面向能耗特征的螺纹绿色多刃硬态干式切削工艺性能协同机理及优化

Multi-cutter hard-dry cutting of screw thread is a typical green machining processes with complex machining characteristics, such as time-varied interrupted cutting, multi-cutter incremental cutting with coupling motions, thermo-mechanical coupling dry cutting. At present, the researches on cutting mechanism and performance of machining screw are still inadequate, especially few researches focusing on energy-smart machining process performance synergies. Considering the complex machining characteristics of multi-cutter hard-dry cutting screw, this project will study machining energy and machining performance based on three aspects of cutting mechanisms. These cutting mechanisms include material removal force mechanism for time-varied interrupted cutting process, geometric forming mechanism for multi-cutter incremental coupling motions, and heat-transfer and losses mechanism for thermo-mechanical coupling cutting. Futhermore, the mapping relations among cutting factors, machining energy and performace will be established quantitatively. Based on the quantitative relations, energy-smart machining process performance synergies will be futher researched from three aspects of geometric-force-thermo cutting mechanisms. The above researches will improve fundamental theories of hard-dry cutting processes, benefit to develop good-quality and environmentally-benign machining processes of screw thread, and have an extensive application especially in batch production of large-size screw. Addtionally, the research methodology can also be extended to other energy-saving machining processes, and provide valuable therical reference.

螺纹多刃硬态干式切削是一种典型的绿色制造工艺，具有时变断续冲击、多刃渐进成形、强热力耦合干式切削等特点，目前对此复杂工况的螺纹切削机理及工艺性能的研究还远不够深入，尤其在加工能耗特征及其与工艺性能协同机理的研究几乎空白。本项目将紧密结合螺纹多刃硬态干式切削的特殊性，从时变断续切削过程的材料去除力学机理、多刃渐进运动过程的几何成形机理和热力强时空耦合的热传递耗散机理三方面，研究螺纹切削过程的工艺性能(几何形貌/残余应力/金相组织等)和能耗特征(材料去除切削能耗特征/尺寸效应能耗特征/干式切削能量耗散特征等)；探索工艺参量与工艺性能、能耗特征间的映射关系；进而建立几何-力-热多维度耦合的能耗特征与工艺性能间的协同优化机制。研究成果将进一步完善硬态干式切削工艺基础理论，为绿色高效的螺纹加工提供理论支持，尤其在大型丝杠批量生产中具有广阔应用前景，研究方法亦可为其他制造工艺节能优化研究提供理论参考。

螺纹硬态干式切削工艺消除了传统螺纹加工过程中导致严重环境污染的冷却液的使用，是一种适用于螺纹丝杠批量生产的典型绿色切削加工工艺，在高档精密数控机床行业乃至大型装备制造业的高品质螺纹成形加工中有着广阔的应用前景。本项目将紧密结合螺纹多刃硬态干式切削的特殊性，解决时变断续切削过程的材料去除力学机理、多刃渐进运动过程的几何成形机理和热力强时空耦合的热传递耗散机理建模关键科学问题。.本项目研究了螺纹切削材料去除能耗及其与工艺性能协同机理，研究内容包括：1、螺纹切削过程的力学建模及切削能耗评价；2、螺纹切削过程的表面三维几何形貌和切屑成形仿真；3、螺纹切削过程刀具-工件-切屑系统热传递机理解析；4、螺纹切削工艺能耗与工艺性能协同的协同优化。.项目执行中，建立了基于拉格朗日方程的螺纹高速切削过程动力学模型，解决了螺纹切削过程中工件振动预测问题；建立了时变断续激励作用下的瞬态切削力模型及材料去除切削能耗模型，揭示了切削工艺参量与材料去除切削比能的映射关系。建立了螺纹滚道表面的走刀轨迹包络面的三维刀具运动模型，揭示了多刃渐进螺纹切削几何成形机理，用于预测螺纹工件滚道各位置的表面几何形貌。揭示螺纹切削系统切削区的热分布和热传递规律，构建了刀具-工件-切屑系统热传递机理解析模型。揭示了螺纹加工工艺能耗与加工效率、表面质量与加工效率、工件温度与表面形貌和切削比能与工艺性能的协同机制，用以识别和优选高能效、高品质螺纹切削工艺边界。.以上成果发表及录用SCI/EI论文12篇，其中SCI一、二区5篇；完成绿色制造理论系列丛书之一《机械加工过程能耗建模和优化方法》（审校阶段）1部；授权发明专利2项，公开1项；项目获教育部自然科学奖二等奖1项。