Machine energy utilization rate during milling of PVC/calcium powder/wood fiber composites.
Machine energy utilization rate during milling of PVC/calcium powder/wood fiber composites.
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DOI：
10.13360/j.issn.2096-1359.202008006
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发表时间：
2021-01-01
期刊：
影响因子：
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通讯作者：
Guo, X. L.
中科院分区：
文献类型：
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作者：
Dong, Wei-hang;Hu, Yong;Guo, X. L.
木塑复合材料是一种可回收利用的环保型绿色材料，以其优越的上级力学性能，使其利用率和市场占有率逐步提高。机床的有效加工能效直接反映了能量利用率，机床的有效加工能效越高，意味着机床在铣削过程中的能量利用率越高。为了提高木塑复合材料混炼过程中的机械能效，降低生产能耗，对PVC/钙粉/木纤维复合材料混炼过程中的机械功率进行了研究。分析了主轴转速（6000、8000、10000 r/min）、铣削深度（0.5mm、1.0mm、1.5mm）、前角（2°、6 °、10°）和后刀面磨损（0.1mm、0.2mm、0.3mm）对机床主轴总功率、空载功率、铣削功率和机床有效加工能效的影响。在计算机数控系统上进行了一系列切削试验，固定进给速度为5 m/min，铣刀为硬质合金单齿柄铣刀。功率信号由机器控制柜用三相功率分析仪采集。每次切削试验重复三次机床功率信号，然后取平均值进行进一步研究。同时，以机床有效加工能量效率最高为优化目标，进行正交分析，得到最优铣削参数。结果表明，在本研究所选取的铣削参数范围内，空载功率仅受主轴转速的影响。总功率和切削功率随主轴转速、铣削深度和后刀面磨损量的增大而增大，随前角的增大而减小。机床的有效加工能量效率随着主轴转速和前角的增大而减小，随着铣削深度的增大而增大。铣削深度对机床有效加工能效的影响最大，其次是前角和主轴转速。因此，在木塑复合材料加工过程中，在保证切削质量的前提下，推荐采用较大前角、较高主轴转速和较大铣削深度的切削条件，以提高机床的有效加工能效，提高机床能量利用率，降低生产过程中的能耗。
Since wood-plastic composite(WPC) is a recyclable and environmentally friendly green material, with its superior mechanical properties, the utilization and market share of WPC have been gradually increased. The effective machining energy efficiency of machine tool directly reflects the energy utilization rate, and the higher the effective machining energy efficiency of machine tool means the higher the energy utilization rate of the machine in the milling process. In order to improve the machine energy efficiency and reduce the production energy consumption during the WPC milling, the machine power during PVC/calcium powder/wood fiber composite milling was studied. The spindle speed(6 000,8 000 or 10 000 r/min), milling depth(0.5,1.0 or 1.5 mm), rake angle(2°,6° or 10°) and flank wear(0.1,0.2 or 0.3 mm) during the milling of WPC that influence the total machine spindle power, idle pow-er, milling power and effective machining energy efficiency of machine tool were analyzed. A series of cutting experiments were carried out on the Computer Numerical Control with a fixed feeding speed of 5 m/min, and the milling cutter was a single-toothed shank cutter, which was made of cemented carbide. The power signal was acquired by the machine control cabinet with a three-phase power analyzer. The signal of machine power was repeated three times for each cutting test, and then the average value was adopted for further investigation. At the same time, the orthogonal analysis was carried out to obtain the optimal milling parameters with the highest effective machining energy efficiency of the machine tool as the optimization objective. The results showed that, within the range of milling parameters selected in this study, the idle power was only affected by the spindle speed. Meanwhile, the total power and cutting power increased with the increase of spindle speed, milling depth and flank wear, but decreased with the increase of rake angle. Furthermore, the effective machining energy efficiency of machine tool decreased with the increase of spindle speed and rake angle, and increased with the increase of milling depth. The effect of milling depth on effective machining energy efficiency of machine tool was the largest, followed by the rake angle and the spindle speed. Therefore, during the machining of WPC, under the premise of cutting quality, the cutting condition with larger rake angle, higher spindle speed and greater milling depth was recommended, which could improve the effective machining energy efficiency of machine tool, increase the machine energy utilization rate and reduce the energy consumption during the production.