Energy consumption investigation of a three-axis machine tool and ball-end milling process
Energy consumption investigation of a three-axis machine tool and ball-end milling process
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DOI：
10.1007/s00170-022-09627-w
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发表时间：
2022-07
期刊：
影响因子：
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通讯作者：
R. Ge;Song Zhang;Ren-quan Wang;Xiaona Luan;I. Ullah
中科院分区：
文献类型：
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作者：
R. Ge;Song Zhang;Ren-quan Wang;Xiaona Luan;I. Ullah
制造业每年消耗大量能源，对资源消耗和环境问题提出了重大挑战。为了克服这些困难，有必要了解机床的动力特性。研究了球头铣刀铣削过程中机床的能耗，建立了球头铣刀铣削过程的切削功率模型。首先，建立了基于切削力无穷小的球头铣刀切削功率理论模型。其次，通过一系列实验，揭示并验证了主轴功率与进给功率的数学关系。最后进行了插铣实验，通过分析切削力与切削功率之间的关系，提出了切削功率经验模型。结果表明，该方法可以准确地预测主轴功率、进给功率和切削功率。进一步揭示了Z轴向下运动时，重力使Z轴电机转化为发电机的进给功率特性。对于切削功率模型，理论模型和经验模型的预测精度相当，而经验模型形式简单，易于应用。提出的功率调查方法为机床能耗特性的研究提供了技术支持。
The manufacturing industry consumes a considerable amount of energy every year, which poses a major challenge to resource consumption and environment problem. To overcome these difficulties, it is necessary to understand the machine tools’ power characteristics. The current research aims to investigate the energy consumption of the machine tool and to establish a cutting power model for ball-end milling process. First, a cutting power theoretical model for a ball-end milling cutter was established based on the infinitesimal cutting force. Secondly, a series of experiments were conducted to reveal and validate the mathematical function of spindle power and feed power. Finally, slotting milling experiments were conducted, and a cutting power empirical model was proposed by analyzing the correlation between cutting forces and cutting power. The results showed that the spindle power, feed power, and cutting power could be exactly predicted by the proposed method. Furthermore, theZ-axis’s feed power characteristic was revealed that the gravity made theZ-axis’s motor transform to the generator whenZ-axis moved in the downward direction. For cutting power model, the theoretical model and empirical model had the same predictive accuracy, while the empirical model had a simpler form and could be easier applied. The proposed power investigation method provided technical support for the research of the machine tools’ energy consumption characteristics.