数控滚齿加工能耗建模及工艺性能协同优化研究

There are many outstanding problems faced by CNC hobbing of China, such as high energy consumption, low quality of the final product and short tool life. It is urgent to carry out a research on energy saving and process performance improvement. To this end, this project firstly analyzes the multi-source and process-related energy consumption characteristics of the CNC hobbing process. Then an energy consumption model is established. Secondly, the influence of the tool parameters and cutting parameters on energy consumption, processing quality and tool life is revealed. On this basis, multi-objective cutting parameter optimization models and algorithms for energy consumption and process performance improvement are proposed. Furthermore, integrated optimization models and algorithms of tool parameters and cutting parameters for energy consumption and process performance are also studied. Finally, the proposed models and algorithms are tested and applied in CNC gear hobbing workshops. This project will form a set of energy-saving and process performance improvement theory and methods for CNC gear hobbing process, which can provide a technical support for the implementation of green manufacturing, energy saving and process performance improvement in gear manufacturing industry. It has vast application prospects.

我国量大面广的数控滚齿加工工艺过程能耗大、加工质量不高、刀具寿命短等问题十分突出，迫切需要开展节能降耗和加工质量、刀具寿命等工艺性能协同优化研究。为此，本项目首先对数控滚齿加工过程多源能耗构成特性和时段特性进行分析，并构建基于时段特性的数控滚齿加工过程能耗模型；然后，基于大量统计数据，揭示刀具特征参数、工艺参数等对能耗及加工质量、刀具寿命等工艺性能的映射关系和作用机理；在此基础上，研究面向能耗及工艺性能协同的数控滚齿加工工艺参数优化模型与方法，以及考虑刀具柔性的数控滚齿加工能耗及工艺性能协同优化模型与方法；最后，将提出的模型和方法在相关数控滚齿加工车间开展实验验证和应用。本项目将形成一套面向节能的数控滚齿加工工艺性能协同优化理论与方法，可为量大面广的齿轮加工制造业实施绿色制造、实现节能降耗和工艺性能优化提升提供技术支撑，具有广阔的应用前景。

滚齿工艺是一种高效的齿轮加工方法，实现滚齿加工过程节能降耗和加工质量、刀具寿命等工艺性能指标协同优化是滚齿工艺重要发展趋势。项目解析了数控滚齿加工过程多源能耗构成特性，揭示了不同时段滚齿机床各部件和整机能耗规律，构建了基于时段特性的数控滚齿加工过程能耗模型；搭建了数控滚齿加工能耗及工艺性能实验测试平台，构建了滚刀特征参数、工艺参数等与能耗及加工质量、刀具寿命等工艺性能的映射关系模型并揭示了其作用机理；分别针对小模数齿轮一次进给成形滚齿加工和大模数齿轮多次进给成形滚齿加工，构建了工艺参数多目标优化模型，并提出了基于智能优化算法的模型求解方法；建立了滚齿刀具参数、工艺参数多目标优化模型及方法，实现了多种刀具柔性下数控滚齿加工能耗及工艺性能协同优化。依托项目开展，共发表期刊论文5篇，在审2篇；申请发明专利1项；制定4项国家标准；获重庆市自然科学二等奖1项；培养研究生2名。