切削稳定性约束下的铣削参数优化技术研究  

Optimization of Milling Parameters under Constrain of Process Stability

作　　者：胡瑞飞[1,2] 殷鸣[1] 刘雁 苏真伟[1] 殷国富[1] 

机构地区：[1]四川大学制造科学与工程学院,成都610065 [2]四川普什宁江机床有限公司,都江堰611830

出　　处：《机械工程学报》2017年第5期190-198,共9页Journal of Mechanical Engineering

基　　金：国家科技支撑计划(2015BAF02B02);四川省科技计划(2014GZ0119)资助项目

摘　　要：目前切削稳定性研究主要集中在不同加工方法及加工条件下的稳定性研究,以无颤振极限切深作为切削参数优化的推荐值,缺少对稳定性与优化模型的深度融合分析。针对这一问题,以材料切除率和刀具寿命构建优化目标函数,提出一种切削稳定性约束下的铣削参数优化模型。通过对铣削稳定性零阶解析算法的分析,论述了切削稳定区域的确定受切削力学模型、刀尖频率响应、及切削参数共同影响关系。在设定机床、工件和刀具的条件下,通过对稳定性叶瓣图形态随切削参数变化规律的研究,得出了极限切深不等效于最大材料去除率;以动态变化的稳定域及机床能效为约束边界,采用变化趋势相反的材料去除率和刀具寿命构建优化目标函数,通过遗传算法获取全局最优解。针对多目标优化中,各分目标权重难以量化设置的问题,提出以材料去除率期望值和刀具寿命期望值作为优化模型设置参数,实现优化参数的量化调节和优化方向的有效控制。在VMC850机床上进行了试验并采用遗传算法对多组参数设定状态进行优化,结果表明切削参数优化结果满足稳定性约束要求,且其优化方向可量化调节。At present, the research of machining stability mostly focuses on the stability of different machining methods or cutting conditions. Maximum depth of cut within stable zone is proposed as optimal cutting parameters, but the incorporation of stability and optimization model is ignored. A new cutting parameter optimization model under constrain of milling stability is proposed. The objective function is constructed with material removal rate （MRR） and TL （tool life） to realize comprehensive optimization of efficiency and cost with quality control. Through the analysis of zero order analytical （ZOA） solution of chatter stability in milling, the influence of cutting force model, tool point frequency response function （FRF）, and cutting parameters to stability zone are discussed. The change of stability lobe is studied which led to the conclusion that maximum depth of cut within stable zone dose not guarantee maximum MRR. Genetic algorithm is introduced to realize global optimization of cutting parameters under constrain of stability and machine limitations. To solve the difficulty of weight setting in multi-objective optimization, MRR and TL expectations are used to make the optimization model quantitative and adjustable. Based on impact test and cutting test on machining center VMC850, optimization trials are conducted using different sets of parameters. Results show that the cutting parameter is in the stable zone and optimization direction is manipulable.

关 键 词：切削稳定性 切削参数优化 目标函数 遗传算法 

分 类 号：TG501[金属学及工艺—金属切削加工及机床]