高速干切滚齿工艺系统热稳定性演变机制及多源协同调控方法研究

High-speed dry hobbing is an advanced green manufacturing technology. However, the heat production greatly increases due to high-speed and dry machining environment, which seriously affects the thermal deformation of the machine tool, the wear of the hob and the surface integrity of the gear. It is urgent to clarify the influence of multi-source intense heat on the process system and the regulation mechanism. Therefore, this project aims to improve the processing quality, and carries out the basic theoretical research on the thermostability evolution mechanism and multi-source collaborative control method of the process system in high-speed dry hobbing. By analyzing the motion behavior of feed units, multi-source heat transfer law and processing uncertainty, the structure-fluid-temperature field coupled heat flow model is established to reveal the dynamic evolution characteristics of the process system thermostability under multi-source and multi-field heat transfer. Using thermal equilibrium analysis, the accurate heat-load prediction model and the representation model of the process system thermostability are established to quantitatively evaluate the internal relationship between the heat load and the thermostability. To realize optimal control of the process system thermostability, a multi-source collaborative optimization model is established, as well as an efficient heat transfer control method of compressed air. It is expected to propose a set of modeling techniques, solving algorithms and process control methods for improving the performance of high-speed dry hobbing, and to provide theoretical and technical support for improving the green manufacturing level of the gear industry in China.

高速干切滚齿是一种先进的绿色制造技术，但高速和干式切削环境导致热量显著增大，严重影响机床热变形、滚刀磨损以及齿轮表面完整性等，迫切需要阐明多源强热对工艺系统的作用及其调控机理。鉴于此，本项目以提高加工质量为目标，开展高速干切滚齿工艺系统热稳定性演变与调控基础理论研究。通过分析进给单元运动行为、多源传热规律、加工不确定性等，建立结构-流体-温度场耦合的工艺系统热流模型，阐明多源多场传热下工艺系统热稳定性的动态演变机制；基于热平衡分析，建立工艺系统载热量精准预测模型和热稳定性表征模型，量化评价载热量与热稳定性之间的内在关联以及多因素矛盾冲突关系；在此基础上，建立工艺系统热稳定性优化模型，提出基于场协同强化的压缩空气高效换热方法，实现工艺系统热稳定性的多源协同调控。项目预期形成一套增强高速干切滚齿工艺系统热稳定性的建模技术和工艺调控方法，为提高我国齿轮行业的绿色制造水平提供理论和使能技术支撑。

本项目重点开展了高速干切滚齿工艺系统热稳定性演变与调控基础理论研究。通过分析机床运动行为、多源传热规律、加工不确定性等，建立了结构-流体-温度场耦合的高速干切滚齿热流模型，阐明了多源多场传热下工艺系统热稳定性的演变行为；基于热平衡分析，建立了工艺系统的热量计算模型和热稳定性模型，对两者的内在关联及多因素矛盾冲突关系进行了量化评价；提出了高速干切滚齿工艺系统热稳定性优化控制方法，包括高速干切滚齿的压缩空气高效换热方法等。项目研究所形成的高速干切滚齿工艺系统热稳定性建模技术和工艺调控方法，可为齿轮行业绿色转型发展提供理论支撑。