基于虚拟制造技术的电火花机床仿真研究
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摘要
虚拟制造作为产品设计的一项新技术,对传统的产品设计方法来说是一次革命性的变革。通过虚拟制造技术,工程师可以采用机械系统运动仿真,在产品设计阶段就发现产品设计中的潜在问题,并快速进行修改,减少设计对物理样机的依赖,这样不仅可以节省成本,缩短产品开发周期,而且可以提高产品性能,增强产品竞争力。
将虚拟制造技术应用于数控电火花机床的设计中,研究了特征造型、动力学分析系统和有限元分析系统之间的转换方法和技术,利用PRO/E软件建立了样机零部件的实体模型,并在此基础上完成电火花机床机械结构的虚拟装配和装配干涉分析,成功建立了机床的虚拟样机。此虚拟样机模型可进一步在ADAMS软件中进行运动仿真和动力学分析,从而节省了建模时间。在用PRO/E建模时,省略和简化了部分对仿真精度影响较小的零部件特征,如安装孔、螺钉、螺纹等,模型完善以后通过在ADAMS中添加约束和载荷来实现运动功能以减少ADAMS仿真所需时间,避免仿真失败。
在ANSYS有限元分析软件平台上,采用模态分析技术获得机床结构的模态固有频率和主振型,从而实现对机床结构的改进和优化设计。基于运动学和动力学仿真软件ADAMS验证分析了影响机床爬行现象的主要因素,从而实现了机床的进给系统的优化设计。对CTS400数控电火花机床进行了运动平稳性分析。采用ADAMS的运动分析技术分析了整机在各种作业工况下各主要连接件之间的作用力,为有限元分析提供边界条件;对CTS400数控电火花机床结构强度进行了有限元分析,得到了高应力、应变的危险区域,通过对该区域进行结构优化设计,结果表明显著地改善了该部位构件的工作状况,从而保证了整机运行的可靠性。
虚拟制造技术的引入,获得了机床静态受力以及运动过程中的微观变形图形及数据,为更直观的了解机床的性能和运动状态提供了可靠的依据,也为日后机床的性能改进提供了技术参考。
As a new technology of product design,VM (Virtual Manufacturing) is a revolution to traditional method of products design. Based on virtual manufacturing,engineers can find underlying problems just during products design by simulating the mechanical system,and revise them quickly so as to throw off the physical prototype,which not only can save the cost of design and manufacturing and reduce the cycle of products development , but also can elevate products’performance and enhance products’competition.
The paper applied virtual prototype technology to the design of EDM (Electrical Discharge Machining) machine tool. It studies the integrating methods and technology among the characteristic modeling、kinematics analysis and finite element analysis system, software PRO/E (Pro/Engineer-3D solids modeling software) was used to draw the 3-D model of machine tool parts which can assembled to be a virtual machine, interference checking was taken between the parts after assembling finished and the VP (Virtual Prototype) of machine tool was successfully constructed in the end, which is the foundation of motion simulation and dynamic analysis using ADAMS (Automatic Dynamic Analysis of Mechanical Systems)software. Some features that hardly affect the simulation accuracy such as installation holes, screws were overleaped or simplified when modeling in PRO/E, constraint and loading which can achieve motion function were applied in ADAMS in order to decrease the time consumed by modeling and calculation and also keep the simulation from failure.
Using the advanced and powerful FEA (Finite Element Analysis) software ANSYS to do the modal analysis on the main structure of machine, then gets the intrinsic frequency and the vibration model in order to achieve improvement and optimum design. Gained optimum design to the feeding system by analysis the main factors effect the problems of crawling based on the dynamics analysis software of machine system ADAMS. Through adopting the technological analysis of ADAMS, analyze the numeric machine tool of CTS400 action force between every main attachment under various operating conditions, so offer the border condition for the finite element analysis; though the finite element analysis about the assembly structure intensity on the numeric machine tool, receive high stress and dangerous area that meet an emergency. Then optimize the structure to this area, and the result indicates that the working condition is improved obviously on this component, thereby guarantee the running reliability of the whole machine.
将虚拟制造技术应用于数控电火花机床的设计中,研究了特征造型、动力学分析系统和有限元分析系统之间的转换方法和技术,利用PRO/E软件建立了样机零部件的实体模型,并在此基础上完成电火花机床机械结构的虚拟装配和装配干涉分析,成功建立了机床的虚拟样机。此虚拟样机模型可进一步在ADAMS软件中进行运动仿真和动力学分析,从而节省了建模时间。在用PRO/E建模时,省略和简化了部分对仿真精度影响较小的零部件特征,如安装孔、螺钉、螺纹等,模型完善以后通过在ADAMS中添加约束和载荷来实现运动功能以减少ADAMS仿真所需时间,避免仿真失败。
在ANSYS有限元分析软件平台上,采用模态分析技术获得机床结构的模态固有频率和主振型,从而实现对机床结构的改进和优化设计。基于运动学和动力学仿真软件ADAMS验证分析了影响机床爬行现象的主要因素,从而实现了机床的进给系统的优化设计。对CTS400数控电火花机床进行了运动平稳性分析。采用ADAMS的运动分析技术分析了整机在各种作业工况下各主要连接件之间的作用力,为有限元分析提供边界条件;对CTS400数控电火花机床结构强度进行了有限元分析,得到了高应力、应变的危险区域,通过对该区域进行结构优化设计,结果表明显著地改善了该部位构件的工作状况,从而保证了整机运行的可靠性。
虚拟制造技术的引入,获得了机床静态受力以及运动过程中的微观变形图形及数据,为更直观的了解机床的性能和运动状态提供了可靠的依据,也为日后机床的性能改进提供了技术参考。
As a new technology of product design,VM (Virtual Manufacturing) is a revolution to traditional method of products design. Based on virtual manufacturing,engineers can find underlying problems just during products design by simulating the mechanical system,and revise them quickly so as to throw off the physical prototype,which not only can save the cost of design and manufacturing and reduce the cycle of products development , but also can elevate products’performance and enhance products’competition.
The paper applied virtual prototype technology to the design of EDM (Electrical Discharge Machining) machine tool. It studies the integrating methods and technology among the characteristic modeling、kinematics analysis and finite element analysis system, software PRO/E (Pro/Engineer-3D solids modeling software) was used to draw the 3-D model of machine tool parts which can assembled to be a virtual machine, interference checking was taken between the parts after assembling finished and the VP (Virtual Prototype) of machine tool was successfully constructed in the end, which is the foundation of motion simulation and dynamic analysis using ADAMS (Automatic Dynamic Analysis of Mechanical Systems)software. Some features that hardly affect the simulation accuracy such as installation holes, screws were overleaped or simplified when modeling in PRO/E, constraint and loading which can achieve motion function were applied in ADAMS in order to decrease the time consumed by modeling and calculation and also keep the simulation from failure.
Using the advanced and powerful FEA (Finite Element Analysis) software ANSYS to do the modal analysis on the main structure of machine, then gets the intrinsic frequency and the vibration model in order to achieve improvement and optimum design. Gained optimum design to the feeding system by analysis the main factors effect the problems of crawling based on the dynamics analysis software of machine system ADAMS. Through adopting the technological analysis of ADAMS, analyze the numeric machine tool of CTS400 action force between every main attachment under various operating conditions, so offer the border condition for the finite element analysis; though the finite element analysis about the assembly structure intensity on the numeric machine tool, receive high stress and dangerous area that meet an emergency. Then optimize the structure to this area, and the result indicates that the working condition is improved obviously on this component, thereby guarantee the running reliability of the whole machine.
引文
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[2] 郑志江. 电火花机床发展趋向分析. 模具制造,2001(1):39
[3] K. Kobayashi,T. Magara,Y. Ozaki,T. Yatomi. The present and future developments of electrical discharge machining,in:Proceedings of 2nd International Conference on Die and Mould Technology,Singapore,1992,pp. 35-47.
[4] 苏景云. 电火花加工机理的研究. 吉林化工学院学报,2002,19(3):59-61
[5] Singh A,Ghosh A. A Thermo-electric Model of Material Removal during Electric Discharge Machining. International Journal of Machine Tools &Manufacture,1999,39(4):669-682
[6] N. Mohri. A New Process of Finish Machining on Free Surface by EDM Methods. Annals of the CIPS,1991(l):207-210
[7] T. Masuzawa. State of the art of micromachining. Annals of the CIRP,2000,49(2): 473-488
[8] 张勤河,张建华,杜如虚,艾兴. 电火花成形加工技术的现状与发展趋势. 中国机械工程, 2005,16(17):1586-1592
[9] 曹凤国,伏金娟. 中国电加工机床现状及发展趋势. 产品与技术,2006(4):66-71
[10] 翟力军,伏金娟,蒋亨顺. 我国电火花成形加工技术的现状及发展方向. 机械工人(冷加工), 2004(1):18-20
[11] 王振龙,赵万生,李文卓. 电火花加工技术的发展趋势与工艺进展. 制造技术与机床,2001 (7):8-11
[12] 付群,郭君,刘宁. 虚拟制造. 一重技术,2007(2):80-81
[13] Martin Bames. Virtual reality and simulation. Proceedings of Wsc96,5-8
[14] Michacl P. Introduction to computer simulation. Proceedings of WSC94,7-14
[15] 邵立,马登哲,严隽琪,钟廷修. 虚拟制造中仿真技术的应用. 工业工程与管理,2000(4): 21-25
[16] Heilala Juhani,Salmi Timo,Apilo Tiina. Virtual production system development in product process C//Proceedings of VTT Symposium:Virtual Prototyping,VTT Research Program me in 1998-2001,Espoo,2001:59-72
[17] National Research Council. Modeling and simulation in manufacturing and defense acquisition:pathway to success. USA:The National Academy Press, 2002
[18] Stytz M R. Distributed Virtual Environments. IEEE Computer Graphics and Application, 1996,16(3):19-31
[19] J R Nichol,C T Wilkes,F A Manola. Object Orientation in heterogeneous distributed computing systems. IEEE Computer,Jun 1993:57-67
[20] 陈爱闽,李生录,宋可总等. 仿真和虚拟设计技术. 起重运输机械,2003(8):6-8
[21] 周海英,陈立潮. 智能技术在仿真平台设计中的应用. 计算机工程,2005,31(9):176-178
[22] 刘宏增,黄靖远. 虚拟设计. 机械工业出版社,1999
[23] 陈定方. 虚拟设计. 北京:机械工业出版社,2002
[24] 罗亚波.虚拟制造设计.北京:机械工业出版社,2003
[25] 郑寿森,祁新梅,社晓荣等.产品可装配性技术指标体系. 机械设计,1999(3):26-28
[26] 刘振宇,谭建荣.面向过程的虚拟环境中产品装配建模研究.机械工程学报,2004,4(3): 93-99
[27] Jayaram S,Jayaram U,Wang Yet al. VADE:A virtual assembly design environment. IEEE Computer Graphics and Applications, 1999,19(6):44-50
[28] 刘振宇,谭建荣. 基于物理模型的虚拟装配技术研究. 中国图像图形学报,2003,8(7): 823-828
[29] 王辉,张林宣,肖田元. 虚拟装配支持系统中面向多方案工艺规划的研究. 机械科学与技术, 2003(9):808-811
[30] 曹杰. 基于 DMAS 的敏捷化集成供应链管理系统. 物流技术,2005(10):209-212
[31] 李培珍,尹玉亮,周建. 基于虚拟样机技术的集装箱吊装状态有限元分析. 计算机与信息技术,2007(22):50,94
[32] Lawrence Associates Inc. Contribution to Virtual Manufacturing Background Research. Technical Report. Virtual Manufacturing User Workshop,Dayton,Ohio,1994:12-13
[33] The Virtual Reality Modeling Language International Standard ISO/IEC14772-1:1997 S. The VRML Consortium Incorporated,1997,12
[34] Lu S C Y, Shpitalni M, Gadh R. Virtual and augmented reality technologies for product realization. Annals of the CIRP, 1999, 48(2):471-495
[35] 隋爱娜,吴威,赵沁平. 虚拟装配与虚拟原型机的理论与技术分析. 系统仿真学报,2000,12(4):386-388
[36] 张德庆. 数字化产品设计制造工程. 航空工程与维修,2000(6):32-35
[37] 黄洪钟,丁国富,王金诺,张爱军. 基于虚拟现实技术的原型设计机理研究. 机械工程学报,1999(5):152-156
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