轮廓铣削表面粗糙度预测及工艺参数增效优化

Prediction of surface roughness in contour milling and optimization of process parameters for efficiency enhancement

  • 摘要: 在轮廓铣削中,为满足质量要求并提高加工效率,提出一种基于轮廓曲率特征的工艺参数优化方法。考虑轮廓曲率特征对加工质量的影响,分别设计了直线、凸弧和凹弧的铣削正交试验,以获取在不同轮廓曲率下的表面粗糙度数据。基于试验结果,利用雪消融优化(snow ablation optimizer,SAO)算法改进的BP(back propagation)神经网络,分别建立直线、凸弧及凹弧铣削的表面粗糙度预测模型。以表面粗糙度与材料去除率为优化目标,构建轮廓铣削工艺参数的多目标优化模型,并运用NSGA-II(non-dominated sorting genetic algorithm II)算法进行求解,获得不同轮廓铣削方式下,满足规定粗糙度要求并最大化材料去除率的铣削工艺参数。将所提出的优化方法应用于实际轮廓加工,结果表明,各轮廓区域的粗糙度均能满足质量要求,且加工效率平均提升了17.1%。

     

    Abstract: In contour milling, to meet quality requirements and improve processing efficiency, an optimization method for process parameters based on contour curvature features is proposed. Considering the influence of contour curvature on machining quality, milling orthogonal experiments are designed for straight lines, convex arcs, and concave arcs, respectively, to obtain surface roughness data under different contour curvatures. Based on the experimental results, surface roughness prediction models for straight lines milling, convex arcs milling, and concave arcs milling are established using a back propagation (BP) neural network improved by the snow ablation optimizer (SAO) algorithm. By taking surface roughness and material removal rate as optimization objectives, a multi-objective optimization model for contour milling machining parameters is constructed, and the non-dominated sorting genetic algorithm II (NSGA-II) algorithm is applied to solve the model, obtaining milling parameters for different contour milling types that satisfy the specified roughness requirements while maximizing material removal rate. The proposed optimization method is applied to actual contour machining, and the results show that the roughness of all contour regions can meet the quality requirements, and the machining efficiency is improved by 17.1% on average.

     

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