Greybox models for in-situ quantification of probabilistic tool life of CVD coated cemented carbide gear hobs

用于现场量化 CVD 涂层硬质合金齿轮滚刀概率刀具寿命的灰盒模型

• 批准号: 521375603
• 负责人: Dr.-Ing. Jens Brimmers
• 金额: --
• 依托单位: Werkzeugmaschinenlabor - WZL
• 依托单位国家: 德国
• 项目类别: Priority Programmes
• 资助国家: 德国
• 项目状态: 未结题
• 来源: https://gepris.dfg.de/gepris/projekt/521375603?language=en
• 关键词: Greybox; models; situ; quantification; probabilistic

The overall objective of the present project proposal is the detailed description of the thermomechanical tool loading during gear hobbing and the resulting tool wear of CVD-coated cemented carbide tools by using deterministic models coupled with in-situ acquired process data and machine learning models to enable service life optimized regulation of the process. Gear hobbing is an established process for gear manufacturing. The load spectrum in gear hobbing leads to abrasive tool wear, which, when increased, negatively affects the dimensional accuracy of the workpiece as well as the stability of the tool cutting edge. Local inhomogeneities in the microstructure of the hard material coating and substrate as well as varying parameters in the coating microstructure result in probabilistically distributed service lives, which change in-situ depending on the real, complex operating conditions. By predicting the remaining service life of a tool depending on the material strength and the stress during machining, the total service life of coated tools can be significantly increased by closed-loop control. To date, the onset of failure, wear progress and remaining service life cannot be identified or predicted with sufficient certainty either by modeling or experimentally. In order to gain a deeper understanding of the process-microstructure-service life relationship, the tribological system is therefore being comprehensively investigated in the present project proposal, taking into account the material system and the manufacturing-related residual stresses. The focus is on gear hobbing tools made of cemented carbide, which are coated with a TiCN base layer and an α-Al2O3 top layer by CVD. These are first characterized in an analogy test. Based on this, a micromechanical model of the coating-substrate microstructure is built up, which enables the determination of the manufacturing-related residual stresses on the one hand and the simulation of the abrasive tool wear on the other hand. From deterministic white-box models for the prediction of stress and strength of the hob as well as by in-situ process data and black-box models, grey-box models are developed, which allow a material-sensitive prediction of the (remaining) tool life within the process time.

本项目提案的总体目标是详细描述滚齿过程中的热机械刀具载荷以及CVD涂层硬质合金刀具的刀具磨损，方法是使用确定性模型，结合现场采集的工艺数据和机器学习模型，以实现工艺的使用寿命优化调节。滚齿是齿轮制造的既定工艺。滚齿加工中的载荷谱会导致磨具磨损，当磨损增加时，会对工件的尺寸精度以及刀具切削刃的稳定性产生负面影响。硬质材料涂层和基底的微观结构中的局部不均匀性以及涂层微观结构中的变化参数导致概率分布的使用寿命，其根据真实的复杂的操作条件而原位改变。通过预测刀具的剩余使用寿命取决于材料强度和加工过程中的应力，涂层刀具的总使用寿命可以显着增加闭环控制。迄今为止，无论是通过建模还是实验，都无法确定或预测失效的发生、磨损进展和剩余使用寿命。 为了更深入地了解工艺-微观结构-使用寿命之间的关系，在本项目建议书中对摩擦学系统进行了全面研究，同时考虑了材料系统和与制造相关的残余应力。重点是由硬质合金制成的滚齿刀具，其通过CVD涂覆有TiCN基层和α-Al 2 O3顶层。这些首先是在类比测试的特点。在此基础上，涂层-基体微观结构的微观力学模型的建立，这使得一方面的制造相关的残余应力的测定，另一方面的磨料工具磨损的模拟。根据用于预测滚刀应力和强度的确定性白盒模型以及现场工艺数据和黑盒模型，开发了灰盒模型，可以对加工时间内的（剩余）刀具寿命进行材料敏感的预测。