复杂结构零件切削过程物理仿真与工艺优化技术研究
|
摘要
虚拟制造技术在制造行业中得到了广泛的应用,切削物理仿真属于虚拟制造技术范畴,对制造技术的发展有重要的意义。但限于技术水平等因素,目前物理仿真技术局限于简单零件切削模拟,复杂结构零件的切削过程物理仿真仍然是一个难点。
本文将二维切削模型仿真与三维实体模型仿真方法相结合,实现了复杂结构零件切削过程的模拟。文中介绍了切削仿真的关键技术及实现方法,研究了将各种类型切削加工抽象简化为二维切削模型的方法,以及三维实体模型加载方式和仿真结果分析方法。
搭建了切削实验平台,研究材料Al6061-T6的切削性能,与仿真结果相比较,验证了仿真方法的有效性。仿真了一款磁盘驱动架零件的切削过程,分析零件及刀具在切削力、切削热作用下应力分布及变形状况,从而评价切削工艺的合理性。
本文研究了基于切削物理仿真的工艺优化方法,详述了多因素多水平条件下系统化的仿真实验设计方法。针对磁盘驱动架切削加工过程,根据物理仿真计算结果对切削参数及刀具几何参数进行优化,使用优化参数加工所得产品质量有较大的提高。此外,针对生产中的刀具折断问题进行分析,找出问题的原因,给出了刀具和切削参数优化方案,降低了刀具的折断率。
Cutting process physical simulation belongs to the virtual manufacturing technology which is widely used in manufacturing industry. It is meaningful to the improvement of manufacturing technology. But restricted by technical level and other factors, physical simulation is only used for ordinary parts cutting. There still have difficulties in realizing the physical simulation of complex parts cutting process.
This paper develops a method to realize physical simulation of complex parts cutting process by integrating 2D and 3D cutting model simulation technique. It introduces the key techniques and realizing mechanism. Method of abstracting ordinary cutting types to 2D cutting model is researched. It also develops 3D model loading and result analysis method.
Cutting experiment platform is established for studying the cutting property of Al6061-T6. Compared with the simulation results, it proves that the simulation method is reliable. A hard disk drive part cutting progress is simulated to analysis the stress distribution and overall deformation under the effect of cutting force and heat. The result can be used to evaluate the cutting technique.
A cutting technique optimization method based on the physical simulation is introduced. The paper describes a systematic experiment method used for influencing factors that have several different values. The cutting parameters and tool geometry of hard disk drive part is optimized, and the products quality is greatly improved. Besides, the paper analyzes a tool break problem and gives a helpful solution to reduce the risk.
本文将二维切削模型仿真与三维实体模型仿真方法相结合,实现了复杂结构零件切削过程的模拟。文中介绍了切削仿真的关键技术及实现方法,研究了将各种类型切削加工抽象简化为二维切削模型的方法,以及三维实体模型加载方式和仿真结果分析方法。
搭建了切削实验平台,研究材料Al6061-T6的切削性能,与仿真结果相比较,验证了仿真方法的有效性。仿真了一款磁盘驱动架零件的切削过程,分析零件及刀具在切削力、切削热作用下应力分布及变形状况,从而评价切削工艺的合理性。
本文研究了基于切削物理仿真的工艺优化方法,详述了多因素多水平条件下系统化的仿真实验设计方法。针对磁盘驱动架切削加工过程,根据物理仿真计算结果对切削参数及刀具几何参数进行优化,使用优化参数加工所得产品质量有较大的提高。此外,针对生产中的刀具折断问题进行分析,找出问题的原因,给出了刀具和切削参数优化方案,降低了刀具的折断率。
Cutting process physical simulation belongs to the virtual manufacturing technology which is widely used in manufacturing industry. It is meaningful to the improvement of manufacturing technology. But restricted by technical level and other factors, physical simulation is only used for ordinary parts cutting. There still have difficulties in realizing the physical simulation of complex parts cutting process.
This paper develops a method to realize physical simulation of complex parts cutting process by integrating 2D and 3D cutting model simulation technique. It introduces the key techniques and realizing mechanism. Method of abstracting ordinary cutting types to 2D cutting model is researched. It also develops 3D model loading and result analysis method.
Cutting experiment platform is established for studying the cutting property of Al6061-T6. Compared with the simulation results, it proves that the simulation method is reliable. A hard disk drive part cutting progress is simulated to analysis the stress distribution and overall deformation under the effect of cutting force and heat. The result can be used to evaluate the cutting technique.
A cutting technique optimization method based on the physical simulation is introduced. The paper describes a systematic experiment method used for influencing factors that have several different values. The cutting parameters and tool geometry of hard disk drive part is optimized, and the products quality is greatly improved. Besides, the paper analyzes a tool break problem and gives a helpful solution to reduce the risk.
引文
[1]朱高峰.新世纪如何提高和发展我国制造业.中国制造业信息化,2003,32(4):4~8
[2]曾新胜.经济全球化中的中国制造业发展战略.国际经济合作,2006,1:22~24
[3]郭春丽.提高陶瓷刀具材料断裂韧性的方法.陶瓷(咸阳),2007,2:43~45
[4]程伟,梁萍.基于Web的数控加工切削参数优化系统的研究.新技术新工艺, 2006,5:37~39
[5]叶荫青.试论虚拟制造在企业快速发展中的作用.机电信息,2005,17:25~27
[6]熊光楞,王昕.仿真技术在制造业中的应用与发展.系统仿真学报,1999,11(3):145~151
[7]赵秀平,龙伟.浅谈虚拟制造.实用测试技术,2001,27(2):23~25
[8]王贵成.国外关于切削毛剌生成机理与去除技术的研究.佳木斯工学院学报,1999,7(4):56
[9]赵琳,傅建中.虚拟制造中铣削力仿真技术的研究.浙江大学硕士学位论文.2005
[10]王孟君,杨立斌等.6063铝合金高温流变本构方程.华中科技大学学报(自然科学版),2003,31(6):20~21
[11]肖诗云,林皋等.Drucker-Prager材料一致率型本构模型.工程力学,2003,20(4):147~151
[12]范亚夫,段祝平.Johnson-Cook材料模型参数的实验测定.力学与实践,2003,25(5):40~43
[13]胡昌明,贺红亮.45号钢的动态力学性能研究.爆炸与冲击,2003,23(2):188~192
[14]冯明德,彭艳菊.SHPB实验技术研究.地球物理学进展,2006,21(1):273~277
[15]郭伟国.高温分离式Hopkinson压杆技术及其应用.实验力学, 2006,21(4):447~452
[16]周立瑞,张志刚.φ100mm大直径分离式霍普金森压杆设备设计.第四届全国爆炸力学实验技术学术会议,2006:49~59
[17]胡时胜.霍普金森压杆技术.兵器材料科学与工程,1991,(11):40～47
[18]付秀丽,艾兴.高速切削加工航空铝合金7050-T7451剪切角模型研究.机械工程学报,2007,18(2):220~224
[19]凤仪,朱震刚.泡沫铝的动态力学性能研究.稀有金属材料与工程,2005,34(4):544~547
[20]左秀荣,樊彬彬等.6063铝合金热变形行为的研究.特种铸造及有色合金,2007,27(1):19~20
[21]王建华.2618耐热铝合金的组织与力学性能的研究.中南大学博士学位论文.2003
[22]杨洪涛,王淑云.新型超高强度铝合金本构方程的研究.塑性工程学报,2005,12(6):38~41
[23]林启权,张辉.2519铝合金热压缩变形流变应力行为.热加工工艺,2002,3:3~5
[24]吴文祥,孙德勤.3003铝合金热变形流变应力特征.材料热处理,2007,3:12~14
[25]刘培德等.切削力学新篇.大连理工大学出版社.1991:95~115
[26]蔡在亶.金属切削原理.同济大学出版社,1994:19~90
[27]沙智华,葛研军.切削加工仿真建模技术研究.系统仿真学报,2005,17(4):789~792
[28]胡创国,张定华等.切削力建模方法综述.力学进展,2006,36(4):564~569
[29] [日]中山一雄.金属切削加工理论(李云芳),北京,机械工业出版社,1985:7~10
[30]赵琳,傅建中.虚拟制造中铣削力仿真技术的研究:[浙江大学硕士学位论文].浙江,2005
[31]肖田元,韩向利.虚拟制造的定义与关键技术.清华大学学报:自然科学版,1998,38(10):102~106
[32]李纯彬等.基于MasterCAM零件的数控加工.工具技术,2008,42(8):62~63
[33]王洪祥等,切削深度对超精密切削过程影响的有限元分析.工具技术,2004, 38(7):6~8
[34] K.-D. Bouzakis, P. Aichouh, K. Efstathiou. Determination of the chip geometry, cutting force and roughness in free form surfaces finishing milling with ball end tools. International Journal of Machine Tools & Manufacture, 2003,43: 499~514
[35] Martin Baker. Finite element simulation of high-speed cutting forces. Journal of Materials Processing Technology,2006,176:117~126
[36] N.A. Abukhshim, P.T. Mativenga, M.A. Sheikh. Heat generation and temperature prediction in metal cutting: A review and implications for high speed machining. International Journal of Machine Tools & Manufacture, 2006,46:782~800
[37] D. Umbrello, L. Filice, S. Rizzuti, F. Micari, L. Settineri. On the effectiveness of Finite Element simulation of orthogonal cutting with particular reference to temperature prediction. Journal of Materials Processing Technology, 2007,189:284~291
[38] Tugrul Ozel, Taylan Altan. Process simulation using finite element method- prediction of cutting forces, tool stresses and temperatures in high-speed flat end milling. International Journal of Machine Tools & Manufacture. 2000,40:713~738
[39] I.W.ParK, D,A,Dornfeld. A Study of Burr Formation Processes Using the Finite Element Method. Journal of Engineering Materials and Technology, 2000, 122:221~227
[40] Christian Hortig, Bob Svendsen. Simulation of chip formation during high-speed cutting. Journal of Materials Processing Technology, 2007,186:66~76
[41] Yuzhong Cao, Y. Altintas. Modeling of spindle-bearing and machine tool systems for virtual simulation of milling operations. International Journal of Machine Tools &Manufacture, 47:1342~1350
[42]宋玉梅.基于数控铣床的物理仿真:[吉林大学硕士学位论文].吉林,2005
[43]张臣.数控铣削加工物理仿真关键技术研究:[南京航空航天大学博士学位论文].南京,2006
[44]金艳丽.球头刀铣削过程物理仿真的研究:[河北工业大学硕士学位论文].河北,2004
[45]杨强,杨晓君等.基于D-P准则的理想弹塑性本构关系积分.工程力学,2005,22(4):15~19
[46]刘金龙,栾茂田等.Drucker-Prager准则参数特性分析.岩石力学与工程学报,2006,25(2):4009~4015
[47]杨晓琦等.基于正应力摩擦模型的金属切削有限元仿真.电子机械工程,2008,24(4):48~50
[48]孟辉.高速切削温度动态有限元建模与数值模拟:[山东大学硕士学位论文].山东,2005
[49]王建华,杨磊等.有限元后验误差估计方法的研究进展.力学进展,2000,30(2):175~190
[50]王璋齐,安利强.温度场分析的自适应有限元方法.热能动力工程,2002,17(1):92~94
[51]冯之敬.机械制造工程原理.清华大学出版社,1999:53~66,252~253
[52]陆剑中,孙家宁.金属切削原理与刀具.机械工业出版社,1985:41~72
[53]张维纪.金属切削原理及刀具.浙江大学出版社,1991,23~34,113~119
[54]韦光等.水幕冷却高温钢板对流换热系数的研究.钢铁,1994,29(1):22~26
[55]周利平,吴能章.基于FEM的三维切削力预报研究.工具技术,2006,40(6):14~18
[56]孙军,经树栋.CAD与ANSYS的接口技术探讨.化工设备与管道,2004,41(2):55~57
[57]杨荣福,董申.金属切削原理,机械工业出版社,1988,287~310,329~345
[58] [日]小野浩二,河村末久等.理论切削学.国防工业出版社(高希正),北京1985,76~77,117~122
[59]张幼桢.金属切削理论,航空工业出版社,1988,55~57
[60] [苏]马卡洛夫,切削过程最优化.国防工业出版社(杨锦华),北京,1988,15~46,49~95
[61]上海市科学技术交流站组.正交试验设计法.上海人民出版社,1975
[62]徐仲安,王天保.正交试验设计法简介.科技情报开发与经济,2002,12(5):148~1505
[2]曾新胜.经济全球化中的中国制造业发展战略.国际经济合作,2006,1:22~24
[3]郭春丽.提高陶瓷刀具材料断裂韧性的方法.陶瓷(咸阳),2007,2:43~45
[4]程伟,梁萍.基于Web的数控加工切削参数优化系统的研究.新技术新工艺, 2006,5:37~39
[5]叶荫青.试论虚拟制造在企业快速发展中的作用.机电信息,2005,17:25~27
[6]熊光楞,王昕.仿真技术在制造业中的应用与发展.系统仿真学报,1999,11(3):145~151
[7]赵秀平,龙伟.浅谈虚拟制造.实用测试技术,2001,27(2):23~25
[8]王贵成.国外关于切削毛剌生成机理与去除技术的研究.佳木斯工学院学报,1999,7(4):56
[9]赵琳,傅建中.虚拟制造中铣削力仿真技术的研究.浙江大学硕士学位论文.2005
[10]王孟君,杨立斌等.6063铝合金高温流变本构方程.华中科技大学学报(自然科学版),2003,31(6):20~21
[11]肖诗云,林皋等.Drucker-Prager材料一致率型本构模型.工程力学,2003,20(4):147~151
[12]范亚夫,段祝平.Johnson-Cook材料模型参数的实验测定.力学与实践,2003,25(5):40~43
[13]胡昌明,贺红亮.45号钢的动态力学性能研究.爆炸与冲击,2003,23(2):188~192
[14]冯明德,彭艳菊.SHPB实验技术研究.地球物理学进展,2006,21(1):273~277
[15]郭伟国.高温分离式Hopkinson压杆技术及其应用.实验力学, 2006,21(4):447~452
[16]周立瑞,张志刚.φ100mm大直径分离式霍普金森压杆设备设计.第四届全国爆炸力学实验技术学术会议,2006:49~59
[17]胡时胜.霍普金森压杆技术.兵器材料科学与工程,1991,(11):40～47
[18]付秀丽,艾兴.高速切削加工航空铝合金7050-T7451剪切角模型研究.机械工程学报,2007,18(2):220~224
[19]凤仪,朱震刚.泡沫铝的动态力学性能研究.稀有金属材料与工程,2005,34(4):544~547
[20]左秀荣,樊彬彬等.6063铝合金热变形行为的研究.特种铸造及有色合金,2007,27(1):19~20
[21]王建华.2618耐热铝合金的组织与力学性能的研究.中南大学博士学位论文.2003
[22]杨洪涛,王淑云.新型超高强度铝合金本构方程的研究.塑性工程学报,2005,12(6):38~41
[23]林启权,张辉.2519铝合金热压缩变形流变应力行为.热加工工艺,2002,3:3~5
[24]吴文祥,孙德勤.3003铝合金热变形流变应力特征.材料热处理,2007,3:12~14
[25]刘培德等.切削力学新篇.大连理工大学出版社.1991:95~115
[26]蔡在亶.金属切削原理.同济大学出版社,1994:19~90
[27]沙智华,葛研军.切削加工仿真建模技术研究.系统仿真学报,2005,17(4):789~792
[28]胡创国,张定华等.切削力建模方法综述.力学进展,2006,36(4):564~569
[29] [日]中山一雄.金属切削加工理论(李云芳),北京,机械工业出版社,1985:7~10
[30]赵琳,傅建中.虚拟制造中铣削力仿真技术的研究:[浙江大学硕士学位论文].浙江,2005
[31]肖田元,韩向利.虚拟制造的定义与关键技术.清华大学学报:自然科学版,1998,38(10):102~106
[32]李纯彬等.基于MasterCAM零件的数控加工.工具技术,2008,42(8):62~63
[33]王洪祥等,切削深度对超精密切削过程影响的有限元分析.工具技术,2004, 38(7):6~8
[34] K.-D. Bouzakis, P. Aichouh, K. Efstathiou. Determination of the chip geometry, cutting force and roughness in free form surfaces finishing milling with ball end tools. International Journal of Machine Tools & Manufacture, 2003,43: 499~514
[35] Martin Baker. Finite element simulation of high-speed cutting forces. Journal of Materials Processing Technology,2006,176:117~126
[36] N.A. Abukhshim, P.T. Mativenga, M.A. Sheikh. Heat generation and temperature prediction in metal cutting: A review and implications for high speed machining. International Journal of Machine Tools & Manufacture, 2006,46:782~800
[37] D. Umbrello, L. Filice, S. Rizzuti, F. Micari, L. Settineri. On the effectiveness of Finite Element simulation of orthogonal cutting with particular reference to temperature prediction. Journal of Materials Processing Technology, 2007,189:284~291
[38] Tugrul Ozel, Taylan Altan. Process simulation using finite element method- prediction of cutting forces, tool stresses and temperatures in high-speed flat end milling. International Journal of Machine Tools & Manufacture. 2000,40:713~738
[39] I.W.ParK, D,A,Dornfeld. A Study of Burr Formation Processes Using the Finite Element Method. Journal of Engineering Materials and Technology, 2000, 122:221~227
[40] Christian Hortig, Bob Svendsen. Simulation of chip formation during high-speed cutting. Journal of Materials Processing Technology, 2007,186:66~76
[41] Yuzhong Cao, Y. Altintas. Modeling of spindle-bearing and machine tool systems for virtual simulation of milling operations. International Journal of Machine Tools &Manufacture, 47:1342~1350
[42]宋玉梅.基于数控铣床的物理仿真:[吉林大学硕士学位论文].吉林,2005
[43]张臣.数控铣削加工物理仿真关键技术研究:[南京航空航天大学博士学位论文].南京,2006
[44]金艳丽.球头刀铣削过程物理仿真的研究:[河北工业大学硕士学位论文].河北,2004
[45]杨强,杨晓君等.基于D-P准则的理想弹塑性本构关系积分.工程力学,2005,22(4):15~19
[46]刘金龙,栾茂田等.Drucker-Prager准则参数特性分析.岩石力学与工程学报,2006,25(2):4009~4015
[47]杨晓琦等.基于正应力摩擦模型的金属切削有限元仿真.电子机械工程,2008,24(4):48~50
[48]孟辉.高速切削温度动态有限元建模与数值模拟:[山东大学硕士学位论文].山东,2005
[49]王建华,杨磊等.有限元后验误差估计方法的研究进展.力学进展,2000,30(2):175~190
[50]王璋齐,安利强.温度场分析的自适应有限元方法.热能动力工程,2002,17(1):92~94
[51]冯之敬.机械制造工程原理.清华大学出版社,1999:53~66,252~253
[52]陆剑中,孙家宁.金属切削原理与刀具.机械工业出版社,1985:41~72
[53]张维纪.金属切削原理及刀具.浙江大学出版社,1991,23~34,113~119
[54]韦光等.水幕冷却高温钢板对流换热系数的研究.钢铁,1994,29(1):22~26
[55]周利平,吴能章.基于FEM的三维切削力预报研究.工具技术,2006,40(6):14~18
[56]孙军,经树栋.CAD与ANSYS的接口技术探讨.化工设备与管道,2004,41(2):55~57
[57]杨荣福,董申.金属切削原理,机械工业出版社,1988,287~310,329~345
[58] [日]小野浩二,河村末久等.理论切削学.国防工业出版社(高希正),北京1985,76~77,117~122
[59]张幼桢.金属切削理论,航空工业出版社,1988,55~57
[60] [苏]马卡洛夫,切削过程最优化.国防工业出版社(杨锦华),北京,1988,15~46,49~95
[61]上海市科学技术交流站组.正交试验设计法.上海人民出版社,1975
[62]徐仲安,王天保.正交试验设计法简介.科技情报开发与经济,2002,12(5):148~1505