螺旋锥齿轮制造数字孪生基础研究

Digital twin，an interaction of cyber and physics, is the basic technology for Industry 4.0. In production of spiral bevel gear, digital twin requires the cutting process be monitored for intelligent manufacturing，and the micro tooth geometry be obtained for prediction of application performance. Presently, the machine tool setting and the measured tooth surface have been linked in the closed-loop manufacturing system, while the cutting process simulation and cut surface description are still unavailable. Thus, the investigation of cutting process and further the prediction model for cutting status form the basis for realization of digital twin of spiral bevel gear..However, due to the complicated cutting kinematics, the solution of cutting geometry is difficult. To solve this problem, the program proposes an interpolating algorithm for the cutting geometry based on the forming regularity of the cut tooth and the evolution mechanism of the chips geometry. On such basis, in order to promote the development of digital twin for spiral bevel gear, the prediction model for the scallop height, tooth roughness, cutting force and cutting vibration are established, the cutting simulation and optimization system are developed, the G-plete cutting method are realized in the Chinese-made equipment, and finally the process-based closed-loop manufacturing system are structured.

数字孪生实现物理与信息的产品全生命周期互融，是工业4.0的基础技术。就螺旋锥齿轮制造而言，数字孪生要求实时监控切削过程以实现智能制造，同时获得齿面的微观几何以预测服役性能。目前锥齿轮闭环制造系统已建立机床参数和测量齿面间的联系，尚缺乏对切削过程的仿真和齿面微观的描述。故而，研究螺旋锥齿轮的切削过程，建立切削状态量的预测模型是数字孪生的实现基础。.然而螺旋锥齿轮切削运动复杂，切削几何（切削齿面、切屑形态）求解难度较大，基于三维软件平台的数值算法效率较低，而简化的切削层的算法又精度较差。为此，本项目基于螺旋锥齿轮铣削齿面几何的形成规律和切屑形态的演化机制，提出切削几何的半解析插值表征方法。以此为基础，建立残留高度、粗糙度、切削力以及切削振动的预测模型，开发铣齿仿真与优化系统，在国产装备上实现全工序、高效、高精度铣齿，构建包含切削过程的螺旋锥齿轮闭环制造系统，推动螺旋锥齿轮制造数字孪生的实现。

本项目根据螺旋锥齿轮制造数字孪生的基础需求，提出切削几何的插值表征.算法，从而建立螺旋锥齿轮切削过程仿真与优化模型。其基本思想是：研究切削.齿面形成规律和切屑几何演化机制，提出齿面几何交截点插值和切屑几何曲边多.边形插值的半解析表征方法，再依据切削过程残留高度、齿面粗糙度、切削力以.及切削振动相应算法，建立螺旋锥齿轮切削过程仿真模型。最后，以 “全工序.法”工艺为切入点，利用人工智能算法优化工艺参数和进给方式，在国产设备上.实现了弧齿锥齿轮的全工序、高效率、高精度加工，推动螺旋锥齿轮制造数字孪生.的实现。