with the cutting force is 2.5173%, and the error of the BP neural network is smaller and closer to the actual situation. The cutting force of the diamond cutting knife in the granite carving process can be predicted more accurately according to the processing process parameters. (6) The wear of the surface of the granite in the process of granite processing is analyzed. The wear and wear of the blade surface were studied. The influence relation and law of the wear and processing parameters of the cutting tool, the main shaft speed n (r/ min), the feeding speed vf (mm/ min) and the cutting depth (p (mm) were analyzed, and the main wear pattern and the influence on the life of the tool were studied. Combined with the wear of the tool, the new tool's exploration experiment is carried out, the plasma thermal spraying technology is introduced into the preparation of the granite processing tool, and the related tool wear experiment is carried out on the prepared tool, and the detailed analysis is given to the experimental results. In this paper, based on the prediction model of the RBF neural network, the experimental results of the tool fracture and the analysis of the wear of the tool, the step of improving the machining efficiency of the tool in the processing of the granite is given, and the process parameters are preferably processed. The material removal rate is improved by the preferred processing parameters, the product cost is reduced from the processing efficiency and the cutting tool, and the feasibility of the method is verified through the practical application of the stone enterprise. The specific application examples are given, and the reference method and the basis for the selection of the process parameters in the granite cutting process are provided. By optimizing the processing parameters, the production cost is reduced, and the processing efficiency is improved.
【學(xué)位授予單位】：東北大學(xué)
【學(xué)位級(jí)別】：博士
【學(xué)位授予年份】：2015
【分類號(hào)】：TG714

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