基于三维离散元法的离心式滚磨光整加工理论分析和仿真模拟
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摘要
表面光整加工技术作为机械加工的最终加工工艺,对提高产品质量和性能、延长零件及产品整机的使用寿命等具有十分重要的影响。随着机械设备的发展,对提高零件表面质量的光整加工技术提出了越来越高的要求。目前,对光整加工新技术和新工艺的加工动态过程缺乏系统深入的认识和研究,从而影响光整加工技术的完善、应用和推广。
本文在国内外离心滚磨光整加工相关理论和研究成果的基础上,首次将三维离散元法、人工智能技术引入光整加工领域,采用宏观和微观相结合、定性和定量相结合、动力学仿真和黑箱仿真相结合、数字实验和物理实验相结合等手段,从理论分析、仿真和实验等方面深入研究离心滚磨加工过程滚筒中混合介质的宏观运动特征、微观加工机理、加工效率及其影响因素,为设备开发和工业应用提供更为完善的理论支持。研究内容和主要成果有:
1.借助颗粒动力学理论,对离心滚磨光整加工的介质受力、运动速度、加工机理等从理论上进行了详细的分析,确定了介质脱离筒壁的条件,推导了临界传动比和加工效率的理论计算公式。
2.采用三维离散元法建立了离心滚磨加工过程的动力学模型,对滚筒中单个介质和混合介质群的运动过程分别进行可视化仿真。通过分析滚筒运转过程中介质的位置、速度、介质间及介质与筒壁之间的接触力、接触能量、筒壁的受力等,探讨不同参数对介质的运动特征、加工机理、加工效率、加工效果的影响规律。
3.首次提出了离心滚磨临界传动比的概念,并通过仿真得出不同机型的临界传动比,与理论临界传动比的计算基本吻合。
4.采用BP神经网络方法建立了离心滚磨加工过程的黑箱预测模型,并利用遗传算法对BP神经网络的权值进行优化,用Matlab软件编程进行仿真,实现不同参数下加工结果的预测,为进一步实现多目标优化提供基础。
5.对离心滚磨加工进行实验研究,对转速、传动比、装入量、混合比、磨块直径等主要影响因素进行实验,验证了仿真分析的正确性和有效性。
本文通过仿真深入系统地研究了离心滚磨光整加工在不同参数下介质运动、加工机理、加工效率、加工效果等的变化规律,研究成果填补和深化了滚磨光整理论;并对离心滚磨机型的设计及操作参数的优化提供了依据;可以代替大量的繁杂实验,节约了人力、物力和财力。对于推动表面滚磨光整加工技术的进一步发展及推广应用具有十分重要的意义。
As final machining process, surface finishing technology has important influence on part or product quality, performance, service life etc. With machining equipment development, there is more request for surface finishing technology improving surface quality. At present, there is not enough research for dynamic finishing course of new surface finishing process, which affects its application.
Based on research results of centrifugal barrel finishing, three-dimensional discrete element method and artificial intelligence is used to surface finishing for the first time, macroscopic motion characteristic of mixed medium, microscopic finishing mechanism, finishing efficiency, etc. are thoroughly studied by theoretic analysis, simulation and experiments, which is done through the combination with macroscopic and microscopic, dynamics simulation and black-box simulation, experiment and simulation. Main research contents are as follows:
1. Based on particle theory, force, velocity and mechanism of particles is analyzed theoretically, and the condition of particles separated from barrel wall is defined. Theoretical calculation formula of critical transmission ratio and finishing efficiency is induced.
2. With three-dimensional discrete element method, dynamics model is established, and visualization simulation is done for finishing process of the single particle and particles. By analyzing particle position, particle velocity, barrel wall force, contact force and contact energy between particles and particle-barrel wall, etc., affecting rules of different parameters is studied for particle motion characteristic, finishing mechanism, finishing efficiency, finishing effect.
3. The concept of critical transmission ratio is proposed for centrifugal barrel finishing, and critical transmission ratio for different type is obtained by simulation, which is basically consistent with theoretic computation.
4. Black-box prediction model is established by BP neural network method, and BP neural network weight is optimized with genetic algorithm. Simulated with Matlab software programming, finishing results prediction of different parameters is realized, which can provide basis for further multi-objective optimization.
5. Major effect factors, rotational speed, transmission ratio, loading capacity, mass ratio, particle diameter etc., are studied by experiments, which can confirm accuracy and the validity of simulation analysis.
In this paper, affecting rules of particles motion, finishing mechanism, finishing efficiency, finishing effect, etc. are thoroughly studied through theory and simulation analysis. Research results can deepen the theory of barrel finishing technology, and can provide perfect theoretic basis for equipment design and industrial application. It can replace massive numerous and diverse experiments, save manpower, physical and financial resource, which should be of great significance for the further development and industrial applications of surface barrel finishing.
本文在国内外离心滚磨光整加工相关理论和研究成果的基础上,首次将三维离散元法、人工智能技术引入光整加工领域,采用宏观和微观相结合、定性和定量相结合、动力学仿真和黑箱仿真相结合、数字实验和物理实验相结合等手段,从理论分析、仿真和实验等方面深入研究离心滚磨加工过程滚筒中混合介质的宏观运动特征、微观加工机理、加工效率及其影响因素,为设备开发和工业应用提供更为完善的理论支持。研究内容和主要成果有:
1.借助颗粒动力学理论,对离心滚磨光整加工的介质受力、运动速度、加工机理等从理论上进行了详细的分析,确定了介质脱离筒壁的条件,推导了临界传动比和加工效率的理论计算公式。
2.采用三维离散元法建立了离心滚磨加工过程的动力学模型,对滚筒中单个介质和混合介质群的运动过程分别进行可视化仿真。通过分析滚筒运转过程中介质的位置、速度、介质间及介质与筒壁之间的接触力、接触能量、筒壁的受力等,探讨不同参数对介质的运动特征、加工机理、加工效率、加工效果的影响规律。
3.首次提出了离心滚磨临界传动比的概念,并通过仿真得出不同机型的临界传动比,与理论临界传动比的计算基本吻合。
4.采用BP神经网络方法建立了离心滚磨加工过程的黑箱预测模型,并利用遗传算法对BP神经网络的权值进行优化,用Matlab软件编程进行仿真,实现不同参数下加工结果的预测,为进一步实现多目标优化提供基础。
5.对离心滚磨加工进行实验研究,对转速、传动比、装入量、混合比、磨块直径等主要影响因素进行实验,验证了仿真分析的正确性和有效性。
本文通过仿真深入系统地研究了离心滚磨光整加工在不同参数下介质运动、加工机理、加工效率、加工效果等的变化规律,研究成果填补和深化了滚磨光整理论;并对离心滚磨机型的设计及操作参数的优化提供了依据;可以代替大量的繁杂实验,节约了人力、物力和财力。对于推动表面滚磨光整加工技术的进一步发展及推广应用具有十分重要的意义。
As final machining process, surface finishing technology has important influence on part or product quality, performance, service life etc. With machining equipment development, there is more request for surface finishing technology improving surface quality. At present, there is not enough research for dynamic finishing course of new surface finishing process, which affects its application.
Based on research results of centrifugal barrel finishing, three-dimensional discrete element method and artificial intelligence is used to surface finishing for the first time, macroscopic motion characteristic of mixed medium, microscopic finishing mechanism, finishing efficiency, etc. are thoroughly studied by theoretic analysis, simulation and experiments, which is done through the combination with macroscopic and microscopic, dynamics simulation and black-box simulation, experiment and simulation. Main research contents are as follows:
1. Based on particle theory, force, velocity and mechanism of particles is analyzed theoretically, and the condition of particles separated from barrel wall is defined. Theoretical calculation formula of critical transmission ratio and finishing efficiency is induced.
2. With three-dimensional discrete element method, dynamics model is established, and visualization simulation is done for finishing process of the single particle and particles. By analyzing particle position, particle velocity, barrel wall force, contact force and contact energy between particles and particle-barrel wall, etc., affecting rules of different parameters is studied for particle motion characteristic, finishing mechanism, finishing efficiency, finishing effect.
3. The concept of critical transmission ratio is proposed for centrifugal barrel finishing, and critical transmission ratio for different type is obtained by simulation, which is basically consistent with theoretic computation.
4. Black-box prediction model is established by BP neural network method, and BP neural network weight is optimized with genetic algorithm. Simulated with Matlab software programming, finishing results prediction of different parameters is realized, which can provide basis for further multi-objective optimization.
5. Major effect factors, rotational speed, transmission ratio, loading capacity, mass ratio, particle diameter etc., are studied by experiments, which can confirm accuracy and the validity of simulation analysis.
In this paper, affecting rules of particles motion, finishing mechanism, finishing efficiency, finishing effect, etc. are thoroughly studied through theory and simulation analysis. Research results can deepen the theory of barrel finishing technology, and can provide perfect theoretic basis for equipment design and industrial application. It can replace massive numerous and diverse experiments, save manpower, physical and financial resource, which should be of great significance for the further development and industrial applications of surface barrel finishing.
引文
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