A novel surface residual stress monitoring method based on the power consumption of machine tool: A case study in 5-axis machining
A novel surface residual stress monitoring method based on the power consumption of machine tool: A case study in 5-axis machining
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DOI：
10.1016/j.jmapro.2022.12.057
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发表时间：
2023-01
影响因子：
6.2
通讯作者：
Zehua Wang;Sibao Wang;Shilong Wang;N. Liu;Zengya Zhao;Yankai Wang
中科院分区：
文献类型：
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作者：
Zehua Wang;Sibao Wang;Shilong Wang;N. Liu;Zengya Zhao;Yankai Wang
加工引起的残余应力显着影响机加工零件的使用性能，应进行良好监测。但直接测量方法耗时长，且只能在加工后进行。同时，现有的预测方法很少考虑实时因素对加工参数的影响，无法满足残余应力在线监测的要求。因此，基于易于测量的在线系数（本文使用五轴机床的功耗），提出了一种新颖的表面残余应力监测方法。首先，使用机床的功耗 (P t) 来模拟平均有效切削功率 (P e)。其次，建立了进给方向表面残余应力（Rs x）与P e 之间的关系。第三，结合这两个模型，基于P t 来预测Rs x 。最后，提出了一种基于P t 的表面残余应力监测新方法。通过各种实验验证了该方法的有效性，平均预测误差率仅为9.5%。从案例研究来看，在主轴转速一定的情况下，当机床功率消耗增加时，Rs x 由拉应力变为压应力。它为控制表面残余应力提供了新的方法和平台，极大有利于复杂零件的高性能制造。
The machining-induced residual stress significantly influences the service performance of machined parts and should be well monitored. However, the direct measurement method is time-consuming and only can be conducted after machining. Meanwhile, the existing prediction method rarely considers the effects of real-time factors on the machining parameters and cannot meet the requirement of online residual stress monitoring. Therefore, a novel surface residual stress monitoring method is proposed based on the easily measured online factor (power consumption of the 5-axis machine tool is used in the paper). Firstly, the power consumption of the machine tool (P t) is used to model the mean effective cutting power (P e¯). Secondly, the relationship between the surface residual stress in the feed direction (Rs x) and P e¯ is established. Thirdly, Rs x is predicted based on P t by combining these two models. Finally, a novel surface residual stress monitoring method based on P t is proposed. The effectiveness of the proposed method is validated by various experiments, and the mean prediction error rate is only 9.5%. From the case study, when the power consumption of machine power increases at a fixed spindle speed, Rs x changes from tensile stress to compressive stress. It provides a new method and platform for controlling the surface residual stress and greatly benefits the high-performance manufacturing of complex parts.