薄壁构件铣削加工工艺参数的动态可靠性优化理论与方法研究

In the milling process of thin-walled structures, the static deformation and cutting vibration (in particularly, chatter) seriously affect the machining accuracy and surface quality of the workpiece. Selecting reasonable milling process parameters can effectively suppress machining deformation and cutting vibration to improve the machining accuracy and surface quality of the workpiece. In this project, the mechanical behavior analysis of the milling process of thin-walled structures is carried out to establish the mechanical model of the milling force and the multi-modal time-lag dynamic model with time-variate parameters. Then the stability analysis and surface location error prediction of the milling process are carried out to reveal the dynamic coupling mechanism of the machine tool，the cutter and the workpiece in the milling process of thin-walled structures. The dynamic reliability and reliability sensitivity analysis of the milling process of thin-walled structures is carried out considering the influences of stochastic uncertain factors on the milling process, to evaluate the reliability of the milling process and the important degree of random parameters. Finally, to solve the problem of the process parameters selection and optimization, the dynamic reliability optimization model of the milling process of thin-walled structures is established under the condition that the reliability of the milling process meets the requirement of the customer. In the dynamic reliability optimization model, the processing parameters are chosen as the optimization parameters and the optimization goals are the high removal efficiency of materials and robust of the milling process.

在薄壁构件铣削加工过程中，刀具与工件的静态变形以及切削振动（特别是颤振）严重影响工件的加工精度和表面质量。选取合理的铣削加工工艺参数可以有效抑制加工变形和切削振动的发生，提高工件的加工精度和表面质量。本项目从薄壁构件铣削加工过程的力学性能分析入手，建立切削力机械力学模型以及变参数多模态时滞动力学模型，开展铣削加工稳定性分析与表面位置误差预测，揭示薄壁构件铣削加工过程中，机床、刀具与工件的动态耦合作用机理。而后考虑随机不确定因素对薄壁构件铣削加工过程的影响，开展薄壁构件铣削加工动态可靠性与可靠性敏感度分析研究，评价铣削加工过程的可靠性状况以及随机参数的重要度。将加工工艺参数作为优化参数，以材料的高切除效率和铣削加工稳健性（即可靠性敏感度最小）作为优化的目标，在铣削加工过程可靠性满足要求的条件下，提出薄壁构件铣削加工动态可靠性优化建模与求解方法，解决薄壁构件铣削加工工艺参数的选取与优化问题。

截止2019年12月31日，项目已按计划完成了项目申请书中规定的全部任务。主要完成的研究内容为：从薄壁构件铣削加工过程的力学性能分析入手，建立了切削力机械力学模型以及变参数多模态时滞动力学模型，开展了铣削加工稳定性分析与表面位置误差预测。而后考虑随机不确定因素对薄壁构件铣削加工过程的影响，开展了薄壁构件铣削加工动态可靠性与可靠性敏感度分析研究，评价铣削加工过程的可靠性状况以及随机参数的重要度。将加工工艺参数作为优化参数，以材料的高切除效率和铣削加工稳健性（即可靠性敏感度最小）作为优化的目标，在铣削加工过程可靠性满足要求的条件下，提出了薄壁构件铣削加工动态可靠性优化建模与求解方法，解决了薄壁构件铣削加工工艺参数的选取与优化问题。基于上述成果，共发表论学术文26篇（其中SCI检索论文19篇，EI检索论文5篇），出版学术专著1部，公开发明专利5项（获批3项，2项在审理过程中），获批软件著作权1项。在项目执行期间，项目负责人曾获教育部科学技术进步奖一等奖1项，获“兴辽英才计划”青年拔尖人才称号、辽宁省“百千万人才工程”千层次人才称号和沈阳市拔尖人才称号。