基于特征尺寸和工艺集成设计的零件机械加工过程能耗优化

Manufacturing industry is a main contributor to China’s total energy consumption, and increasing energy price and emission reduction requirements are new challenges faced by modern manufacturers. A considerable amount of manufacturing energy consumption is attributed to the machining of mechanical parts, while most of the machining energy consumed for a mechanical part has already been determined at its design phase. Thus, it is effective to consider and optimise the machining energy consumption at the part design phase, thereby reducing China’s manufacturing energy consumption and carbon emissions. This research project aims to determine the dimension and process parameters of each feature (e.g., excircle, hole, thread, groove, and stair) in designing a mechanical part to minimise its future machining energy consumed by the CNC machine tools. Therefore, this project introduces the machining energy consumption optimisation problem for a part through the integrated design of the dimension and process parameters of each feature. To solve this optimisation problem, the machining energy consumption models for independent and intersecting features based on the multiple variables (dimensions, feature sequences, and cutting parameters) are developed. Then deterministic algorithms and meta-heuristics are employed, and the optimal design of the dimension and process parameters of the part that results in the minimum machining energy consumption is obtained. By our project, new perspectives and techniques are provided for the accurate research on the product design theory for sustainability. The outcomes of our project can promote the standards of low carbon design and manufacturing in China.

制造企业是我国能源消耗的主要贡献者，面临节能减排的压力和挑战。在制造企业，相当大能源消耗归结于零件机械加工，而零件机械加工阶段所需能耗很大程度在其设计阶段就已经决定了。所以，在零件设计阶段就考虑和优化后续机械加工阶段能耗，对于降低我国制造能耗和碳排放可发挥较大作用。本项目关注如何在设计阶段确定零件中每个特征（例如外圆、圆孔、螺纹、方槽和台阶）的尺寸和工艺参数，使得数控机床执行该零件机械加工所需的电能消耗将最小。为此，引入了基于特征尺寸和工艺集成设计的零件机械加工能耗优化问题。为解决该优化问题，本项目构建基于尺寸、特征排序和切削参数多层变量的独立特征和相交特征机械加工能耗模型，运用确定性算法和启发式算法对该多层模型求解，得到最节能的零件尺寸和工艺设计方案。本项目为产品可持续设计理论更准确的研究和实践提供了新视角和技术，研究成果有助于促进我国低碳设计与制造的深入开展和实施。

为促进我国工业制造绿色可持续发展，本项目围绕低碳设计与制造，研究基于特征尺寸和工艺集成设计的机械加工过程能耗优化问题。以外圆特征、端面特征和圆孔特征为对象，研究如何在设计阶段确定这些特征及组合的尺寸和工艺参数最优值，使得后续机械加工制造阶段所需的能耗将最小。具体研究工作包括：（1）分析这些特征的尺寸和工艺设计参数如何影响机械加工能耗；（2）分别构建外圆特征和端面特征关于设计参数的机械加工能耗模型，构建外圆特征的机械加工与运输综合能耗模型，构建外圆与圆孔特征组合的机械加工能耗模型；（3）设计枚举算法、模拟退火算法和差分进化算法求解基于特征设计的机械加工过程能耗优化问题；（4）开展了实例研究，通过实验和算例验证模型和算法表现，展示所提优化方法的节能效果和优势。依托本项目，主持人共发表SCI收录论文14篇，申请/授权国家发明专利10项，登记计算机软件著作权2项。培养博士1名，硕士1名。本项目成果的应用和推广能够缓解全球工业制造能源消耗大及碳排放高的问题，有助于实现我国“十四五”规划中的“碳达峰、碳中和”目标。