基于粒子群算法的滚削齿面综合轮廓误差预测模型与试验研究

摘要/Abstract

摘要： 在配备有自主研发的数控滚齿系统的精密卧式滚齿机上，运用三因素两水平响应曲面法设计滚削试验，研究齿轮滚削加工刀具转速、轴向进给速度、背吃刀量对齿轮齿面轮廓误差的影响规律。根据试验结果，分析得出齿轮齿廓总偏差、齿轮螺旋线总偏差、齿距累计总偏差的预测模型及各工艺影响因素对齿面轮廓误差的作用显著程度，并以三个预测模型的附加权重值之和达到最小值为目标，建立可以评定多目标误差的齿面综合轮廓误差数学模型，运用粒子群优化算法对齿面综合轮廓误差数学模型进行分析优化，寻找最佳滚齿加工工艺参数。试验表明，采用粒子群优化算法对响应曲面法建立的齿面综合轮廓误差数学模型进行优化可以作为滚削加工前的工艺参数选取方案。

关键词: 粒子群优化算法, 响应曲面法, 滚齿加工, 轮廓误差

Abstract: A series of 3 factors and 2 levels response surface method experiments were carried out to research the influence rules of processing parameters including the spindle speed, the feed rate in Z direction, and the hobbing depth on the gears' tooth profile errors on the precision horizontal gear hobbing machine equipped with home-made CNC system. The mathematical models of the total profile deviation, the total helix deviation and the total cumulative pitch deviation were built respectively and the influence degrees of the three gear profile errors were finished based on the statical experimental data analyses. A more appropriate model for gear profile errors was established based on the weighting factor of each deviation. A method of using particle swarm optimization to improve the gear hobbing parameters was applied based on the final mathematical model. The results show that it is feasible to preselect the hobbing parameters based on the particle swarm optimization of the gear profile errors model established by response surface method.

Key words: particle swarm optimization, response surface method, gear hobbing, profile error

中图分类号:

TH161

袁彬, 韩江, 吴路路, 田晓青, 夏链. 基于粒子群算法的滚削齿面综合轮廓误差预测模型与试验研究[J]. 中国机械工程.

Yuan Bin, Han Jiang, Wu Lulu, Tian Xiaoqing, Xia Lian. A Prediction Model and Experimental Study of Gear Hobbing Profile Errors Based on Particle Swarm Optimization[J]. China Mechanical Engineering.

参考文献

[1]Karpuschewski B, Knoche H J, Hipke M. Gear finishing by Abrasive Processes[J]. CIRP Annals—Manufacturing Technology, 2008, 57(2)：621-640.

[2]Silva D, Sandro P, Moni R F. Particle Swarm Optimization for Achieving the Minimum Profile Error in Honing Process[J]. Precision Engineering—Journal of the International Societies for Precision Engineering and Nanotechnology, 2014, 38(4)：759-768.

[3]Pathak S, Jain N K, Palani I A. On Use of Pulsed-electrochemical Honing to Improve Micro-Geometry of Bevel Gears[J]. Materials & Manufacturing Processes, 2014, 29(11/12):1461-1469.

[4]Mohanasundararaju N. Optimisation of Work Roll Grinding Using Response Surface Methodology and Evolutionary Algorithm[J]. International Journal of Manufacturing Research, 2008, 3:236-251.

[5]Raja S B, Baskar N. Application of Particle Swarm Optimization Technique for Achieving Desired Milled Surface Roughness in Minimum Machining Time[J]. Expert Systems with Applications, 2012,39(5)：5982-5989.

[6]Pawar P J, Rao R V, Davim J P. Multiobjective Optimization of Grinding Process Parameters Using Particle Swarm Optimization Algorithm[J]. Materials and Manufacturing Processes, 2010,25(6)：424-431.

[7]潘永智, 艾兴, 唐志涛, 等. 基于切削力预测模型的刀具几何参数和切削参数优化[J]. 中国机械工程, 2008, 19(4)：428-431.

Pan Yongzhi, Ai Xing, Tang Zhitao, et al. Optimization of Tool Geometry and Cutting Parameters Based on a Predictive Model of Cutting Force[J].China Mechanical Engineering, 2008, 19(4)：428-431.

[8]冯勇, 汪木兰, 王保升, 等. 基于权重粒子群算法的工件铣削温度研究[J]. 机械工程学报, 2014, 50(19)：205-212.

Feng Yong, Wang Mulan, Wang Baosheng, et al. Research on Cutting Temperature of Workpiece in Milling Process Based on WPSO [J]. Journal of Mechanical Engineering, 2014, 50(19)：205-212.

[9]雷伟军, 程筱胜, 戴宁, 等. 基于改进遗传算法的多模型加工路径规划[J]. 机械工程学报, 2014, 50(11)：163-169.

Lei Weijun, Cheng Xiaosheng, Dai Ning, et al. Multi-model Machining Path Planning Based on Improved Genetic Algorithm[J]. Journal of Mechanical Engineering, 2014, 50(11)：163-169.

[10]Timac G, Braut S, Ziguli R. Comparative Analysis of PSO Algorithms for PID Controller Tuning[J]. Journal of Mechanical Engineering, 2014, 27(5)：928-936.

[11]常智勇, 杨建新, 赵杰, 等. 基于自适应蚁群算法的工艺路线优化[J]. 机械工程学报, 2012, 48(9)：163-169.

Chang Zhiyong, Yang Jianxin, Zhao Jie, et al. Optimization of Process Based on Adaptive Ant Colony Algorithm[J]. Journal of Mechanical Engineering, 2012, 48(9)：163-169.

[12]胡小平, 奚长庆, 于保华. 基于响应曲面法的珩磨工件圆柱度预测模型和工艺参数优化研究[J]. 中国机械工程, 2014, 25(15)：2098-2106.

Hu Xiaopin, Xi Changqing, Yu Baohua, et al. Research on Cylindricity Prediction and Process Parameter Optimization in Honing Based on Response Surface Methodology[J]. China Mechanical Engineering, 2014, 25(15):150-160.

[13]谢书童, 郭隐彪. 双刀并行数控车削中的切削参数优化方法[J]. 中国机械工程, 2014, 25(14)：1941-1946.

Xie Shutong, Guo Yinbiao. Optimization Approach of Cutting Parameters in Parallel NC Turnings with Two Cutters[J]. China Mechanical Engineering, 2014, 25(14)：1941-1946.

[14]陈建岭, 孙杰, 李剑峰. 钛合金铣削加工参数多目标优化研究[J]. 中国机械工程, 2014, 25(2)：169-173.

Chen Jianling, Sun Jie, Li Jianfeng. Multi-objective Optimization of Cutting Parameters during Milling of Titanium Alloys [J]. China Mechanical Engineering, 2014, 25(2)：169-173.

[15]Zhang Guojun, Liu Min, Li Jian. Multi-objective Optimization for Surface Grinding Process Using a Hybrid Particle Swarm Optimization Algorithm [J]. International Journal of Advanced Manufacturing Technology, 2014, 71(9/12)：1861-1872.