切屑折断过程及其仿真的研究
摘要
随着现代机械制造业向着自动化、集成化、智能化的先进制造模式方向的发展,实现理想切削加工过程的一个主要问题是切屑控制问题。本文主要通过计算机仿真技术来实现车削加工过程中的切屑控制仿真。
基于切屑形成、卷曲、折断机理及其数学模型的研究,通过对不同类型切屑形成、卷曲、折断机理的分析,讨论了切屑生成、卷曲和折断的规律。提出了一种几何特征造型法,即“基于四边形拓扑造型法”,讨论了仿真几何模型的构建和具体算法;并进一步分析了在切屑参数改变的情况下驱动切屑的类型和尺寸所发生的变化,实现了不同切削参数下切屑的实体造型。
在Visual C++6.0编程环境下,采用目前广泛使用的图形标准格式OpenGL作为开发平台,利用其特有的双缓存功能,加速了切屑仿真图形的实现,并将其融入车削加工仿真过程中,实现了切屑生成与工件材料去除过程的无缝连接。
实现了切屑形成与折断过程的建模、仿真。通过两次数学模型的解算,得出切屑形成参数及切屑运动轨迹参数,再将各参数通过坐标变换转换到同一坐标系统中,然后通过对生成切屑段的坐标跟踪,以及所得坐标值和障碍物坐标在相同坐标系统中的分析和比较,监测车削运动过程中切屑与工件及刀具的接触情况。建立了切屑折断的条件判别式,并由此判断切屑的类型及其折断。
本系统操作简便,有较好的实时性、交互性和可移植性,对车削加工具有一定的参考作用。
研究成果对缩短数控刀片的生产周期以及刀片在生产应用中的断屑预报系统的研究打下有力的基础。
With contemporary machinery manufacturing converting to automatic, integrated and integrated and intelligent advanced manufacture mode, chip control is crucial in order to realize ideal mechanical manufacture process. This thesis implements the simulation of chip control in turning process through computer simulation technology.
Mathematics models for chip’s simulation is established according to the mechanism of it’s generation. The regulations of chip’s generation, curling and breaking is analyzed by studying the different of chip-forming theories. A method of chip’s geometry feature modeling which is based on quadrangle developing is presented. Furthermore this dissertation analyzes the changing of chip’s varieties and sizes under the conditions of cutting parameter’s changing, realizes the chip and the solid feature simulation modeling with different cutting parameters. Under condition of Visual C++6.0 programme, OpenGL as the developing tool is applied. The double buffers of OpenGL make the realization to the graph of chip’s simulation more quickly. The chip simulation is embedded in turning process simulation in real-time, which realizes the seamless connection between the generation of chip and the removal of material.
Get the needing parameter through twice calculating of mathematics models. Changing parameters to the same reference frame through reference transforming. Check-up the collided between chip, piece and tool in turning process of through coordinate track of the part of chip generation, and analyzed the coordinate of them in the same coordinate.
With a preferable real-time, interactive and transplantable characteristics, this system can be manipulated simply and will have a broader perspective for application.
The results of this research that provided the foundation for shortening production cycle of numerical tool and chip breaking forecasting of tool in
基于切屑形成、卷曲、折断机理及其数学模型的研究,通过对不同类型切屑形成、卷曲、折断机理的分析,讨论了切屑生成、卷曲和折断的规律。提出了一种几何特征造型法,即“基于四边形拓扑造型法”,讨论了仿真几何模型的构建和具体算法;并进一步分析了在切屑参数改变的情况下驱动切屑的类型和尺寸所发生的变化,实现了不同切削参数下切屑的实体造型。
在Visual C++6.0编程环境下,采用目前广泛使用的图形标准格式OpenGL作为开发平台,利用其特有的双缓存功能,加速了切屑仿真图形的实现,并将其融入车削加工仿真过程中,实现了切屑生成与工件材料去除过程的无缝连接。
实现了切屑形成与折断过程的建模、仿真。通过两次数学模型的解算,得出切屑形成参数及切屑运动轨迹参数,再将各参数通过坐标变换转换到同一坐标系统中,然后通过对生成切屑段的坐标跟踪,以及所得坐标值和障碍物坐标在相同坐标系统中的分析和比较,监测车削运动过程中切屑与工件及刀具的接触情况。建立了切屑折断的条件判别式,并由此判断切屑的类型及其折断。
本系统操作简便,有较好的实时性、交互性和可移植性,对车削加工具有一定的参考作用。
研究成果对缩短数控刀片的生产周期以及刀片在生产应用中的断屑预报系统的研究打下有力的基础。
With contemporary machinery manufacturing converting to automatic, integrated and integrated and intelligent advanced manufacture mode, chip control is crucial in order to realize ideal mechanical manufacture process. This thesis implements the simulation of chip control in turning process through computer simulation technology.
Mathematics models for chip’s simulation is established according to the mechanism of it’s generation. The regulations of chip’s generation, curling and breaking is analyzed by studying the different of chip-forming theories. A method of chip’s geometry feature modeling which is based on quadrangle developing is presented. Furthermore this dissertation analyzes the changing of chip’s varieties and sizes under the conditions of cutting parameter’s changing, realizes the chip and the solid feature simulation modeling with different cutting parameters. Under condition of Visual C++6.0 programme, OpenGL as the developing tool is applied. The double buffers of OpenGL make the realization to the graph of chip’s simulation more quickly. The chip simulation is embedded in turning process simulation in real-time, which realizes the seamless connection between the generation of chip and the removal of material.
Get the needing parameter through twice calculating of mathematics models. Changing parameters to the same reference frame through reference transforming. Check-up the collided between chip, piece and tool in turning process of through coordinate track of the part of chip generation, and analyzed the coordinate of them in the same coordinate.
With a preferable real-time, interactive and transplantable characteristics, this system can be manipulated simply and will have a broader perspective for application.
The results of this research that provided the foundation for shortening production cycle of numerical tool and chip breaking forecasting of tool in
引文
1 黄雪梅,高国利,王启义.拟实制造的机械加工过程仿真.机械制造,2000,18(12):12~15
2 王玉生,马正元,王迎春等.虚拟加工系统运动仿真的研究.沈阳工业大学学报,2004,26(6):23~26
3 王小彬,王太勇,李宏伟等.虚拟制造中数控加工过程三维仿真技术的研究.机床与液压,2004,23(6):13~16
4 周凡,潘振显,毛勋才等.数控车削加工过程仿真系统的研究.组合机床和自动化技工技术,2004,13(5):20~23
5 熊光楞.计算机仿真及其在机械制造业的应用.计算机仿真,1996,1(13):31~34
6 赵玢,施志辉,孔宪庶等.切屑生成、卷曲、折断过程的实时仿真研究.组合机床与自动化加工技术,2000:12~15
7 施志辉,赵玢,王启义等.金属切削加工切屑形成过程仿真技术.大连铁道学院学报,2000,9(21):64~68
8 葛研军,施志辉,沙智华等.车削加工屑型建模与仿真技术研究.计算机辅助设计与图形学报,2002,10(14):922~927
9 向世明.OpenGL 编程与实例.电子工业出版社,2000
10 老虎工作室编著.OpenGL 编程实例与技巧.人民邮电出版社,2000
11 平鸽工作室编著.OpenGL 三维图形系统开发与实用技术.清华大学出版社,2004
12 冠科技.VisualC++6.0 时尚编程百例.机械工业出版社,2001
13 王华.VisualC++6.0 编程实例与技巧.机械工业出版社,2003
14 王占礼,王尧,杜爽等.利用 Visual C++6.0 和 OpenGL 实现数控铣削加工仿真.机电产品开发与创新,2005,18(6):137~139
15 I.stopher J.Chuter,S.Ramaswamy and K.S.Barber.A Virtual Environment for Construction and Analysis of Manufacturing Prototypes.ASME,2005:927~932
16 李振加,郑敏利,徐亦红等.切屑折断过程研究.机械工业出版社,1996
17 郑敏利.切屑形成与折断过程及其预报系统.黑龙江科学技术出版社,2001
18 中山一雄.金属切削加工理论.李云芳译.机械工业出版社,1985
19 A.Kharkevich.,K.Patri Venuvinod.Basic geometric analysis of 3-D chip forms in metal cutting.Machine Tool & Manufacture,1999,39:755~762
20 陈永洁,方宁,师汉民等.切屑的三维卷曲流动.华中理工大学学报,1993,21(4):1~6
21 李振加,吴雪松,杨永芝等.切屑折断过程研究.大连理工大学出版社,1990
22 李振加,郑敏利,韦银利等.切屑空间运动轨迹及其约束方程的研究.机械工程学报,2001,12(37):42~46
23 李振加,魏雪冬,郑敏利等.切屑折断过程与槽型 CAD 专家系统.机械工业出版社,1996
24 吴丽君.切屑形成和折断的仿真与虚拟现实.硕士学位论文,哈尔滨理工大学,2003
25 吴丽君.在虚拟现实环境下切屑空间运动轨迹的基础研究.黑龙江工程学院学报,2003,1(17):11~14
26 韦银利,李振加,郑敏利.切屑空间运动轨迹的数学模型及其动态仿真. 哈尔滨理工大学学报.2000,(5)
27 李振加.横向卷曲 C 形屑折断数学模型及试验研究.机械工程学报,1997,33(1):33~38
28 李振加,曲贵民,董丽华等.横向卷曲短螺卷屑折断数学模型与折断判据.机械工程学报,1996,32(6):105~110
29 郑敏利,李振加,韦银利等.形成切屑向上弯曲非折断插入区的理论研究.机械工程学报,2001,37(8):106~109
30 Id W.Rosen,Bert Bras,Farrokh Mistree.Virtual Prototyping for Product Remanufacture and Service Using a Virtual Design Studio Approach.ASME,2005:951~958
31 钱能.C++程序设计教程.清华大学出版社,2001
32 侯杰.深入浅出 MFC.第二版.华中科技大学出版社,2003
33 周江华,蔡忠闽,李宏等.基于 OpenGL 的制造系统虚拟仿真环境研究.测控技术,2003,19(7):22~25
34 Dinesh K.Pai,Juhani Siira,Kees van den Doel.Interactive Simulation of Physical Systems in Virtual Environments.SIVE,2003:169~171
35 X.Daniel Fang.Using Virtual Reality in Engineering Education.Proceedingsof the 58th Annual American Society of Engineering Education,2005,10:IVA-1.1~IVA-1.9
36 熊光楞.先进仿真技术与仿真环境.国防工业出版社,1997
37 邓子琼.柔性制造系统建模及仿真.国防工业出版社,1993
38 韦有双,王飞,冯允成.虚拟现实与系统仿真[J].计算机仿真,2004,16(2):63~66
39 V.ColwellPredicting . The Angle of Chip Flow for Single Point Cutting Tools.ASME,1954,76(2):199~202
40 Jurgen,Gausemeier.The Visualization of Automized Manufacturing Processes in a Virtual Enterprise.ASME,1995:921~926
41 Richard Taylor,Gary Bayliss,Adrian Bowyer and Philip Willis.A Virtual Workshop for Design by Manufacture.ASME,2003:921~926
42 K.Nakayam , M.Ogawa . Basic rules on the form of chip in metal cutting.Annals of the CIRP,1978,27(1):17~21
43 K.Nakayama,M.Arai.Comprehensive chip form classification based on the cutting mechanism.Annals of the CIRP,1992,41(1):71~74
44 周泽华.金属切屑原理.第二版.上海科学技术出版社,1997:15~33
45 张幼桢.金属切削理论.航空工业出版社,1988:50~64
2 王玉生,马正元,王迎春等.虚拟加工系统运动仿真的研究.沈阳工业大学学报,2004,26(6):23~26
3 王小彬,王太勇,李宏伟等.虚拟制造中数控加工过程三维仿真技术的研究.机床与液压,2004,23(6):13~16
4 周凡,潘振显,毛勋才等.数控车削加工过程仿真系统的研究.组合机床和自动化技工技术,2004,13(5):20~23
5 熊光楞.计算机仿真及其在机械制造业的应用.计算机仿真,1996,1(13):31~34
6 赵玢,施志辉,孔宪庶等.切屑生成、卷曲、折断过程的实时仿真研究.组合机床与自动化加工技术,2000:12~15
7 施志辉,赵玢,王启义等.金属切削加工切屑形成过程仿真技术.大连铁道学院学报,2000,9(21):64~68
8 葛研军,施志辉,沙智华等.车削加工屑型建模与仿真技术研究.计算机辅助设计与图形学报,2002,10(14):922~927
9 向世明.OpenGL 编程与实例.电子工业出版社,2000
10 老虎工作室编著.OpenGL 编程实例与技巧.人民邮电出版社,2000
11 平鸽工作室编著.OpenGL 三维图形系统开发与实用技术.清华大学出版社,2004
12 冠科技.VisualC++6.0 时尚编程百例.机械工业出版社,2001
13 王华.VisualC++6.0 编程实例与技巧.机械工业出版社,2003
14 王占礼,王尧,杜爽等.利用 Visual C++6.0 和 OpenGL 实现数控铣削加工仿真.机电产品开发与创新,2005,18(6):137~139
15 I.stopher J.Chuter,S.Ramaswamy and K.S.Barber.A Virtual Environment for Construction and Analysis of Manufacturing Prototypes.ASME,2005:927~932
16 李振加,郑敏利,徐亦红等.切屑折断过程研究.机械工业出版社,1996
17 郑敏利.切屑形成与折断过程及其预报系统.黑龙江科学技术出版社,2001
18 中山一雄.金属切削加工理论.李云芳译.机械工业出版社,1985
19 A.Kharkevich.,K.Patri Venuvinod.Basic geometric analysis of 3-D chip forms in metal cutting.Machine Tool & Manufacture,1999,39:755~762
20 陈永洁,方宁,师汉民等.切屑的三维卷曲流动.华中理工大学学报,1993,21(4):1~6
21 李振加,吴雪松,杨永芝等.切屑折断过程研究.大连理工大学出版社,1990
22 李振加,郑敏利,韦银利等.切屑空间运动轨迹及其约束方程的研究.机械工程学报,2001,12(37):42~46
23 李振加,魏雪冬,郑敏利等.切屑折断过程与槽型 CAD 专家系统.机械工业出版社,1996
24 吴丽君.切屑形成和折断的仿真与虚拟现实.硕士学位论文,哈尔滨理工大学,2003
25 吴丽君.在虚拟现实环境下切屑空间运动轨迹的基础研究.黑龙江工程学院学报,2003,1(17):11~14
26 韦银利,李振加,郑敏利.切屑空间运动轨迹的数学模型及其动态仿真. 哈尔滨理工大学学报.2000,(5)
27 李振加.横向卷曲 C 形屑折断数学模型及试验研究.机械工程学报,1997,33(1):33~38
28 李振加,曲贵民,董丽华等.横向卷曲短螺卷屑折断数学模型与折断判据.机械工程学报,1996,32(6):105~110
29 郑敏利,李振加,韦银利等.形成切屑向上弯曲非折断插入区的理论研究.机械工程学报,2001,37(8):106~109
30 Id W.Rosen,Bert Bras,Farrokh Mistree.Virtual Prototyping for Product Remanufacture and Service Using a Virtual Design Studio Approach.ASME,2005:951~958
31 钱能.C++程序设计教程.清华大学出版社,2001
32 侯杰.深入浅出 MFC.第二版.华中科技大学出版社,2003
33 周江华,蔡忠闽,李宏等.基于 OpenGL 的制造系统虚拟仿真环境研究.测控技术,2003,19(7):22~25
34 Dinesh K.Pai,Juhani Siira,Kees van den Doel.Interactive Simulation of Physical Systems in Virtual Environments.SIVE,2003:169~171
35 X.Daniel Fang.Using Virtual Reality in Engineering Education.Proceedingsof the 58th Annual American Society of Engineering Education,2005,10:IVA-1.1~IVA-1.9
36 熊光楞.先进仿真技术与仿真环境.国防工业出版社,1997
37 邓子琼.柔性制造系统建模及仿真.国防工业出版社,1993
38 韦有双,王飞,冯允成.虚拟现实与系统仿真[J].计算机仿真,2004,16(2):63~66
39 V.ColwellPredicting . The Angle of Chip Flow for Single Point Cutting Tools.ASME,1954,76(2):199~202
40 Jurgen,Gausemeier.The Visualization of Automized Manufacturing Processes in a Virtual Enterprise.ASME,1995:921~926
41 Richard Taylor,Gary Bayliss,Adrian Bowyer and Philip Willis.A Virtual Workshop for Design by Manufacture.ASME,2003:921~926
42 K.Nakayam , M.Ogawa . Basic rules on the form of chip in metal cutting.Annals of the CIRP,1978,27(1):17~21
43 K.Nakayama,M.Arai.Comprehensive chip form classification based on the cutting mechanism.Annals of the CIRP,1992,41(1):71~74
44 周泽华.金属切屑原理.第二版.上海科学技术出版社,1997:15~33
45 张幼桢.金属切削理论.航空工业出版社,1988:50~64