面向节能的数控机床能量模型的基础研究

Saving energy and reducing the cost is a significant subject faced by the mechanical manufacturing industry currently. In the view of lacking the effective energy-efficiency model and accurate calculation method for energy consumption in machining processes at present, this project manages to do some profound researches and experiments about the basic theory of machine tools' energy consumption model during the machining processes by taking computerized numerical control (CNC) machine tools as the typical representation and focusing on the common cutting processing techniques (such as milling, boring, and so on). During the project's research, many tasks will be done: we will reveal the energy dissipation mechanism of material removal in cutting processes; build the material removal energy consumption theoretical model and it's calculating modification functions; establish the experimental platform of measuring CNC machine tools' specific cutting energy, and gain available accurate basic date of Chinese specific cutting energy through the experiments; reveal the characteristic of various sources of machine tools' energy consumption and the changing discipline of every sub-system's energy transfer and consumption; build the energy balance equation and energy-efficiency models of CNC machine tools; study the energy flow distribution and energy consumption changing disciplines in the machining processes of CNC machine tools; establish energy consumption models of CNC machine tools' machining processes and find out the method for energy saving and optimization. The achievements of this project will establish the basis of calculating theory and data for the design and evaluation of CNC machine tool system's energy saving and cost reducing, for calculating energy consumption and optimizing energy efficiency of machining, for making criterion of machine tool's energy consumption efficiency, and for how manufacturing system operates in a high efficiency, low carbon and optimization way, and so on.

节能降耗是当前机械加工制造业所面临的一项重大课题。本项目针对目前缺乏有效的机床加工过程能效模型及准确能耗计算方法问题，拟以数控机床为典型代表，针对常用切削加工工艺（铣、镗等），对机床加工过程中能量模型基础理论展开研究和实验。通过本项目的研究，将揭示切削加工中材料去除能量耗散机理，建立材料去除能量理论模型及计算修正函数；建立数控机床切削比能实验平台，实验获得准确可用的中国切削比能基础数据；揭示机床多源能耗特性及各种能量子系统的能量传递和消耗变化规律，建立数控机床能量平衡方程及能效模型；研究数控机床加工过程能量流分布及能耗变化规律，建立数控机床加工过程能耗模型及节能优化方法。本项目的研究成果将为数控机床系统节能降耗设计与评价、机床加工能耗计算与能效优化、机床能效标准制定以及制造系统高效低碳优化运行等提供计算理论和数据基础。

针对数控机床高能耗、低能量效率的特点，分析数控机床能耗特性、探寻数控机床节能优化方法对于我国实现绿色制造具有重要意义。机床能耗过程的评估和分析是机床节能优化研究的基础，本项目首先建立数控机床的能耗模型，然后对机床的能量效率以及切削参数的节能优化开展研究。.根据数控机床各能耗部件的特性及与加工过程的关联性，将数控机床整机能耗分为四大部分：主传动系统空载能耗、进给系统空载能耗、辅助系统能耗、切削能耗。根据耗能机理和实验统计规律分别对四大部分进行建模，进而建立机床整机一般能耗模型。为了探究数控机床能量效率与切削参数的关系，开展了切削单因素实验和双因素实验，研究在改变单个或两个切削参数的情况下机床能量效率的变化规律，并揭示其影响机理。研究发现：增大切削参数中的任一参数均有利于提高机床生产率和机床能量效率；当工艺系统刚度较小时，从机床节能角度考虑，优先选取大的铣削速度、每齿进给量和侧吃刀量；当工件材料去除率保持不变时，改变每齿进给量、背吃刀量、侧吃刀量中的任意两个参数对机床加工比能影响作用大致相同，结合工艺系统刚度、强度方面影响，优先选择增大每齿进给量或侧吃刀量而减小背吃刀量；为降低机床能耗，应尽量避免机床主轴在主传动系统空载功率的最大值点附近运转。以数控铣削加工的切削参数为优化变量，建立了面向高效节能的数控铣削切削参数优化数学模型，基于带精英策略的快速非支配排序遗传算法（NSGA-II）运用MATLAB语言编程对优化模型进行求解。通过优化案例研究验证了优化模型的可行性和有效性。结果表明：在满足加工要求和约束条件的情况下，采用大的每齿进给量，有利于在提高机床生产率的同时降低机床能耗。.研究成果能够为数控机床节能降耗设计与评价、机床加工能耗计算与能效优化、机床能效标准制定以及制造系统高效低碳优化运行等提供理论和数据基础。发表学术论文共计5篇，其中EI论文2篇；培养硕博研究生8名，其中毕业博士1名、毕业硕士6名。