面向设计属性和制造属性协同的机械零件加工特征能耗建模及优化

Reducing energy consumption of machining workpiece in manufacturing stages is a challenge for manufacture industry. The features of workpiece is considered as basic component unit of workpiece. Energy consumption of features in manufacturing stage is a complex process which is influenced by both design- and manufacturing-related attributes. Recent research on energy consumption of workpiece mainly concentrates on the influences of manufacturing-related attributes on energy. However, few research focuses on synergism effect integrated design- and manufacturing-related attributes, which results in environmental burden of design stage being shifted to the manufacturing stage and further affects the energy consumption of features in manufacturing stage. Therefore, this project regards features of machining workpiece as research object and focuses on multi-attributes energy effect for features of workpiece, revealing various energy characteristics caused by the variation of design- and manufacturing-related attributes. Then, based on the energy transfer and consumption characteristics considering the design- and manufacturing-related attributes, the energy consumption of the features is modeled. Finally, synergism optimization methods based on the multi-scale and multi-dimensionality rules is proposed. The research would extend the energy consumption of machining workpiece to design stages and provide basic theory and method support for energy modeling and optimization for workpiece.

降低机械零件的制造能耗是当前机械制造业面临的重要挑战。机械零件加工特征作为零件结构的基本组成单元，其制造过程能耗本质上是一个受设计属性和制造属性共同作用的复杂过程。目前对机械零件制造能耗研究主要集中在制造属性对能耗影响方面，缺乏与设计属性协同作用下能耗特征研究，这一问题会导致环境负荷从设计阶段转移到制造阶段，从而影响机械零件在制造过程的能量消耗。为此，本项目以机械零件加工特征为研究对象，研究机械零件加工特征的多属性能耗效应，揭示机械零件加工特征能耗随不同设计属性和制造属性而产生的各种能耗规律；研究机械零件加工特征在设计属性和制造属性协同作用的能量传递和消耗特性，建立加工特征多属性效应作用的能耗模型；在此基础上，研究面向加工特征的多尺度多维度协同优化方法。本项目的研究成果可以将机械零件制造过程的能耗研究从广度上延伸到设计阶段，从深度上为机械零件制造过程的能耗研究提供基础理论和方法。

实现制造业的节能减排对于实现可持续与绿色制造具有重大意义，如何减少机械零件的能源消耗是当前制造业面临的一项重大课题。本项目针对机械零件加工特征设计属性和制造属性对加工特征能耗的影响机制、多属性协同的能耗模型和协同优化机制等内容展开研究。具体包括：.1）提出了一种考虑机械产品全生命周期的环境影响评价方法，揭示了环境负荷从设计阶段转移到制造阶段的问题，进一步分析了机械零件设计属性对制造过程的环境负荷的影响。针对零件加工时制造属性的变化特征，提出了一种分层面向对象的Petri网（HOONet）的机械零件制造过程中数控加工系统动态能耗评估方法，揭示制造属性对制造过程的能耗影响规律。.2）以螺纹这一机械零件加工特征为对象，建立了螺纹特征材料去除比能预测模型，揭示了螺纹特征工艺参数对材料去除比能、材料去除率的影响机制。进一步提出了一种集成工件设计属性和制造属性的机械零件机加工能耗预测方法，揭示了设计属性和制造属性对机械零件制造过程的能耗影响规律。进一步针对机械零件的再制造加工环节，提出了一种基于知识重用的再制造加工工艺规划快速生成方法。.3）提出一种集成特征加工顺序和走刀策略的机械零件机加工能耗优化方法，揭示以能耗为目标的加工工艺优化规则，构建了机械零件加工特征多属性与能耗的协同优化机制；进一步提出了一种动态环境下的机械加工产品特征的节能优化方法。.依托本项目共发表及录用论文8篇（SCI/EI7篇），授权发明专利1项；培养硕士4名，博士1名。上述研究突破了当前机械零件的能耗研究停留在分析制造属性对能耗的影响方面的局限性，将目前的能耗问题研究延伸到设计阶段，为进一步完善机械零件制造过程能耗研究的基础理论提供支持。