随着能源问题的日益突出，节能减排引起了全世界越来越多学者的关注。制造业每年耗能巨大，是节能减排的重点对象。机械加工是完成产品零件制造的重要途径，因此，为待加工零件制定合理的数控加工方案是实现高效低耗加工的有效方法。建立机床加工过程能耗模型是实现面向节能的零件工艺规划的基础和前提，现有能耗模型主要用于揭示加工时的能耗规律，较少从待加工工件的角度建立模型。因此，本文的主要研究内容如下： 首先，建立三轴铣床空载能耗模型。分析数控机床切削加工过程的能耗特性，分别建立机床待机及辅助状态下各能耗部件的理论功率模型，在此基础上，揭示了影响三轴数控铣床空载能耗的因素。为获取数控机床能耗数据，搭建数控机床能耗实时监测平台，采用机理与经验分析并用的方法建立加工参数与数控机床能耗之间的数学关系。建立数控机床主轴空载状态功率模型和进给轴空载功率模型，简化理论模型，提出主轴功率与主轴转速间存在分段的线性关系、进给轴功率与进给轴的速度间存在非线性关系。研究发现，在每个转速分段区间内，主轴功率随转速增加呈增长趋势，且基本服从线性关系，进给轴功率与进给速度呈非线性函数关系。 其次，建立考虑刀具刃口形状的数控机床铣削过程切削能耗模型。分别建立切削功率与切削时间的数学模型。通过对金属切削能量消耗机理进行分析，推导了包含金属剪切变形功耗、刀具与工件接触区摩擦功耗的理论切削功率计算公式。并建立了加工时间的计算模型，最终得到加工过程切削参数与切削能耗之间的关系模型。采用本文搭建的数控机床加工过程能耗实时监测平台，通过铣削实验对所建立能耗模型的有效性进行验证，实现了对加工过程能耗的准确预测。通过分析理论模型和台阶铣削过程实验结果，阐述了主轴转速、进给速度、背吃刀量和切削宽度对切削能耗的影响规律，为后续铣削过程能耗预测和高效低耗的数控机床加工过程优化研究奠定了基础。 然后，提出基于典型加工特征切削能耗模型的建模方法。本文结合面向对象的新型NC编程数据接口国际标准(ISO 14649)标准，根据加工特征的特点，将加工特征分解成加工单元，基于上文切削能耗建模方法，分析切削时刀具与工件的接触状态，建立四种加工单元(直线、曲线、切入／切出和孔加工单元)的能耗模型，随后考虑包含不同加工策略下的相同加工特征的切削能耗，分别给出了六种典型加工特征(边、台阶、槽、平面、型腔和孔加工特征)的能耗模型计算方法，从而得到了加工完整零件的能量需求。通过铣削加工一个包含所建立加工特征的零件，验证所提出的加工特征能耗建模方法的可行性和有效性。 最后，将机床加工过程能耗作为工艺参数优化的目标之一，提出一种综合考虑加工效率、加工过程能耗和表面加工质量三者权衡的多目标优化方法。分别建立数控加工过程能耗和加工时间目标函数，将加工过程能耗最小、生产效率最高作为粗加工阶段优化目标，将加工过程能耗最小和加工质量最好作为精加工阶段优化目标，并确定优化变量，然后，采用带精英策略的非支配排序的遗传算法(NSGA-II)对模型开展优化求解。基于上述研究，设计能耗预测及优化软件。通过切削实验研究，验证仿真软件及优化结果的可行性，为面向高效低耗的加工过程中工艺参数的选择提供有效工具及加工方案。 关键词 铣削；能耗建模；切削能耗；加工特征；参数优化

 With the increasingly prominent energy problem, energy saving and emission reduction have attracted more and more attention of scholars all over the world. Manufacturing industry consumes enormous energy every year, and is also the focus of energy saving and emission reduction. Machining is an important way to complete the manufacturing of product parts. Therefore, it is an effective way to achieve high efficiency and low consumption to develop a reasonable CNC machining scheme for the parts to be processed. Establishing energy consumption model of machine tools is the basis and premise of realizing energy-saving process planning for parts. The existing energy consumption models are mainly used to reveal the energy consumption law in processing, and less from the perspective of the workpiece to be processed to complete the model. Therefore, the main contents of this thesis are as follows: Firstly, the un-load energy consumption model of three-axis milling machine is established. The energy consumption characteristics of NC machine tools in cutting process are analyzed. The theoretical power models of energy consumption components in standby and auxiliary states of machine tool are established respectively. On this basis, the influence factors of the un-load energy consumption of three-axis CNC machine tool are revealed. In order to obtain the energy consumption data of CNC machine tools, a real-time monitoring platform for energy consumption of CNC machine tools is established. The mathematical relationship between cutting parameters and energy consumption of CNC machine tools was established by mechanism and empirical analysis. The power models of CNC machine tool spindle and feed axes in un-load state are established. After simplifying the theoretical models, the piecewise linear relationship between spindle power and spindle speed and the non-linear relationship between feed axes power and feed rate are proposed. It is found that the spindle power increases with the spindle speed in each segment interval, and basically subject to the linear equations. The power of the feed axes has a non-linear function relationship with the feed rate. Secondly, the cutting energy consumption model of CNC machine tool considering the shape of cutting edge is established. The mathematical models of cutting power and processing time are established respectively. Based on the analysis of the energy consumption mechanism of metal cutting, the theoretical cutting power calculation formulas including shear deformation power consumption of metal and friction power consumption of tool and workpiece contact area are derived. Finally, the relationship between cutting parameters and cutting energy consumption is obtained. Using the real-time monitoring platform of CNC machine tool processing energy consumption built in this paper, the validity of the energy consumption model is verified by milling experiments, and the accurate prediction of energy consumption in processing is realized. By theoretical and experimental analyzing of step milling process, the influences of spindle speed, feed rate, cutting depth and cutting width on cutting energy consumption are elaborated. It lays a foundation for energy consumption prediction in subsequent milling process and optimization of CNC machine tool processing process towards high efficiency and low consumption. Then, a modeling method of cutting energy consumption model based on typical machining features is proposed. Based on the Standard for the Exchange of Product Model Data-Numerical Control (STEP-NC) and the characteristics of machining features, the machining features are decomposed into machining elements. Based on the above modeling method of cutting energy consumption, the contact state between tool and workpiece during cutting is analyzed. Four processing units which are linear machining element, curve machining element, cut-in/cut-out machining element and hole machining element are established. Considering the cutting energy consumption of the same machining features under different machining strategies, the calculation methods of energy consumption model of six typical machining features which are side, step, slot, face, pocket and hole are given respectively. Thus, the energy requirement of machining is obtained. The feasibility and validity of the proposed energy consumption modeling method for machining features are verified by milling a part containing the established machining features. Finally, taking the energy consumption of machine tool processing as one of the objectives of cutting parameter optimization, a multi-objective optimization method considering the trade-offs of machining efficiency, energy consumption and surface quality is proposed. The objective functions of energy consumption, processing time and surface roughness in CNC machining process are established respectively. Minimum energy consumption and maximum production efficiency are taken as optimization objectives in rough. Minimum energy consumption and best processing quality are taken as optimization objectives in finish. The optimization variables are determined as spindle speed, feed rate, cutting depth and cutting width in rough and finishing respectively. Then, the model is optimized by using the NSGA-II algorithm. Based on the above research, energy consumption prediction and optimization software is designed and developed. Through cutting experiments, the feasibility of simulation software and optimization results is verified. Effective tool is provided for the selection of cutting parameters towards high efficiency and low consumption. Keywords Milling, energy modelling, cutting energy consumption, machining feature, cutting parameter optimization