曲面数控加工仿真多层次细节建模与应用
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摘要
某大型轧钢厂加工轧辊需要各种成形车刀刀片,有些刀片的形状很复杂。目前采用手工打磨,与样板比对的方法进行刃磨,精度差,效率低,劳动强度大。需要用数控磨削对其手工刃磨的加工方法进行改造,以提高加工精度和效率,并减轻工人的劳动强度。作为数控磨削系统的一部分,为了避免数控程序的错误和返工,有必要建立虚拟数控磨削加工仿真系统,在实际加工前对数控程序进行验证。为了建立轧辊成形车刀刀片的数控磨削系统,需要对轧辊成形车刀刀片的加工方法以及刀具轨迹的优化方法进行研究。为了建立轧辊成形车刀刀片的虚拟磨削系统,需要对刀片加工仿真的实体模型和加工仿真方法进行研究。在研究过程中发现数控加工过程仿真模型的复杂化面临的问题之一是仿真过程的逼真性与实时性的矛盾。为解决这些问题,本文所进行的研究及其创新性成果有:
提出并构建了一种用于曲面数控加工仿真的多层次细节模型(G-LOD)。基于G-LOD的数控加工过程仿真能根据不同的仿真目的在模型上的不同区域和细节层次上进行,从而节省了不必要的计算时间和数据存储空间。加工过程仿真中,在得到加工曲面实体模型的同时,能够对曲面加工误差进行评估。G-LOD是在离散刀触点(CC)轨迹上建立的,采用G-LOD模型的数控加工过程仿真能较好地逼真实际加工过程。作为在物理仿真中的应用,对基于G-LOD的动态切削力的仿真进行了研究。仿真的结果表明,根据不同的仿真目的应采用不同细节层次的模型,可以大大减少计算机的计算量。
提出了一种新的CC轨迹的优化方法。该方法在等参数CC轨迹的基础上,采用自适应网格的方法对离散CC轨迹进行优化,得到的优化CC轨迹在满足一定加工精度要求的前提下,具有等残余高度CC轨迹的特点,且比等残余高度CC轨迹有较少的离散CC轨迹数量和更高的加工效率。在优化过程中,利用本文建立的仿真模型和加工仿真方法对曲面进行加工仿真,然后根据仿真结果和对加工误差的分析对网格参数进行调整,并对优化结果进行验证。本文采用等参数CC轨迹和自适应网格优化CC轨迹分别对一个曲面进行了实际加工实验。检测结果显示:在加工效率相同的情况下,采用自适应网格优化CC轨迹加工得到的曲面比采用等参数CC轨迹加工得到的曲面的加工误差要小。
为了建立辊成形车刀刀片的磨削加工系统,对轧辊成形车刀刀片的磨削加工方法进行了研究。提出了辊成形车刀刀片的2.5D CNC的最少轴数控磨削加工方法。并提出了一种采用浮动极坐标的2.5D CNC磨削加工方法。有利于降低数控磨削联动轴数和增强磨削过程稳定性。
集成本文的研究成果,开发了轧辊成形车刀刀片的虚拟磨削原型系统。该原型系统在输入刀片刀刃曲线型值点的基础上,可以拟合刀刃曲线,生成离散CC轨迹,对离散CC轨迹进行优化,生成刀片后刀面曲面的G-LOD模型,采用最少轴数控磨削方法对轧辊成形车刀刀片进行了磨削加工仿真,对加工得到的刀刃曲线和刀具后角进行验证。
With the increasing complexity of simulation model, machining process simulations have to face the increasing conflict between simulation in real-time and the computational and storage capacity of the computer. In order to deal with this problem, the research work and innovative achievements presented in this dissertation are as follows:
A novel simulation model for surface CNC machining process simulation, named G-LOD, is proposed and established. Simulations based on G-LOD can be carried out at different levels of detail and areas on surface models corresponding to different simulation aims, and this will save unnecessary computational time and storage space of the computer. Simulations based on G-LOD can obtain the machined solid model and vector-based model of surface simultaneously, so it can be used to evaluate the machining errors of machining process and verify CNC program. Because G-LOD is constructed on the basis of discrete CC path, machining simulations based on G-LOD will accord with the real machining processes more properly. Some simulation examples of surface CNC machining are completed. As an application in physical simulations, the method of dynamic cutting-force simulation of CNC machining is explored. From the simulation results it is found that using models of different levels of detail the computational time of computer will be decreased largely.
A new CC path optimization method is presented. The optimized CC path is generated on the basis of iso-parametric CC path by using adaptive grid generation method. The optimized CC path possesses the merits of iso-scallop CC path and less number of discrete path than iso- scallop CC path, and so that it is a kind of optimal CC path. In the optimization process, the simulation model and method presented in this dissertation can be adopted to adjust grid factors and verify optimization results. The examples of real surface machining based on optimized CC path and iso-parametric CC path respectively have been completed. From the measurement results, it can be observed that the machining errors obtained by the optimized CC path are smaller than that obtained by iso-parametric CC path.
The least-axis CNC grinding method for formed bits of mill roller is developed, and a 2.5 CNC grinding method is presented.
Integrating the research fruits of this dissertation a prototype system of virtual grinding of formed bit of mill roller is developed. The system can fit the cutting edge profiles based on the given formed points, generate discrete CC path, optimize the generated CC path, produce G-LOD model of the bit, use the least-axis CNC machining method to simulate grinding the formed bit, and verify the obtained cutting edge profiles and clearances in the simulation.
提出并构建了一种用于曲面数控加工仿真的多层次细节模型(G-LOD)。基于G-LOD的数控加工过程仿真能根据不同的仿真目的在模型上的不同区域和细节层次上进行,从而节省了不必要的计算时间和数据存储空间。加工过程仿真中,在得到加工曲面实体模型的同时,能够对曲面加工误差进行评估。G-LOD是在离散刀触点(CC)轨迹上建立的,采用G-LOD模型的数控加工过程仿真能较好地逼真实际加工过程。作为在物理仿真中的应用,对基于G-LOD的动态切削力的仿真进行了研究。仿真的结果表明,根据不同的仿真目的应采用不同细节层次的模型,可以大大减少计算机的计算量。
提出了一种新的CC轨迹的优化方法。该方法在等参数CC轨迹的基础上,采用自适应网格的方法对离散CC轨迹进行优化,得到的优化CC轨迹在满足一定加工精度要求的前提下,具有等残余高度CC轨迹的特点,且比等残余高度CC轨迹有较少的离散CC轨迹数量和更高的加工效率。在优化过程中,利用本文建立的仿真模型和加工仿真方法对曲面进行加工仿真,然后根据仿真结果和对加工误差的分析对网格参数进行调整,并对优化结果进行验证。本文采用等参数CC轨迹和自适应网格优化CC轨迹分别对一个曲面进行了实际加工实验。检测结果显示:在加工效率相同的情况下,采用自适应网格优化CC轨迹加工得到的曲面比采用等参数CC轨迹加工得到的曲面的加工误差要小。
为了建立辊成形车刀刀片的磨削加工系统,对轧辊成形车刀刀片的磨削加工方法进行了研究。提出了辊成形车刀刀片的2.5D CNC的最少轴数控磨削加工方法。并提出了一种采用浮动极坐标的2.5D CNC磨削加工方法。有利于降低数控磨削联动轴数和增强磨削过程稳定性。
集成本文的研究成果,开发了轧辊成形车刀刀片的虚拟磨削原型系统。该原型系统在输入刀片刀刃曲线型值点的基础上,可以拟合刀刃曲线,生成离散CC轨迹,对离散CC轨迹进行优化,生成刀片后刀面曲面的G-LOD模型,采用最少轴数控磨削方法对轧辊成形车刀刀片进行了磨削加工仿真,对加工得到的刀刃曲线和刀具后角进行验证。
With the increasing complexity of simulation model, machining process simulations have to face the increasing conflict between simulation in real-time and the computational and storage capacity of the computer. In order to deal with this problem, the research work and innovative achievements presented in this dissertation are as follows:
A novel simulation model for surface CNC machining process simulation, named G-LOD, is proposed and established. Simulations based on G-LOD can be carried out at different levels of detail and areas on surface models corresponding to different simulation aims, and this will save unnecessary computational time and storage space of the computer. Simulations based on G-LOD can obtain the machined solid model and vector-based model of surface simultaneously, so it can be used to evaluate the machining errors of machining process and verify CNC program. Because G-LOD is constructed on the basis of discrete CC path, machining simulations based on G-LOD will accord with the real machining processes more properly. Some simulation examples of surface CNC machining are completed. As an application in physical simulations, the method of dynamic cutting-force simulation of CNC machining is explored. From the simulation results it is found that using models of different levels of detail the computational time of computer will be decreased largely.
A new CC path optimization method is presented. The optimized CC path is generated on the basis of iso-parametric CC path by using adaptive grid generation method. The optimized CC path possesses the merits of iso-scallop CC path and less number of discrete path than iso- scallop CC path, and so that it is a kind of optimal CC path. In the optimization process, the simulation model and method presented in this dissertation can be adopted to adjust grid factors and verify optimization results. The examples of real surface machining based on optimized CC path and iso-parametric CC path respectively have been completed. From the measurement results, it can be observed that the machining errors obtained by the optimized CC path are smaller than that obtained by iso-parametric CC path.
The least-axis CNC grinding method for formed bits of mill roller is developed, and a 2.5 CNC grinding method is presented.
Integrating the research fruits of this dissertation a prototype system of virtual grinding of formed bit of mill roller is developed. The system can fit the cutting edge profiles based on the given formed points, generate discrete CC path, optimize the generated CC path, produce G-LOD model of the bit, use the least-axis CNC machining method to simulate grinding the formed bit, and verify the obtained cutting edge profiles and clearances in the simulation.
引文
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