High-efficiency And Energy-saving Milling Processing Optimization Method For Complex Curved Surfaces Based On Clustering Features

Mechanical manufacturing is a pillar industry for economic development and a major source of resource consumption and environmental pollution.At present,problems of high energy consumption and low efficiency in machinery manufacturing industry of China generally exists,which is a key field for the country to implement major strategies such as energy conservation,emission reduction,and environmental protection.For NC machining of complex curved surface parts such as aero-engine impeller,large naval propeller,steam turbine rotor,automobile panel precision die,high energy efficiency manufacturing is directly related to national economic development and national defense security,and manufacturing level represents the core competitiveness of national manufacturing industry.However,due to the complex geometric characteristics of complex curved surface parts,a series of problems such as long processing time,high cost and high energy consumption have become a challenging issue in the study of energy consumption of workshop manufacturing system.For this reason,this paper studies the efficient and energy-saving optimization processing method of complex surface.Firstly,the surface machining complexity model based on clustering features and energy consumption law is studied.At first,the concept of surface machining complexity and the characteristics of surface clustering are researched.On the basis of this,the iso-parameter sampling method is used to discretize the complex surface,and complex surface is roughly divided based on the curvature characteristics of the discrete points of the surface.Then the C-means algorithm is done to finish the fine partition of complex surface;what's more,the influencing factors of surface machining complexity are analyzed in detail from five aspects: machining object,machining equipment,machining tool,machining strategy and machining target,and the model of surface machining complexity is established by integrating the influencing factors of each aspect.In the end,the processing law between surface machining complexity and energy consumption as well as machining time is obtained through the processing experiments of different surface models.Secondly,on the basis of complex surface clustered and partitioned,the optimization method based on high efficiency and energy saving for various regions of complex surface partitioned with various parameter controlled and milling tool path is proposed.The cutting parameters and tool path are optimized for different surface types of clustering regions in the complex surface.At first,an optimization experiment for high-efficiency and energy-saving CNC milling is conducted.The experiment is based on the actual constraints of machine tools,tools and machining quality.The spindle speed,feed rate and tool path are optimized variables,and the machining energy consumption and machining time are the objective function.Orthogonal test method is utilized to determine the optimal cutting parameters and tool path to reduce energy consumption and machining time.What's more,milling simulation of the surface region is performed in Master CAM,and the optimal cutting parameters and tool paths are used in milling for each partition surface.As a result,the energy consumption and machining time of complex surface are the lowest.In the end,the effectiveness of the proposed optimization method compared with the traditional milling method of curved surface is verified by experiments,which provides a new idea for machining complex surface.Finally,the tool path of the surface region with different clustering features is optimized by the Hybrid algorithm.Hybrid algorithm based on optimization method for zoning milling of complex surface is proposed.At first,according to the shape features of complex surfaces,on the basis of surface clustered and partitioned,the geometric parameters of the complex surface are discretized with the iso-parametric sampling method,and certain tool points with reasonable number and suitable position is obtained.What's more,the tool path optimization model is established.In the model,taking the tool path length as the optimization variable under certain conditions of other parameters and processing energy consumption and machining time as the objective function,the hybrid algorithm is used to obtain the optimal tool path matching the surface area.In the end,the effectiveness of the proposed method is verified to improve machining efficiency and reduce energy consumption,which provides a technical basis for craftsmen to process curved surfaces.