Research On Cutting Energy Consumption Prediction Methods For Workpiece Machining Process And The Development Of Application System

Workpiece machining process is an important production process in mechanical manufacturing industry. Workpiece machining process consumes energy in large quantities and with poor energy efficiency, which implies a great potential for energy saving. Thus, it is important to do some research on the energy consumption and energy efficiency of workpiece machining process. The evaluation and calculation of the cutting energy consumption of workpiece machining process is the foundamental questions. As a result, this paper is constructed to model and predict the cutting energy of workpiece machining process funded by the National Natural Science Foundation of China(Grant No. 51375513) and other projects. The main contents of this paper are concluded as follows:This paper first analyzes prediction oriented cutting energy consumption for workpiece machining process which includes the service phases during the service process of workpiece machining, the energy consumption of the workpiece machining process. Then, through analyzing the production mechanism of cutting energy, the theoretical and empirical models of cutting energy consumption are proposed. The predicting characteristics of the theoretical and empirical models are summarized based on the prediction models of cutting force.This paper analyzes the comprehensive methods for the cutting energy consumption prediction in workpiece machining process. This paper analyzes the existing exponential cutting energy consumption model and specific cutting energy consumption model. Based on a large amount of experimental data, this paper summarizes the advantages and disadvantages of the two models: exponential cutting energy consumption model exhibits high precision in large cutting parameters and low precision in small cutting parameters. In contrast, the specific cutting energy consumption model exhibits opposite features. Based on the regularity, this paper proposes a comprehensive cutting energy consumption prediction model. The weight coefficients are proposed based on the regularity which can be obtained by polynomial fitting. Based on the comprehensive cutting energy consumption prediction model, the prediction flow of this novel method is presented which exhibits wide application scope.At last, this paper develops the application system for cutting energy consumption forecasting. The application system demand analysis is made first. Based on it, design goal and principle of the system are presented. After that, the overall framework design and function module design of the application system are made based on the design goal and principle. Then the software is developed on the Qt platform. The application system can simplify the procedures of the cutting energy consumption prediction and supply tool support for the cutting energy consumption prediction in production site.The case study and application study proves that the approach presented in this paper is able to efficiently and easily predict the cutting energy consumption with small errors. The comprehensive method for predicting cutting energy consumption is available and practical for analyzing the total energy consumption of machine tools, evaluating the energy efficiency, forecasting the energy consumption and planning the energy quota for workpiece machining process.