基于NPSO算法整体刀具容屑槽高精度多层次刃磨成形策略研究

As representative of the upscale CNC cutting tools, integral tools have direct relation to the performance of high-end CNC machine tools, as well as the manufacturing precision and capacity of aerospace, rail transit, medical, mould and other advanced industries. Groove is one of the key structures of integral tools. However, the current theories and methods could not make an effective way to grinding a design groove, especially for some new and complex grooves. Therefore, the project devotes to solve the wheel geometry, position and posture according to the groove rake angle, inner diameter and width. Firstly, a precise prediction model of grinding results is built and the impacts of wheel geometry, position and posture on the results are studied. Accordingly, the constraints to grinding an integrated groove are discussed. Secondly, considering the design precise varied with groove structures, three models are established to calculate the double-oblique wheel position, the double-oblique wheel geometry and position, and the forming wheel geometry separately. All the models are solved by NPSO algorithm. Thus, three grinding strategies are established: choosing wheel from the existing double-oblique wheel database, design a new double-oblique wheel, and design a forming wheel. Lastly, the strategies are verified and programmed. The research has great significance in theory and practical to improve the design and manufacture level of integral tools.

作为高档数控刀具代表的整体刀具直接决定着高端机床性能的发挥和航空航天、轨道交通、医疗模具等零部件的制造水平和能力，容屑槽是决定整体刀具性能的关键因素之一，现有理论和方法无法满足不断涌现新型容屑槽的高精度刃磨需求。为此，提出以前角、芯径、槽宽等容屑槽结构设计精度为驱动的砂轮形状、尺寸、位姿等刃磨成形策略几何要素求解理论和方法。首先，构建容屑槽精确预测模型，揭示双斜面型砂轮尺寸和位姿对容屑槽刃磨精度影响机制，建立容屑槽完整刃磨成形砂轮尺寸及位姿约束条件；在此基础上，建立不同设计精度驱动的双斜面型砂轮位姿求解、位姿和尺寸组合求解以及成形砂轮轮廓求解理论模型，并采用NPSO算法求解，形成基于现有双斜面型砂轮库、双斜面型砂轮尺寸优化、成形砂轮设计的多层次刃磨策略；最后，研发容屑槽刃磨成形策略软件系统，实现决策过程的高效化和便捷化。研究成果对于提高我国整体刀具研制水平具有重要理论意义和工程应用价值。

建立了高效、精确的容屑槽预测模型，揭示了双斜面型砂轮尺寸及位姿对容屑槽结构的影响机理，阐明了刃磨缺陷形成和控制机理，建立了砂轮位姿反求、双斜面型砂轮尺寸及位姿组合求解以及成形砂轮轮廓求解理论。具体包括：.(1) 提出了基于双斜面型砂轮容屑槽精确刃磨成形方法.以“双斜面型砂轮”为重点研究对象，与传统砂轮相比具有多方面优势：包含1A1型、1V1型等常用标准砂轮，具有代表性；具有较广的容屑槽加工范围；其轮廓母线为多条直接及圆弧的组合，砂轮修磨简单。.(2) 建立了精度驱动的容屑槽多样化成形理论.以前角、芯径、槽宽等容屑槽结构为变量，以协调系数的形式反应不同结构的精度需求，将复杂的刃磨方法求解问题转化为目标函数极小值求解问题，建立了基于现有双斜面型砂轮库、双斜面型砂轮优化设计、成形砂轮设计的多样化容屑槽刃磨成形理论和方法。.(3) 建立了基于环型拓扑NPSO的理论模型求解算法.采用多模函数优化思想，提出了基于标准“环型拓扑NPSO”算法的成形理论求解方法，为提高算法的收敛速度和求解精度，对粒子初始速度、初始位置、加速常数等参数进行了改进，该方法可获得理论模型所有可行解，为成形精度与成本的协调统一提供了理论和技术基础。.