凸轮轴数控磨削工艺智能应用系统的研究与开发
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摘要
磨削加工是机械制造业重要的加工方法,大多数情况下,作为最终加工工序的磨削加工,直接决定着工件成品的质量。当前磨削加工所面临的主要问题是严重依赖操作人员的经验,磨削加工工艺方案的确定方式仍以传统的“试切”法和“经验”法为主,加工效率低,加工柔性差,磨削加工工艺知识数据难以积累和重用。凸轮轴作为汽车、内燃机、国防等众多行业所需的关键零部件,其加工的精度、效率直接影响着发动机及相关产品的质量、寿命和节能标准。本文以凸轮轴数控磨削加工为研究对象,以加工工艺最优化和智能化为目标,开发了专门针对凸轮轴数控磨削加工的工艺智能优选与数控加工软件平台,该软件平台拥有机床库、砂轮库、材质库、冷却液库、工艺辅件库等基础工艺数据库,拥有工艺实例库、元知识规则库、预报模型库等工艺智能库,软件平台在数据库的支持下能实现凸轮轴磨削加工工艺方案的智能优选和自动数控加工编程。由于该软件平台涉及的研究内容众多,本文主要针对磨削加工工艺系统运动过程的建模、凸轮轴数控磨削加工智能平台软件的体系架构、磨削工艺问题的定义、工艺系统3D虚拟磨削加工仿真、磨削加工数控自动编程等内容进行研究。具体所做的研究工作内容主要包括如下：
建立了凸轮轴数控磨削工艺智能应用平台软件的系统框架。确立了系统的运行框架及主要功能模块,即磨削工艺专家系统模块、磨削工艺智能优选模块、磨削误差分析与智能补偿模块、工艺问题定义模块、3D虚拟磨削仿真模块、磨削速度优化与调节模块、磨削加工自动数控编程模块、通用数学模型求解模块、基础工艺核心数据库与工艺智能库模块等。并对主要构成功能的总体性要求和所采用的技术思路做了分析。
对零件加工的工艺问题详细探讨了加工工艺问题的具体信息构成,对加工的工艺类别的具体划分作了讨论并给出了分类方法,建立了基于信息理论的制造资源信息模型和零件信息模型,在这两个模型的基础上,提出了加工工艺问题定义模块的总体结构,建立了工艺问题信息描述的通用模型,据此,结合凸轮轴具体加工工艺详细阐述了凸轮轴加工工艺问题定义模型建立的过程,建立了凸轮轴磨削工艺问题定义的理论模型,并依据该模型开发了对应的功能模块。
对凸轮轴磨削过程3D虚拟仿真技术的开发进行了详细的理论分析和实践探讨。对3D虚拟仿真的框架进行了具体设计,规划了其主要的功能构成。建立了磨削加工工艺系统几何架构模型、磨削加工工艺系统运动模型、磨削加工工艺系统运动模型装配树等仿真理论原理模型。探讨了实现虚拟运动仿真的轨迹运动数据驱动原理与方法。通过采用OpenGL技术,实现了基于以上原理模型的凸轮轴磨削加工3D虚拟仿真环境及加工运动仿真等功能。
确立及实现了凸轮轴磨削自动数控加工编程框架体系方案。提出了凸轮轴磨削自动数控加工编程技术框架,对砂轮走刀轨迹规划和自动计算进行了理论研究,提出了轨迹自动规划与计算方案。讨论了基于砂轮走刀轨迹的机床各运动轴的运动解析原理,并建立了机床运动的通用解析模型,依据该模型实现了机床运动仿真的数据驱动,最终依据运动驱动数据生成了数控加工程序,用于实际零件加工
提出了凸轮轴磨削加工速度优化与调节的理论原理和技术方法。根据X-C轴联动磨床的运动原理,采用三次样条插值法,建立了凸轮转速优化调节的数值计算模型。结合具体凸轮轴零件及其磨削加工工艺方案的具体参数,计算出机床各运动轴加工过程的运动数据,在确保无工艺故障的前提下,最终把各轴的运动数据自动转换为对应数控控制系统的数控加工程序,从而进一步提高凸轮轴的加工精度、表面质量和加工效率。
对凸轮轴数控磨削工艺智能应用软件进行了开发与实验验证。对软件整体、工艺问题定义模块、磨削加工过程3D虚拟仿真、加工速度优化与调节、磨削数控自动编程等模块进行了相应的程序设计和软件开发,实现了各功能模块的总体集成。以某型凸轮轴磨削加工为例对平台软件的合理性和有效性进行了验证。
Grinding process is an important processing method of machinery manufacturing industry. In most instances, grinding process that acts as the last manufacturing procedure directly decided the manufacturing quality of a manufactured product. At the moment, the principal problem facing the grinding process is extremely dependent upon the experiences of the worker. Grinding process solution is mainly still determined by conventional trial cut and empirical approach, which could be lower efficiency and worse flexibility and would to make it dificultly when the grinding process knowledge data be accumulated and reused. Camshaft is one of the key parts of many industries such as vehicle, internal-combustion engine, national defense and so on. Its processing accuracy and efficiency has directly influenced on the quality, life and energy-saving standard of the engines and other allied products.Tthis paper kept the camshaft NC grinding as object of study, and took process optimization and intelligentize as method. A software platform, that specially aim at camshaft NC grinding process intelligent optimum decision and digital control processing, has been developed. This software platform has a base process database and a process intelligent database. The base process database contains data of machine tool, grinding wheel, material, coolant and process auxiliary, etc. The process intelligent database stores data of process case, rule metadata, prediction model and so on. Based on the databases, the software platform can execute camshaft grinding process solution intelligent optimum decision and automatically NC programming. There was so much study content involved of the software platform that this paper could only analysis and discuss those objects as grinding process system movement modeling, system framework of camshaft NC grinding intelligent software platformware, grinding process problem definition,3D virtual machining of grinding process system, digital control grinding automactically NC programming and so on. The main study work included as follows:
The intelligent software platform frame of camshaft digital control grinding has been built. The operating framework and the functional module of system have been defined including the expert system of grinding process module, the intelligent optimum decision of grinding process module, the error analysis and intelligent compensation module, the process problem definition module, the3D virtual grinding simulation module, the grinding speed optimization and regulating module, the automactical digital control grinding module, the general mathematical model solving module, the base process core database and process intelligent database module. The entire property of the main functional modules and the technical ideas used are also analysised.
The process problem of workpiece was defined. The information structure detail of process problem was detailedly studied. The process classification concrete determining was discussed and a means of classification was provided. The manufacturing resources information model and part information model based on ormation theory are created. On the basis of the two models, the whole architecture of process problem was provided and the general description information model of process problem was also built. According to camshaft specific grinding process, the procedure of camshaft grinding process problem model building was elaborated, and the theoretic model of camshaft grinding process problem space has been created, and the theoretic model has also been instantiated.
Development and implementation of camshaft grinding3D virtual simulation technology were theoretical analysised and practical researched. According to practical situation of enterprise, general requirement and overall technical architecture of camshaft grinding simulation were brought out. The framework of3D virtual simulation was specifically schemed out and the main constitutive functions were also programed. The grinding process system theoretic models including geometrical framework model, system kinematics model and the kinematics assembly tree were created. The path movement data driven principle and method of virtual kinetic simulation were discussed. The3D virtual simulation environment and realistic scene grinding movement simulation of camshaft grinding were realized by adopting OpenGL technique.
The automatic NC programming framework architecture of camshaft digital control grinding has been confirmed and realized, and it's technical framework has been provided. The theoretical study of wheel path layout and automatical computation were done. The path automatical planning and calculational procedure have been proposed. The movement analytical principle of machine tool all motion axles, which were based on wheel path, particularly discussed. The general analytical model of axles motion was been created. The data driven of machine kinetic simulation was achieved by this model. At last, the NC program has been builded by those data of driven, and also been used to real part machining.
The theoretical model of constant linear velocity grinding process of camshaft has been established according to the X-C Axis linkage motion principle of grinding machine. Base on this theoretical model, a numerical calculation model of grinding speed optimization and regulation has also be built by way of cubic spline fitting interpolation method. Combined with the specific camshaft part and the real parameter of the grinding processing plan, the processing motion data all of grinding machine kinematic axises were calculated. And then the motion data were automatically changed into NC processing program of specified numerical control system without processing faults.By the way, the machining precision, surface quality and processing efficiency of camshaft would further more improved.
The camshaft digital control grinding intelligent software platform has been developed and experimental verified. The soft programming approach and interface development have been done about the overall intelligent software platform, the process problem definition module, the3D virtual grinding simulation module, the grinding speed optimization and regulating module and the automactical digital control grinding programming module, and all of models have been systematically integrated. At last, the software platform rationality and validity have inspected and verified by a certain camshaft grinding machining practice.
建立了凸轮轴数控磨削工艺智能应用平台软件的系统框架。确立了系统的运行框架及主要功能模块,即磨削工艺专家系统模块、磨削工艺智能优选模块、磨削误差分析与智能补偿模块、工艺问题定义模块、3D虚拟磨削仿真模块、磨削速度优化与调节模块、磨削加工自动数控编程模块、通用数学模型求解模块、基础工艺核心数据库与工艺智能库模块等。并对主要构成功能的总体性要求和所采用的技术思路做了分析。
对零件加工的工艺问题详细探讨了加工工艺问题的具体信息构成,对加工的工艺类别的具体划分作了讨论并给出了分类方法,建立了基于信息理论的制造资源信息模型和零件信息模型,在这两个模型的基础上,提出了加工工艺问题定义模块的总体结构,建立了工艺问题信息描述的通用模型,据此,结合凸轮轴具体加工工艺详细阐述了凸轮轴加工工艺问题定义模型建立的过程,建立了凸轮轴磨削工艺问题定义的理论模型,并依据该模型开发了对应的功能模块。
对凸轮轴磨削过程3D虚拟仿真技术的开发进行了详细的理论分析和实践探讨。对3D虚拟仿真的框架进行了具体设计,规划了其主要的功能构成。建立了磨削加工工艺系统几何架构模型、磨削加工工艺系统运动模型、磨削加工工艺系统运动模型装配树等仿真理论原理模型。探讨了实现虚拟运动仿真的轨迹运动数据驱动原理与方法。通过采用OpenGL技术,实现了基于以上原理模型的凸轮轴磨削加工3D虚拟仿真环境及加工运动仿真等功能。
确立及实现了凸轮轴磨削自动数控加工编程框架体系方案。提出了凸轮轴磨削自动数控加工编程技术框架,对砂轮走刀轨迹规划和自动计算进行了理论研究,提出了轨迹自动规划与计算方案。讨论了基于砂轮走刀轨迹的机床各运动轴的运动解析原理,并建立了机床运动的通用解析模型,依据该模型实现了机床运动仿真的数据驱动,最终依据运动驱动数据生成了数控加工程序,用于实际零件加工
提出了凸轮轴磨削加工速度优化与调节的理论原理和技术方法。根据X-C轴联动磨床的运动原理,采用三次样条插值法,建立了凸轮转速优化调节的数值计算模型。结合具体凸轮轴零件及其磨削加工工艺方案的具体参数,计算出机床各运动轴加工过程的运动数据,在确保无工艺故障的前提下,最终把各轴的运动数据自动转换为对应数控控制系统的数控加工程序,从而进一步提高凸轮轴的加工精度、表面质量和加工效率。
对凸轮轴数控磨削工艺智能应用软件进行了开发与实验验证。对软件整体、工艺问题定义模块、磨削加工过程3D虚拟仿真、加工速度优化与调节、磨削数控自动编程等模块进行了相应的程序设计和软件开发,实现了各功能模块的总体集成。以某型凸轮轴磨削加工为例对平台软件的合理性和有效性进行了验证。
Grinding process is an important processing method of machinery manufacturing industry. In most instances, grinding process that acts as the last manufacturing procedure directly decided the manufacturing quality of a manufactured product. At the moment, the principal problem facing the grinding process is extremely dependent upon the experiences of the worker. Grinding process solution is mainly still determined by conventional trial cut and empirical approach, which could be lower efficiency and worse flexibility and would to make it dificultly when the grinding process knowledge data be accumulated and reused. Camshaft is one of the key parts of many industries such as vehicle, internal-combustion engine, national defense and so on. Its processing accuracy and efficiency has directly influenced on the quality, life and energy-saving standard of the engines and other allied products.Tthis paper kept the camshaft NC grinding as object of study, and took process optimization and intelligentize as method. A software platform, that specially aim at camshaft NC grinding process intelligent optimum decision and digital control processing, has been developed. This software platform has a base process database and a process intelligent database. The base process database contains data of machine tool, grinding wheel, material, coolant and process auxiliary, etc. The process intelligent database stores data of process case, rule metadata, prediction model and so on. Based on the databases, the software platform can execute camshaft grinding process solution intelligent optimum decision and automatically NC programming. There was so much study content involved of the software platform that this paper could only analysis and discuss those objects as grinding process system movement modeling, system framework of camshaft NC grinding intelligent software platformware, grinding process problem definition,3D virtual machining of grinding process system, digital control grinding automactically NC programming and so on. The main study work included as follows:
The intelligent software platform frame of camshaft digital control grinding has been built. The operating framework and the functional module of system have been defined including the expert system of grinding process module, the intelligent optimum decision of grinding process module, the error analysis and intelligent compensation module, the process problem definition module, the3D virtual grinding simulation module, the grinding speed optimization and regulating module, the automactical digital control grinding module, the general mathematical model solving module, the base process core database and process intelligent database module. The entire property of the main functional modules and the technical ideas used are also analysised.
The process problem of workpiece was defined. The information structure detail of process problem was detailedly studied. The process classification concrete determining was discussed and a means of classification was provided. The manufacturing resources information model and part information model based on ormation theory are created. On the basis of the two models, the whole architecture of process problem was provided and the general description information model of process problem was also built. According to camshaft specific grinding process, the procedure of camshaft grinding process problem model building was elaborated, and the theoretic model of camshaft grinding process problem space has been created, and the theoretic model has also been instantiated.
Development and implementation of camshaft grinding3D virtual simulation technology were theoretical analysised and practical researched. According to practical situation of enterprise, general requirement and overall technical architecture of camshaft grinding simulation were brought out. The framework of3D virtual simulation was specifically schemed out and the main constitutive functions were also programed. The grinding process system theoretic models including geometrical framework model, system kinematics model and the kinematics assembly tree were created. The path movement data driven principle and method of virtual kinetic simulation were discussed. The3D virtual simulation environment and realistic scene grinding movement simulation of camshaft grinding were realized by adopting OpenGL technique.
The automatic NC programming framework architecture of camshaft digital control grinding has been confirmed and realized, and it's technical framework has been provided. The theoretical study of wheel path layout and automatical computation were done. The path automatical planning and calculational procedure have been proposed. The movement analytical principle of machine tool all motion axles, which were based on wheel path, particularly discussed. The general analytical model of axles motion was been created. The data driven of machine kinetic simulation was achieved by this model. At last, the NC program has been builded by those data of driven, and also been used to real part machining.
The theoretical model of constant linear velocity grinding process of camshaft has been established according to the X-C Axis linkage motion principle of grinding machine. Base on this theoretical model, a numerical calculation model of grinding speed optimization and regulation has also be built by way of cubic spline fitting interpolation method. Combined with the specific camshaft part and the real parameter of the grinding processing plan, the processing motion data all of grinding machine kinematic axises were calculated. And then the motion data were automatically changed into NC processing program of specified numerical control system without processing faults.By the way, the machining precision, surface quality and processing efficiency of camshaft would further more improved.
The camshaft digital control grinding intelligent software platform has been developed and experimental verified. The soft programming approach and interface development have been done about the overall intelligent software platform, the process problem definition module, the3D virtual grinding simulation module, the grinding speed optimization and regulating module and the automactical digital control grinding programming module, and all of models have been systematically integrated. At last, the software platform rationality and validity have inspected and verified by a certain camshaft grinding machining practice.
引文
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