Modeling And Optimization Of Energy Consumption In High Speed Milling Of 45 Steel

The manufacturing industry which is closely related to the aerospace,military,food and other industries is the pillar industry of the national economy and embodies the comprehensive national strength of a country.The manufacturing industry has also consumed a large amount of resources and produced a large amount of waste.The proposal of the green manufacturing strategy is to save the resources,reduce the environmental pollution,and make the economic and social benefits of the enterprise to develop in a coordinated way.The energy consumption in the manufacturing industry needs to be controlled to realize the green manufacturing.Therefore,the energy consumption of the machine tool process needs to be studied.There are many sources of energy consumption in machine tool processing and production.How to predict energy consumption in machine processing and reduce energy consumption in machine processing and production is of great significance for achieving green manufacturing.Modeling and cutting parameters optimization of the energy consumption system of CNC milling machine are studied in this paper.The energy consumption of machine tool system is divided into two parts: machine tool idle energy consumption and metal cutting energy consumption.The model of machine tools idle energy consumption is mainly obtained by the experiment of the spindle no-load energy consumption of machine tools.The establishment of energy consumption model for metal cutting requires the establishment of micro element milling force model and establish the function relation of milling force factor on milling factors by milling force coefficient identification.Then the conversion relationship between the energy consumption coefficient and the milling force coefficient is obtained through the conversion between unit dimensions and the energy consumption model of the element is established.This paper selects spindle speed,feed per tooth,milling depth and milling width as experimental factors taking 45 steel as an experimental material.Single factor and multi factor milling experiments are carried out respectively and milling force and machine power are measured.The influence of spindle speed on the no-load power of machine tool and the empty load of machine tool is studied,and the model of machine tool no-load power is realized through single factor experiment.What is more,the milling force coefficient is identified,and the influence rule of four factors on milling force coefficient is studied.The influence rule of four factors on the energy consumption of metal cutting per unit volume and the energy consumption of the unit volume of machine tools is verified and studied.Through multi factor orthogonal experiment,the coefficient of milling force is identified and the function relation of milling force coefficient on spindle speed,feed per tooth and milling depth is realized.At last,the energy consumption model of high speed milling 45 steel is established by combining the model of empty load energy consumption.The influence of spindle speed,feed per feed,milling depth and milling width on unit milling energy and unit energy consumption is analyzed.With the increase of four elements of milling,the unit energy consumption is reduced.The energy consumption prediction and optimization software for high speed milling 45 steel is developed in this paper.The optimization objective function,optimization variable and constraint condition of high speed milling 45 steel are studied.The energy consumption model of high-speed milling 45 steel and the cutting time of workpiece are selected as the optimization objective function.Then genetic algorithm is applied to optimize the machining parameters.Compared with the single objective optimization results,the optimized machining parameters get a reasonable value in terms of machine energy consumption and processing time.With the function of MATLAB software GUI,the development of energy consumption prediction optimization software for high speed milling 45 steel is developed in this paper.The software can not only optimize the processing parameters of high speed milling 45 steel,but also reduce the energy consumption and production efficiency of machine tools,and predict the energy consumption of machine tool cutting which is of great significance to optimize the production process and realize green manufacturing.