数字化机床建模及其切削仿真技术研究
摘要
数控加工过程仿真技术是数字化制造技术的一个重要组成部分,是数字化制造系统各种后期产品评价方法的实现基础之一,是实现数字化制造系统并保证该系统有效性与适用性的关键。
本文对数字化制造技术中数字化机床建模和切削过程仿真技术进行了深入研究,针对数控加工仿真系统可重构性与可扩展性的需求和数控系统产品种类繁多的特点,采用了面向对象技术对数字化机床仿真系统进行了总体研究和设计,并提出了模块化设计方案来建立数字化机床的加工仿真环境。本文主要进行的工作如下:
1.根据数字化机床的现有研究成果和发展趋势,总结并提出了数字化机床的设计准则和分解原则;根据数控加工仿真系统的功能需求,采用面向对象技术对数字化机床仿真系统进行了总体设计,建立了该系统的各个抽象对象类,并对数字化车床和铣床仿真系统的总体结构及其各个模块进行了研究和设计。
2.通过对数字化机床仿真系统几何建模方法的详细研究,采用图形功能强大的3DS Max软件对数字化机床进行三维建模,并以OpenGL为图形接口将其导入仿真系统中,提高了模型构建的速度;自行设计了3DS文件与OpenGL的接口程序。
3.采用基于Z-MAP的三角网格离散方法来实现毛坯材料去除仿真过程。根据数控加工过程的具体特征提出了三维仿真加工零件的实体表达模型及其数据结构;针对车削和铣削过程中零件模型的特点,提出了铣削和车削过程中基于三角网格方法的毛坯算法模型。
4.根据本文提出的建模方法,对数字化机床仿真系统进行了设计和开发,研制了一个美观大方、真实感强、图文并茂的仿真环境;并针对研制过程中涉及到的相关技术进行了设计,比如加工环境的建模方法、数控程序译码过程、虚拟操作面板、刀具库的定义以及夹具库的定义等,提出了数字化机床仿真系统的开发方案。
本系统采用面向对象的程序设计方法,开发的程序具有封装、继承、多态等优点,减少了程序的数据污染,增加了程序的易开发性、可读性、可维护性和可移植性,大大提高了系统的编程效率。
The simulation technology of digital machining process is a key component of digital manufacturing system,and is one of the foundations of evaluation methods during product development. It is the crucial to realize digital manufacture system, and to ensure the validity and applicability of the system.
In this dissertation, the simulation and modelling technology of NC machining process has been studied deeply. Aiming at the expandability of digital machining system and the reconfigurability of machining process controller for different NC systems, the object-oriented idea is adopted to analyze and design digital machine simulation system,and the modular design method is proposed to set up a process simulation environment of the digital machining platform. The main content of this dissertation is as follows:
1.According to existing achievements and development of digital machining,the rules and principles of design is primarily discussed in the dissertation;According to the function requirements of the NC machining simulation,the digital machine simulation system is analyzed and designed with object-oriented method;And the base classes of digital turning and mliing machine system is established,which also introduces the whole configuration and every modules of the simulation system.
2.Based on particularly researching the modeling methods of the geometric model,the digital machine simulation system adopts 3ds Max to realize the 3D modeling of static entities, which is saved as 3ds format. Then use OpenGL and VC++ as the development tool to import the 3ds file into the simulation system to realize modeling of digital equipments,which can accelerate the digital manufacturing system running.And design a interface program between 3DS files and OpenGL.
3.The discretization of triangle mesh which is based on Z-MAP structure has been used in the dynamic simulation of machining process, which effectively solves the anamorphic animation of the model. The 3-D solid representation models and their data structures of machined parts are presented based on the characteristics of turning and milling processes. Upon on both structures, the milling model and turning model based on the method of triangle piece is presented.
4.According to the modeling method in the paper,the system has developed a prototype of digital machine simulation system for digital manufacturing, and designed a beautiful 3D simulating environment which has graphics and music. And some key problems of develop are studied,such as the processing environment modeling method, NC program decoding process, interpolation method, cutter magazine for the definition and so on.
This system adopts target's procedure design method, the procedure that develops has advantages, such as encapsulation, inheriting, much attitudes, etc, the data which have reduced the procedure are polluted, increase exchanging exploration,readability ,portability and maintainability of the procedure, have improved systematic programming efficiency greatly.
本文对数字化制造技术中数字化机床建模和切削过程仿真技术进行了深入研究,针对数控加工仿真系统可重构性与可扩展性的需求和数控系统产品种类繁多的特点,采用了面向对象技术对数字化机床仿真系统进行了总体研究和设计,并提出了模块化设计方案来建立数字化机床的加工仿真环境。本文主要进行的工作如下:
1.根据数字化机床的现有研究成果和发展趋势,总结并提出了数字化机床的设计准则和分解原则;根据数控加工仿真系统的功能需求,采用面向对象技术对数字化机床仿真系统进行了总体设计,建立了该系统的各个抽象对象类,并对数字化车床和铣床仿真系统的总体结构及其各个模块进行了研究和设计。
2.通过对数字化机床仿真系统几何建模方法的详细研究,采用图形功能强大的3DS Max软件对数字化机床进行三维建模,并以OpenGL为图形接口将其导入仿真系统中,提高了模型构建的速度;自行设计了3DS文件与OpenGL的接口程序。
3.采用基于Z-MAP的三角网格离散方法来实现毛坯材料去除仿真过程。根据数控加工过程的具体特征提出了三维仿真加工零件的实体表达模型及其数据结构;针对车削和铣削过程中零件模型的特点,提出了铣削和车削过程中基于三角网格方法的毛坯算法模型。
4.根据本文提出的建模方法,对数字化机床仿真系统进行了设计和开发,研制了一个美观大方、真实感强、图文并茂的仿真环境;并针对研制过程中涉及到的相关技术进行了设计,比如加工环境的建模方法、数控程序译码过程、虚拟操作面板、刀具库的定义以及夹具库的定义等,提出了数字化机床仿真系统的开发方案。
本系统采用面向对象的程序设计方法,开发的程序具有封装、继承、多态等优点,减少了程序的数据污染,增加了程序的易开发性、可读性、可维护性和可移植性,大大提高了系统的编程效率。
The simulation technology of digital machining process is a key component of digital manufacturing system,and is one of the foundations of evaluation methods during product development. It is the crucial to realize digital manufacture system, and to ensure the validity and applicability of the system.
In this dissertation, the simulation and modelling technology of NC machining process has been studied deeply. Aiming at the expandability of digital machining system and the reconfigurability of machining process controller for different NC systems, the object-oriented idea is adopted to analyze and design digital machine simulation system,and the modular design method is proposed to set up a process simulation environment of the digital machining platform. The main content of this dissertation is as follows:
1.According to existing achievements and development of digital machining,the rules and principles of design is primarily discussed in the dissertation;According to the function requirements of the NC machining simulation,the digital machine simulation system is analyzed and designed with object-oriented method;And the base classes of digital turning and mliing machine system is established,which also introduces the whole configuration and every modules of the simulation system.
2.Based on particularly researching the modeling methods of the geometric model,the digital machine simulation system adopts 3ds Max to realize the 3D modeling of static entities, which is saved as 3ds format. Then use OpenGL and VC++ as the development tool to import the 3ds file into the simulation system to realize modeling of digital equipments,which can accelerate the digital manufacturing system running.And design a interface program between 3DS files and OpenGL.
3.The discretization of triangle mesh which is based on Z-MAP structure has been used in the dynamic simulation of machining process, which effectively solves the anamorphic animation of the model. The 3-D solid representation models and their data structures of machined parts are presented based on the characteristics of turning and milling processes. Upon on both structures, the milling model and turning model based on the method of triangle piece is presented.
4.According to the modeling method in the paper,the system has developed a prototype of digital machine simulation system for digital manufacturing, and designed a beautiful 3D simulating environment which has graphics and music. And some key problems of develop are studied,such as the processing environment modeling method, NC program decoding process, interpolation method, cutter magazine for the definition and so on.
This system adopts target's procedure design method, the procedure that develops has advantages, such as encapsulation, inheriting, much attitudes, etc, the data which have reduced the procedure are polluted, increase exchanging exploration,readability ,portability and maintainability of the procedure, have improved systematic programming efficiency greatly.
引文
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[2] W.B. Lee,C.F.Cheung,J.G.Li.Application of virtual manufacturing in materials processing [J].Journal of Materials Processing Technology,2001(113):416~423
[3] Lee K.I.,Noh S.D..Virtual manufacturing system-a lest bed of engineering activities.Annals of the CIRP,1997,46(1):347~350
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[11] 罗垂敏.数字化制造技术.无线电电子学与电信技术,2006,26(2):8~10
[12] 潘紫微.数字化设计与制造的进程与发展.安徽工业大学学报,2003,20(4):2~3
[13] 孙林夫.面向产品开发过程的数字化设计技术研究.计算机集成制造系统,2003,9(12):1088~1091
[14] 谭同德,乔木,吴博.基于 OpenGL 的虚拟环境建模技术的研究.中州大学学报,2005,22(4):99~100
[15] 余斌.基于 OpenGL 的数控加工仿真系统的研究与开发:[硕士学位论文].成都:四川大学,2002
[16] 严隽琪.数字化与网络化制造.工业工程与管理,2000(1):8~11
[17] 杨海成.制造业信息化工程总体实施方案.航空制造技术,2002,(7):17~22
[18] 李军锋,李剑,席平.数控加工仿真技术及应用.计算机仿真,2003,20(4):92~95
[19] 王霄,刘会霞,杨润党,等.虚拟设备的建模和加工过程仿真技术.中国机械工程,2003,14(17):1489~1492
[20] 黄雪梅.虚拟数控车削物理仿真模型及实用系统的开发.机电工程,17(6):48~49
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[22] 罗亚波,陈定方,肖田元.远程数控仿真的一种编程实现方法.武汉理工大学学报,2004,28(1):62~65
[23] 张怀宇.基于 VRML 的数控加工仿真系统的研究与实现:[硕士学位论文].成都:四川大学,2002
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[26] 杨岳,罗意平,刘德福,等.一种基于真实预切削的三维数控加工仿真系统.制造业自动化,2002,24(1):10~14
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[28] 罗亚波,陈定方.图像与建模相结合的虚拟现实关键技术.交通与计算机,2000,18(6):58~60
[29] 杨海成,敬石开,和延立,等.数字化制造的研究发展与应用实践.数字制造科学,2003,1(1/4):39~51
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