非圆磨削加工过程中磨削能耗建模与分析  

Modelling and Analysis of Grinding Energy Consumption in Non-circular Grinding Process

作　　者：沈南燕[1,2] 王为东[1,2] 李静[1,2] 曹雁灵 王宇 

机构地区：[1]上海大学机电工程与自动化学院,上海200072 [2]上海大学上海市智能制造及机器人重点实验室,上海200072 [3]上海机床厂有限公司,上海200093

出　　处：《机械工程学报》2017年第15期208-216,共9页Journal of Mechanical Engineering

基　　金：国家科技重大专项资助项目(2016ZX04004003)

摘　　要：非圆磨削加工过程的磨削能耗研究对实现曲轴、凸轮轴等复杂轴类零件大批量生产的低碳制造具有重要意义。分析异形零件非圆磨削运动特点,建立异形零件非圆磨削加工过程中的磨削力经验模型,并结合零件的受力情况,构建非圆磨削中工件所受扭矩以及磨削能耗的计算模型。通过仿真分析发现,在扭矩计算模型的参数中切向与法向磨削力比值?对其计算结果影响较大。为此在模型参数辨识中,提出以扭矩计算值和实测值对应各点间及峰峰值间相对误差为目标函数构造关于参数?的多目标约束优化问题,通过求解该优化问题得到最优的参数?。试验证明该方法能有效提高扭矩模型在实际应用中的可信度。以RV减速器偏心轴非圆磨削过程中的磨削能耗为例,利用提出的能耗计算模型,分析了不同磨削参数和磨除率对非圆磨削过程磨削能耗的影响,指导了非圆磨削低能耗加工参数的选取,为进一步优化非圆磨削加工能效提供了基础。Modelling and analysis of grinding energy consumption in non-circular grinding plays an important role in the low-carbon processing for the mass production of the complex shaft parts, such as the crankshaft and camshaft. An empirical model of the grinding force is established based on the movement characteristics of non-circular grinding process. And then the mathematical models of the torque applied on the part and the corresponding grinding energy consumption are built up according to the analysis on the grinding force acting on the part. The result of the simulated calculation by the torque model demonstrates that it is affected greatly by the ratio of the tangential and the normal grinding force among all the model parameters. The multi-objective constraint optimization problem for the optimal parameter ？ is proposed by constructing the relative errors of every sample values and the peak-peak value between the calculated torque and the measured one. The experimental results verify the accuracy and reliability of the torque model whose parameters are identified by the proposed method in non-circular grinding of the eccentric shaft in the RV reducer. And also the influences of the different grinding parameters and the material removal rate on the grinding energy consumption are analyzed based on the proposed energy consumption mathematical model which helps the grinding parameter optimization and the energy-saving in non-circular grinding.

关 键 词：非圆磨削 扭矩模型 磨削能耗 参数辨识 磨除率 

分 类 号：TG580[金属学及工艺—金属切削加工及机床]