Research On Integrated Cutter Diameter And Cutting Parameter Optimization Model And Method For Energy-aware CNC Machining

Facing the increasingly severe problem of resource consumption and carbon emission,the ‘low-carbon economy' manufacturing model which regard low energy consumption and high energy efficiency as the core is spring up gradually.Aiming at the existing high energy consumption and low energy efficiency characteristics of machinery manufacturing industry,analyzing energy consumption characteristics of machine tools in CNC machining process,exploring the regulation of reducing energy consumption and improving energy efficiency of CNC machine tools is an inevitable choice for the sustainable development of China's economy.Cutter diameter and cutting parameters not only affect the machinig cost,the machining time and the surface quality in practical machining process,they are also closely revelant to energy consumption.With the support from key projects of the National High-Tech R&D Program of China(863 Program)(No.2014AA041506)and National Natural Science Foundation of China(No.51475059),the multi-objective cutter diameter and cutting parameters integrated optimization models and methods of CNC machining for energy saving are studied.This has important research significance that can provide theoretical reference for transformation,upgrading and energy saving of China's machinery manufacturing enterprises.Firstly,in single tool planar CNC milling process,a multi-objective cutter diameter and cutting parameters integrated optimization model for energy saving is presented.The constituent characteristic of energy consumption in the process of single tool plane milling is explained.On this basis,redgarding cutter diameter and cutting parameters as the variables,a multi-objective integrated optimization model for minimizing both energy consumption and machining cost in plane CNC milling is established,which is solved based on multi-objective particle swarm optimization algorithm.Secondly,an optimal selection method of cutter combination for reducing energy consumption in multi-tool 2.5D pocket CNC milling is proposed in this paper.The influence of cutter combination in terms of cutter diameter selection and accessible region determination on energy consumption in 2.5D pocket CNC milling process is explicitly analyzed.A mathematical optimization model is then established to select the best cutter combination with objective of minimizing both energy consumption and machining cost.A hybrid approach with integration of directed graph and Dijkstra algorithm is proposed to solve the optimization model.Thirdly,the problem of cutter diameter and cutting parameters integrated optimization in multi-tool hole machining for energy reduction is also studied in this paper.The energy consumption characteristics of multi-tool hole making by the process that drilling first and then milling is analyzed.And then the multi-objective integrated optimization model for reducing energy consumption and machining cost is established with the variables of cutter diameter and cutting parameters.The optimization is carried out using multi-objective particle swarm optimization algorithm.Finally,the models and methods of cutter diamater and cutting parameters multi-objective integrated optimization in the processes of single tool palnar millling,multi-tool 2.5D pocket milling and multi-tool hole machining are applied and analyzed through several cases respectively,in order to verify the feasibility and practicability of the proposed models and methods above.