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.
Studying the cutting temperature is critical for unlocking the secrets of sawblade wear, lifespan, and the metallurgical alterations beneath the surface. This paper describes an investigation into the temperature of 45 steel during dry sawing, using a cemented carbide circular saw blade under various cutting conditions. A temperature acquisition system was developed, enabling the determination of the average temperature of the arc zone in the workpiece and the temperature of the sawtooth tip via a semi-automated thermocouple measurement and an embedded dynamic artificial thermocouple method, respectively. Results obtained from these two methods indicate a positive correlation between the sawing temperature and the saw blade speed and feed rate, with an optimal combination of cutting process parameters identified for maintaining stability within reasonable ranges. Finite element simulations reveal a cyclical fluctuation in temperature along the workpiece surface and sawtooth, with a gradual decrease after an increase in the intermittent step, and confirm the relationship between the sawing temperature and the saw blade and feed rates observed experimentally. Overall, this study presents valuable insights into the temperature changes occurring during the sawing process, with important implications for improving productivity and maintaining stability in industrial applications.
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