基于UG & VERICUT的弧面凸轮多轴数控加工仿真实现
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摘要
弧面分度凸轮机构具有传动链短,精度高,运动平稳,转位可靠,转位与停歇时间比不受限制等优点,已成为机械行业中应用最为广泛的凸轮机构,尤其在数控机床、自动化生产线等领域应用日益普遍。然而,由于结构复杂,制造难度大,在承载能力、可靠性、使用寿命方面国产弧面分度凸轮机构与国外同类产品相比还存在较大差距。滞后的制造工艺严重影响了我国弧面分度凸轮机构产品的质量、效率和应用。因此,深入开展弧面凸轮的虚拟加工仿真技术研究对弧面凸轮实现快捷、高效、高质开发生产具有重要现实意义。为此,本文基于UG & VERICUT软件,通过阐述不同滚子类型弧面凸轮工作廓面方程,建立弧面凸轮多轴数控加工工艺,确立弧面凸轮多轴数控加工仿真方案,从而实现了弧面凸轮范成法和刀位偏置法的多轴数控加工程序仿真检验。具体研究工作如下：
1)综述弧面分度凸轮机构基本理论、弧面凸轮加工仿真的研究现状和存在的问题,对不同滚子类型的弧面凸轮工作廓面方程进行了系统阐述,同时建立了弧面凸轮范成法和刀位偏置法多轴数控加工工艺。
2)建立弧面凸轮多轴虚拟加工仿真环境。利用UG和VERICUT软件建立各相关部件及组件的三维实体模型,包括弧面凸轮零件,毛坯、刀具、用于加工弧面凸轮的DMU80T五轴加工中心的机床简化实体模型等。
3)完成了不同滚子类型弧面凸轮的范成法和刀位偏置法多轴数控加工自动编程。具体运用UG软件进行刀轨规划,生成刀位文件,并利用UG/Post Builder实现了DMU80T五轴加工中心后置处理器的定制,生成了可供加工仿真检验的NC程序。
4)实现了弧面凸轮范成法和刀位偏置法的多轴数控加工程序仿真检验。利用VERICUT软件对不同类型滚子弧面凸轮的范成法和刀位偏置法多轴数控加工程序进行仿真,可检查刀具轨迹和加工参数是否正确合理、加工过程是否存在干涉、过切等不合理现象,弧面凸轮在实际加工前其多轴数控加工程序能得到有效完整检验。
综上,本文的研究为弧面凸轮实现快捷、高效、高质开发生产提供了基于UG &VERICUT的弧面凸轮多轴数控加工编程仿真有效平台,也进一步完善了弧面凸轮的多轴数控加工工艺。
A globoidal cam mechanisim has some advantages of short transmission chain,high precision, smooth movement, reliable translocation, unrestricted ratio of translocation and the idle time, etc. So it has had a widespread availability in the fields such as NC machines, automatic production line, etc. However, the complex structure of globoidal cams makes it very difficult to manufacture. Presently, compared with foreign like products, the globoidal cams made in China have some drawbacks such as bad bearing capacity, unreliable performance, short service life, etc.. The lag manufacturing process has seriously impact on the domestic globoidal cam product quality, efficiency and application. Therefore, deep research on multi-axes CNC machining simulation for globoidal cams has important practical significance for rapid, efficient, and high-quality development and production. For this reason, based on UG&VERICUT, in order to realize the simulation verification of multi-axes CNC machining with the generation method and the tool offset method, globoidal cam profile surface equations for different type rollers are built and the multi-axes CNC machining technology and simulation program for globoidal cams are established in this paper. The main research works are as follows:
1) The present situation and problems about the design and manufacture theory of the globoidal cam mechanisms have been summarized. Globoidal cam profile surface equations of different type rollers are built and the multi-axes NC machining technology of the generation method and the tool offset method are proposed.
2) Globoidal cam multi-axes virtual machining simulation environment is built. Based on UG & VERICUT, the 3D solid models of the relevant parts and components are created including globoidal cam, roughcast, cutlery, simplify model of DMU80T five-axis machining center,etc..
3) The multi-axes CNC automatic programming of machining different type rollers with generation method and tool offset method are accomplished. Specifically, tool path planning is finished and cutter location file is geerated by applying UG software. Then the postprocessor of DMU80T five-axis machining center is by customized through UG/Post Builder. The generated NC program is available for machining simulation verification.
4)The simulation verification for multi-axes NC program of machining globoidal cams is realized with generation method and tool offset method. Applying VERICUT software, the multi-axes NC program simulation for different type rollers with generation method and tool offset method are realized. Whether the tool paths and processing parameters are reasonable or not and whether interference or gouge phenomenon is exited or not in machining process can all be checked. Then the multi-axes NC program can be effective verified before machining the globoidal cam practically.
In conclusion, in order to achieve rapid, efficient, and high-quality exploitation and production for globoidal cams, this paper provides an effective platform for multi-axes CNC programming and machining simulation for Globoidal cams based on UG & VERICUT. Also the multi-axes CNC machining technique for globoidal cams can be more improved.
1)综述弧面分度凸轮机构基本理论、弧面凸轮加工仿真的研究现状和存在的问题,对不同滚子类型的弧面凸轮工作廓面方程进行了系统阐述,同时建立了弧面凸轮范成法和刀位偏置法多轴数控加工工艺。
2)建立弧面凸轮多轴虚拟加工仿真环境。利用UG和VERICUT软件建立各相关部件及组件的三维实体模型,包括弧面凸轮零件,毛坯、刀具、用于加工弧面凸轮的DMU80T五轴加工中心的机床简化实体模型等。
3)完成了不同滚子类型弧面凸轮的范成法和刀位偏置法多轴数控加工自动编程。具体运用UG软件进行刀轨规划,生成刀位文件,并利用UG/Post Builder实现了DMU80T五轴加工中心后置处理器的定制,生成了可供加工仿真检验的NC程序。
4)实现了弧面凸轮范成法和刀位偏置法的多轴数控加工程序仿真检验。利用VERICUT软件对不同类型滚子弧面凸轮的范成法和刀位偏置法多轴数控加工程序进行仿真,可检查刀具轨迹和加工参数是否正确合理、加工过程是否存在干涉、过切等不合理现象,弧面凸轮在实际加工前其多轴数控加工程序能得到有效完整检验。
综上,本文的研究为弧面凸轮实现快捷、高效、高质开发生产提供了基于UG &VERICUT的弧面凸轮多轴数控加工编程仿真有效平台,也进一步完善了弧面凸轮的多轴数控加工工艺。
A globoidal cam mechanisim has some advantages of short transmission chain,high precision, smooth movement, reliable translocation, unrestricted ratio of translocation and the idle time, etc. So it has had a widespread availability in the fields such as NC machines, automatic production line, etc. However, the complex structure of globoidal cams makes it very difficult to manufacture. Presently, compared with foreign like products, the globoidal cams made in China have some drawbacks such as bad bearing capacity, unreliable performance, short service life, etc.. The lag manufacturing process has seriously impact on the domestic globoidal cam product quality, efficiency and application. Therefore, deep research on multi-axes CNC machining simulation for globoidal cams has important practical significance for rapid, efficient, and high-quality development and production. For this reason, based on UG&VERICUT, in order to realize the simulation verification of multi-axes CNC machining with the generation method and the tool offset method, globoidal cam profile surface equations for different type rollers are built and the multi-axes CNC machining technology and simulation program for globoidal cams are established in this paper. The main research works are as follows:
1) The present situation and problems about the design and manufacture theory of the globoidal cam mechanisms have been summarized. Globoidal cam profile surface equations of different type rollers are built and the multi-axes NC machining technology of the generation method and the tool offset method are proposed.
2) Globoidal cam multi-axes virtual machining simulation environment is built. Based on UG & VERICUT, the 3D solid models of the relevant parts and components are created including globoidal cam, roughcast, cutlery, simplify model of DMU80T five-axis machining center,etc..
3) The multi-axes CNC automatic programming of machining different type rollers with generation method and tool offset method are accomplished. Specifically, tool path planning is finished and cutter location file is geerated by applying UG software. Then the postprocessor of DMU80T five-axis machining center is by customized through UG/Post Builder. The generated NC program is available for machining simulation verification.
4)The simulation verification for multi-axes NC program of machining globoidal cams is realized with generation method and tool offset method. Applying VERICUT software, the multi-axes NC program simulation for different type rollers with generation method and tool offset method are realized. Whether the tool paths and processing parameters are reasonable or not and whether interference or gouge phenomenon is exited or not in machining process can all be checked. Then the multi-axes NC program can be effective verified before machining the globoidal cam practically.
In conclusion, in order to achieve rapid, efficient, and high-quality exploitation and production for globoidal cams, this paper provides an effective platform for multi-axes CNC programming and machining simulation for Globoidal cams based on UG & VERICUT. Also the multi-axes CNC machining technique for globoidal cams can be more improved.
引文
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[3]陆金贵.凸轮制造技术[M].北京：机械工业出版社,1986.
[4]杨冬香.弧面分度凸轮机构CAD/CAM/CNC集成研究[D].湘潭：湘潭大学,2007.
[5]刘艳申,朱航科.弧面凸轮专用数控机床的研究[J].机械工程师,2008,(6)：64-65.
[6]刘艳申,曹巨江.弧面凸轮专用数控机床的研究与开发[J].机床与液压,2008,36(9)：81-82.
[7]韩伟.五坐标加工弧面凸轮数控铣床的虚拟样机研究与开发[D].陕西：陕西科技大学,2004.
[8]刘向红.弧面凸轮专用数控机床方案研究[J].制造技术与机床,2005,(7)：22-23.
[9]曹巨江,赵云龙等.一种加工弧面凸轮及复杂曲面零件用数控铣床[P].中国专利：03218823,2004-05-19.
[10]杨延峰,张跃明,张玲爱,等.弧而分度凸轮廓而的加工[J].现代制造工程,2005,(5)：69-72.
[11]Tsay D M, Ho H C. Consideration of Manufacturing Parameters in the Design of Grooved Glohoidal Cam Indexing Mechanisms[J]. Journal of Engineering Manufacture,2001,215(1): 95-103.
[12]滕皓,蔡卫东等.圆柱分度凸轮非等径数控加工自动编程[J].济南大学学报,2003,17(2)：188-190.
[13]杨玮,曹巨江.弧面凸轮机构的压力角与曲率分析[J].机械科学与技术,2004,23(1)：74-76.
[14]高秀兰,雷改丽,白静,等.圆柱滚子空间凸轮的两重包络法加工分析与改进[J].轻工机械,2005,(2)：78-80.
[15]彭国勋,肖正扬,王其超.滚子齿传动机构空间凸轮的数控加工[J].组合机床与自动化加工技术,1990,(6)：12-14.
[16]薛红前,田惠民.圆柱凸轮廓面的不完全坐标测量与范成法加工[J].机械科学与技术,1996,15(4)：598-600.
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