Process Planning Technology Of Mechanical Machining System For Generalized Energy Efficiency

Manufacturing industry is widely distributed and consumes a significant portion of total energy consumption of the industry sector.Reducing energy consumption and improving energy efficiency of the manufacturing industry become an important strategy and research hotspot for all the manufacturing industrial practitioners who want to keep the sustainable development of it.The mechanical machining system is a system of close interaction among the machine tool,workpiece and cutting tool.During the machining process,it will consume not only a huge amount of electrical energy,but also a lot of embodied energy of the auxiliary materials such as the cutting tools and cutting fluids.The energy characteristics of the machining system tend to be quite complicated and huge amount of energy consumption is consumed in a low efficiency.How to reduce the energy consumption and improve the energy efficiency of the mechanical machining system is an imperative research area worth of further investigation.With the support of the National Natural Science Foundation of China(No.51475059)and the National High-Tech R&D Program of China(863 Program)(No.2014AA041506),this research focused on process planning technology of mechanical machining system for generalized energy efficiency.The detailed research points are elaborated as follows.Firstly,the generalized energy consumption characteristics of the mechanical system is explicitly analyzed and the generalized energy efficiency models are developed by considering the electrical energy and embodied energy of the auxiliary materials such as the cutting tools and cutting fluids.Then the influence of process planning on the generalized energy efficiency of the mechanical machining system are explicitly analyzed.On this basis,a process optimization framework is proposed for generalized energy efficiency improvement.Secondly,by considering maximum generalized energy efficiency and minimum production time as the optimization objectives,a multi-objective optimization model is established with the variables of cutting passes and cutting parameters such as cutting velocity,feed rate and cutting depth.A modified Multi-objective Particle Swarm Optimization algorithm is used to solve the proposed model.On the basis,case studies are conducted to validate the effectiveness of the proposed model and algorithm.The influence of cutting parameters and cutting passes on generalized energy efficiency is analyzed.Thirdly,a multi-objective optimization model is established to maximize generalized energy efficiency and minimize production time with the variables of cutting tool specifications such tool material,tool diameter and number of inserts and cutting parameters such as cutting velocity,feed rate and cutting depth.A Multi-objective Cuckoo Search algorithm is adopted to solve the proposed model.Through case studies,the necessity of integrating optimization of cutting tools and cutting parameters is demonstrated and the generalized energy efficiency improvement performance of the proposed model is verified.On the basis,the interactions of the cutting tools and cutting parameters on generalized energy efficiency is analyzed.Fourthly,the influence of process route on generalized energy efficiency is analyzed.By considering maximum generalized energy efficiency and minimum production time as the optimization objectives,a multi-objective optimization model is established with the variables of operation sequence,machine tool selection,cutting tool selection,tool approaching direction and cutting parameters.A Multi-objective Simulated Annealing algorithm is adopted to solve the proposed model.On the basis,case studies are conducted to validate the effectiveness of the proposed model and algorithm.Fifthly,a process planning support system of mechanical machining for generalized energy efficiency improvement is developed based on the above mentioned models and algorithm.The framework,workflow and functions of the proposed system are introduced.An application case of the proposed system in the machining workshop of Chongqing Shengong Agricultural Equipment Co.,Ltd.is used to verify its effectiveness and practicality.