基于拟实体数控车削加工仿真研究
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摘要
长期以来,金属切削加工作为制造形状、尺寸精度和表面质量高的零件的最经济加工方法,在各国经济中都占有十分重要的地位。由于工件材料和工艺参数的多样性以及切削加工的复杂性,在很长时间内对切削加工的研究都局限在经验实验的范围内。这严重影响了切削加工的效率,并导致加工成本高、加工过程中错误甚至事故的频繁发生。切削加工仿真是计算机仿真技术在机械制造业的重要应用领域之一。该技术对减少制造成本、缩短产品制造周期和提高产品质量意义重大。
本文针对现存切削加工仿真方法及模型的优点与不足,提出了切削加工拟实体仿真概念体系和模型体系,并基于拟实体对数控车削加工仿真关键技术进行了深入研究。
1.对现存的切削加工仿真方法进行归纳,将其分为几何仿真、物理仿真和加工过程仿真三个方面,对每个方面的主要算法实现原理进行了介绍,总结了其优缺点,提出了切削加工仿真的发展趋势。
2.基于金属切削加工的本质特性,提出了切削加工拟实体仿真概念体系。其中,拟实体是指模拟切削加工现实环境中物体的本质特性由计算机生成的“实在物体”。根据对切削加工结果的影响程度,将拟实体分为细化拟实体和整体拟实体两类。细化拟实体是由代表其根本性质的微粒组成,并称这种微粒为微实体。提出了微实体在细化拟实体中的构成原则及组织方式,将细化拟实体分为核心区和边缘区两个区域,并根据微实体在细化拟实体中不同位置,将其分为力学微实体和几何微实体两类。基于现实加工环境中物体的特点,将整体拟实体分为整体装配拟实体和整体零件拟实体两类。对基于拟实体的切削加工仿真过程及其实现原理进行了描述,并以数控车削加工为例,建立了切削加工拟实体仿真系统结构。
3.基于切削加工拟实体仿真概念体系,对实现数控车削加工仿真的关键技术进行了深入探讨,建立了切削加工拟实体仿真模型体系。
依据特征建模技术原理,对整体零件拟实体的几何特征和外观特征进行了详细描述,建立了整体零件拟实体模型;基于实际机床中部件的装配特征,整体零件拟实体按照一定位置关系进行组装即可形成整体装配拟实体。
依据工件的材料特性及仿真要求,对工件拟实体核心区中力学微实体的组织方式进行了规划。设力学微实体为具有一定质量且可表现被加工工件材料基本属性的不可分割的刚体。基于Morse势能模型,建立了力学微实体之间的相互作用关系模型和力学微实体运动模型,实现了工件拟实体核心区车削加工过程仿真。
将分形理论引入到工件拟实体边缘区建模中,建立了单元长度以2的幂次递增的工件拟实体边缘区分形组织结构模型。根据车削加工工件及其中间形体的回转体特征,将扇环体作为车削加工的基本分形体。基于上述分形组织结构及基本分形体,建立了车削加工工件拟实体边缘区模型,并实现了边缘区的加工过程仿真。
基于正常卷曲切屑的螺旋形结构,将切屑拟实体中的几何微实体的基本形状也设为扇环体,通过对影响切屑生长及卷曲的各种因素进行深入的理论及试验研究,求解了控制其几何微实体形状的几何参数,得到了与实际切屑形状较为接近的不同切削参数下切屑的自
For a long time, as the most economic method to manufacturing products with high quality and surface integrity, machining plays an important role in the national economy. Due to the variety of work-piece material and the versatility of the process parameters, the study on the machining process is limited to empirical extent for a long time. It not only leads to low machining efficiency, but also results in high manufacturing cost and frequent errors even accidents in machining process. Machining simulation is one of the important applications of computer simulation in modern mechanical manufacturing industry. It is of great significance in producing quality parts more quickly and economically.Based on the characteristics of machining simulation, the imitated-solid conception system and modeling system for machining simulation is presented in this paper, and its key realizating technologies for NC turning simulation based on imitated-solid is studied in detail.1. Though extensive investigation, the existed methods of machining simulation can be divided into three acspects: geometric simulation, physical simulation, and process simulation. The principle of the dominating algorithms in these three acspects is introduced. The advantages and disadvantages for those algorithms are summarized, and the developing trends for machining simulation are also discussed.2. Based on the essence of metal cutting, the imitated-solid conception system for machining simulation is presented. Here, Imitated-Solid is the "actual object" formed by computer which can represent the intrinsical characteristics of the object in real machining environment. According to its influence to the machining result, the imitated-solid in the virtual machining environment can be devided into two kinds: divisible imitated-solid and indivisible imitated-solid. The divisible imitated-solid is supposed to be constructed by the particles which can represent its basic characteristics, and here named it as "Micro-solid". The constructing guideline and mode of micro-solids in divisible imitated-solid is presented. In term of the guideline, the divisible imitated-solid can be portioned into two zones: kernel and boundary, and the micro-solids in these zones are classified into geometric micro-solids and dynamic micro-solids respectively. Based on the character of object in real machining environment, the indivisible imitated-solid can be classified into two formats: indivisible part imitated-solid and indivisible assembly imitated-solid. The principle and process of machining simulation based on imitated-solid theory is presented. Take NC turning as an example, the structure of imitated-solid machining simulation system is presented.3. According to the imitated-solid conception system for machining simulation, the key technologies for its realization in NC turning is discussed thoroughly, the modeling system for machining simulation is established.Based on the feature modeling technology, the geometric and apparent features of undivisible part imitated-solid are described in detail, the model of undivisible part imitated-solid is
developed. Based on the features of components in the real machine tools, the undivisible assembly imitated-solids can be formed by assembling undivisible part imitated-solids with certain positional relationship.According to the influence of cutting tool to the micrometric structure of workpiece in the machining process, the constructing structure of dynamic micro-solids in the workpiece imitated-solid kernel zone are determined. The dynamic micro-solid is supposed to be indiscerptible rigid body with certain mass which can reflect the essential characters of the workpiece material. Based on Morse potential energy function, the interacting relationship of dynamic micro-solids is developed. In terms of the second classical Newtonian equation of motion, the kinetic model of dynamic micro-solids is presented. Based on the aforementioned models, the turning simulation of workpiece imitated-solid kernel zone is realized.Introducing the fractal theory into the modeling of workpiece imitated-solid boundary zone, the fractal constructing structure model of boundary zone that unit length is increased in 2's exponents is developed. In terms of the revolving feature of the turning workpiece and its in-between shapes, the quasi-sector shape is determined to be the basic fractal shape for turning. Based on the constructing structure model and basic fractal shape, the model of workpiece imitated-solid boundary zone for turning is obtained, and the process simulation of boundary zone is realized.According to the twist shape of the natural curled chip, the basic shape for geometric micro-solid in chip imitated-solid is supposed to be quasi-sector shape. Though investigating the all kinds of factors affecting chips' forming and curling, the geometric parameters controlling the chip shape are caculated, and the natural curled chip model for different cutting parameter group which is resemble to the real circumstance is obtained. Based on the positional relationship of workpiece and cutting tool in the time of chip forming, the chip breaking model is presented, the function for chip classes judging is developed, the dynamic simulation for chip's forming, curling and breaking is realized.Aimed to the limitation of present NC code compiler, e.g. specialization and difficult tomaintain, a method of developing NC code compile module by using special compiling tools------Lex&Yacc is presented. By presenting the method of system customization, the compile module can adapt various codes from different NC system.Intergrated the aforementioned models together, the imitated-solid simulation system for NC turning is established. The 3D turning simulation which can describe the microscopical geometric and physical change of the material and its macroscopical interaction results is realized.
本文针对现存切削加工仿真方法及模型的优点与不足,提出了切削加工拟实体仿真概念体系和模型体系,并基于拟实体对数控车削加工仿真关键技术进行了深入研究。
1.对现存的切削加工仿真方法进行归纳,将其分为几何仿真、物理仿真和加工过程仿真三个方面,对每个方面的主要算法实现原理进行了介绍,总结了其优缺点,提出了切削加工仿真的发展趋势。
2.基于金属切削加工的本质特性,提出了切削加工拟实体仿真概念体系。其中,拟实体是指模拟切削加工现实环境中物体的本质特性由计算机生成的“实在物体”。根据对切削加工结果的影响程度,将拟实体分为细化拟实体和整体拟实体两类。细化拟实体是由代表其根本性质的微粒组成,并称这种微粒为微实体。提出了微实体在细化拟实体中的构成原则及组织方式,将细化拟实体分为核心区和边缘区两个区域,并根据微实体在细化拟实体中不同位置,将其分为力学微实体和几何微实体两类。基于现实加工环境中物体的特点,将整体拟实体分为整体装配拟实体和整体零件拟实体两类。对基于拟实体的切削加工仿真过程及其实现原理进行了描述,并以数控车削加工为例,建立了切削加工拟实体仿真系统结构。
3.基于切削加工拟实体仿真概念体系,对实现数控车削加工仿真的关键技术进行了深入探讨,建立了切削加工拟实体仿真模型体系。
依据特征建模技术原理,对整体零件拟实体的几何特征和外观特征进行了详细描述,建立了整体零件拟实体模型;基于实际机床中部件的装配特征,整体零件拟实体按照一定位置关系进行组装即可形成整体装配拟实体。
依据工件的材料特性及仿真要求,对工件拟实体核心区中力学微实体的组织方式进行了规划。设力学微实体为具有一定质量且可表现被加工工件材料基本属性的不可分割的刚体。基于Morse势能模型,建立了力学微实体之间的相互作用关系模型和力学微实体运动模型,实现了工件拟实体核心区车削加工过程仿真。
将分形理论引入到工件拟实体边缘区建模中,建立了单元长度以2的幂次递增的工件拟实体边缘区分形组织结构模型。根据车削加工工件及其中间形体的回转体特征,将扇环体作为车削加工的基本分形体。基于上述分形组织结构及基本分形体,建立了车削加工工件拟实体边缘区模型,并实现了边缘区的加工过程仿真。
基于正常卷曲切屑的螺旋形结构,将切屑拟实体中的几何微实体的基本形状也设为扇环体,通过对影响切屑生长及卷曲的各种因素进行深入的理论及试验研究,求解了控制其几何微实体形状的几何参数,得到了与实际切屑形状较为接近的不同切削参数下切屑的自
For a long time, as the most economic method to manufacturing products with high quality and surface integrity, machining plays an important role in the national economy. Due to the variety of work-piece material and the versatility of the process parameters, the study on the machining process is limited to empirical extent for a long time. It not only leads to low machining efficiency, but also results in high manufacturing cost and frequent errors even accidents in machining process. Machining simulation is one of the important applications of computer simulation in modern mechanical manufacturing industry. It is of great significance in producing quality parts more quickly and economically.Based on the characteristics of machining simulation, the imitated-solid conception system and modeling system for machining simulation is presented in this paper, and its key realizating technologies for NC turning simulation based on imitated-solid is studied in detail.1. Though extensive investigation, the existed methods of machining simulation can be divided into three acspects: geometric simulation, physical simulation, and process simulation. The principle of the dominating algorithms in these three acspects is introduced. The advantages and disadvantages for those algorithms are summarized, and the developing trends for machining simulation are also discussed.2. Based on the essence of metal cutting, the imitated-solid conception system for machining simulation is presented. Here, Imitated-Solid is the "actual object" formed by computer which can represent the intrinsical characteristics of the object in real machining environment. According to its influence to the machining result, the imitated-solid in the virtual machining environment can be devided into two kinds: divisible imitated-solid and indivisible imitated-solid. The divisible imitated-solid is supposed to be constructed by the particles which can represent its basic characteristics, and here named it as "Micro-solid". The constructing guideline and mode of micro-solids in divisible imitated-solid is presented. In term of the guideline, the divisible imitated-solid can be portioned into two zones: kernel and boundary, and the micro-solids in these zones are classified into geometric micro-solids and dynamic micro-solids respectively. Based on the character of object in real machining environment, the indivisible imitated-solid can be classified into two formats: indivisible part imitated-solid and indivisible assembly imitated-solid. The principle and process of machining simulation based on imitated-solid theory is presented. Take NC turning as an example, the structure of imitated-solid machining simulation system is presented.3. According to the imitated-solid conception system for machining simulation, the key technologies for its realization in NC turning is discussed thoroughly, the modeling system for machining simulation is established.Based on the feature modeling technology, the geometric and apparent features of undivisible part imitated-solid are described in detail, the model of undivisible part imitated-solid is
developed. Based on the features of components in the real machine tools, the undivisible assembly imitated-solids can be formed by assembling undivisible part imitated-solids with certain positional relationship.According to the influence of cutting tool to the micrometric structure of workpiece in the machining process, the constructing structure of dynamic micro-solids in the workpiece imitated-solid kernel zone are determined. The dynamic micro-solid is supposed to be indiscerptible rigid body with certain mass which can reflect the essential characters of the workpiece material. Based on Morse potential energy function, the interacting relationship of dynamic micro-solids is developed. In terms of the second classical Newtonian equation of motion, the kinetic model of dynamic micro-solids is presented. Based on the aforementioned models, the turning simulation of workpiece imitated-solid kernel zone is realized.Introducing the fractal theory into the modeling of workpiece imitated-solid boundary zone, the fractal constructing structure model of boundary zone that unit length is increased in 2's exponents is developed. In terms of the revolving feature of the turning workpiece and its in-between shapes, the quasi-sector shape is determined to be the basic fractal shape for turning. Based on the constructing structure model and basic fractal shape, the model of workpiece imitated-solid boundary zone for turning is obtained, and the process simulation of boundary zone is realized.According to the twist shape of the natural curled chip, the basic shape for geometric micro-solid in chip imitated-solid is supposed to be quasi-sector shape. Though investigating the all kinds of factors affecting chips' forming and curling, the geometric parameters controlling the chip shape are caculated, and the natural curled chip model for different cutting parameter group which is resemble to the real circumstance is obtained. Based on the positional relationship of workpiece and cutting tool in the time of chip forming, the chip breaking model is presented, the function for chip classes judging is developed, the dynamic simulation for chip's forming, curling and breaking is realized.Aimed to the limitation of present NC code compiler, e.g. specialization and difficult tomaintain, a method of developing NC code compile module by using special compiling tools------Lex&Yacc is presented. By presenting the method of system customization, the compile module can adapt various codes from different NC system.Intergrated the aforementioned models together, the imitated-solid simulation system for NC turning is established. The 3D turning simulation which can describe the microscopical geometric and physical change of the material and its macroscopical interaction results is realized.
引文
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