复杂曲面五轴铣削能效机理多尺度解析与多回路耦合优化控制研究

To the problem of low efficiency and high energy consumption for sculptured surfaces in 5-axis milling, this project focuses on multi-scale mechanism analysis and multi-loop coupling optimization control method of energy efficiency improvement for sculptured surface in 5-axis milling. Firstly, the multi-scale mechanism of the 5-axis milling on energy efficiency is analyzed, and the energy efficiency mechanism of micro geometric features is studied, and the effects between the clustered geometrical surface and energy efficiency are revealed. Secondly, the energy efficiency characteristics of 5-axis milling machine tools are investigated, and an energy model and its optimization method using dynamic kinematic control for 5-axis milling machine tools are proposed. Thirdly, the effects of cutter angles, cutter parameters, and tool positions for the clustered geometrical surface on energy efficiency in 5-axis milling are studied, and energy-efficient models and optimization methods of cutter angles, cutting parameters, tool positions planning in 5-axis sculptured surface milling are presented. Then, a multi-loop for energy efficiency in sculptured surface 5-axis milling are developed. A Markov-Chain based multi-loop coupling optimization control model for high energy efficiency is presented, and an optimization method based on big data and deep leaning is proposed. Finally, a number of typical workpieces with sculptured surfaces are used for 5-axis milling experimental for further validation of the proposed models and methods. This project will develop fundamental theory and methods for sculptured surface 5-axis milling with hign energy efficiency , which have important guiding significance for energy efficiency enhancement in 5-axis milling.

针对复杂曲面五轴铣削加工效率低和能量消耗大的问题，本项目围绕复杂曲面五轴铣削能效机理多尺度解析与多回路耦合优化控制问题展开研究。首先，研究复杂曲面五轴铣削能效多尺度分析与表征，分析曲面微观几何特征的能效机理，揭示曲面聚类特征与能效的映射规律；对五轴联动机床宏观能效机理解析，建立基于键合图的五轴联动机床运动控制能效模型与优化方法；揭示曲面聚类特征与刀具参数、切削参数、刀位轨迹的能效映射规律，提出基于复杂曲面聚类特征的刀具参数、切削参数、刀位轨迹能效优化模型与方法；构建复杂曲面五轴铣削能效多层次控制回路，建立基于马尔可夫决策过程的复杂曲面五轴铣削多回路耦合综合优化控制模型，提出基于大数据与深度学习的多回路能效优化方法。最后选取典型复杂曲面零件五轴联动铣削开展实验验证与应用研究。本项目将形成一套复杂曲面五轴联动高效节能铣削加工理论与技术，对复杂曲面类零件加工能效提升有重要理论意义和应用价值。

复杂曲面类零件的复杂几何特征性质，造成该类零件存在加工时间长、成本高、能耗大等一系列问题，成为车间制造系统能量消耗研究极具挑战的问题。但目前关于复杂曲面加工方面的研究较少对复杂曲面加工能效机理进行解析，缺乏全面、深入地研究其加工过程的高效节能优化控制模型与方法。项目组选取多个不同形貌的典型复杂曲面零件模型，通过机床能效实验平台建立了加工能效模型，进而揭示了复杂曲面聚类特征与能效的映射关系与作用机理，深入研究了复杂曲面五轴铣削多尺度能效机理与多回路耦合优化控制模型与方法。主要研究成果为：（1）分析了复杂曲面五轴铣削加工的能效表征特性，建立了其能效多尺度表征模型，并研究了其不同尺度下的内在耦合关系；（2）研究了复杂曲面几何特征的能效机理，揭示了复杂曲面聚类特征与能效的映射规律；（3）研究了五轴联动数控机床各个子系统的能量传递规律、耦合关系以及加工过程中的动态变化规律，建立了五轴联动数控机床的空间运动的键合图物理模型及运动控制能效模型，并提出了基于运动控制的五轴联动数控机床能效优化方法；（4）建立了复杂曲面聚类特征与切削参数能效优化模型，提出了基于变参的复杂曲面聚类特征刀位轨迹能效优化模型与方法；（5）构建了复杂曲面加工能效多层面控制回路，提出了一种复杂曲面五轴铣削能效多回路耦合优化控制方法；6）选取典型复杂曲面零件，对以上模型与方法进行了应用研究，开发了面向离散加工车间数据监管系统。通过项目实施，形成了一套复杂曲面五轴联动高效节能铣削加工理论与技术，对复杂曲面类零件加工能效提升有重要理论意义和应用价值。