Abstract
To optimize the rigidity and dynamic mechanical properties of a sawing machine and improve its processing quality and stability, a design method for the sawing machine’s gearbox was proposed. First, a lightweight design of the gearbox was realized by topology optimization. Second, the sensitivity of different design variables of the new gearbox was determined via sensitivity analysis of the objective function. Finally, multi-objective optimization was used to obtain the optimal solution for the gearbox. Considering the complexity of the internal structure of the gearbox assembly and the accuracy of the numerical calculation process, a modeling method with mass points was proposed. A comparison between the numerical calculation results and the operation mode analysis revealed that the former was accurate and can be applied to the verification of the optimized gearbox. By optimizing the vibration signals before and after, and the analysis of the end face quality of the workpiece, the results revealed that the optimized gearbox has a significantly reduced amplitude under various operating conditions. In addition, the vibration stability was improved, and the end face quality of the workpiece was significantly enhanced compared to that before optimization. This study serves as a theoretical reference for multi-body dynamics modeling and optimization of machine tools, and also outlines technical solutions for high-speed stable cutting with sawing machines.
Highlights
An integrated piezoelectric sensor was used to acquire the acceleration signal of each component transmitted to the Leuven Measurement Systems (LMS) data acquisition front end via a coaxial cable, and the vibration signal was of the gearbox during the sawing process
Based on the requirements for operation of the sawing machine, this study mainly considers a comparison of the experimental data under the three working conditions of idling, 70 r/min, and
(1) Simulating the modal parameters of the gearbox via the addition of mass points, it was conclusions are as follows:that the calculated modality has a good correlation with the operational modal determined analysis
Summary
Circular sawing machine cutting is an important operation in the processing of mechanical parts. Belingardi et al [24] vibration proposed a multi‐body dynamic modeling and analysis method for gearbox power transfer, whichmethod, can obtain and the dynamic frequency introduced a physical programming method to the robust design focused on optimizing response function and transmission error of the system. Liu et al [23] proposed a hybrid user-defined element method (HUELM) to analyze the coupling dynamic characteristics of the gear transmission process They developed the dynamic vibration model and obtained modal parameters of the gear transmission system under different working conditions. When an optimization algorithm is used to obtain a solution, many working conditions are often ignored, resulting in a deviation between the final optimization result and actual performance Considering these problems, an optimization design method that combines topology optimization, sensitivity analysis, and response surface optimization is hereby proposed.
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