基于VERICUT的数控钢轨精磨机加工仿真
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摘要
随着中国铁路建设的发展,铁路运输朝着高速、安全、舒适的方向迈进,钢轨作为承载机车车辆运行的媒介,更是在铁路建设中有着举足轻重的作用,高速铁路的发展,极大的推动了无缝钢轨在高速铁路中的应用。
在无缝钢轨加工的过程中,将标准长度的钢轨焊接成轨道,在焊接接头的地方,会产生焊瘤,如何高效的处理焊瘤就成为了制约无缝钢轨在高速铁路中应用的关键。
传统的无缝钢轨焊缝处理手段效率低下,显然无法满足无缝钢轨在高速铁路建设中的需求。因此急需高自动化的、适用于车间生产的钢轨打磨设备对钢轨焊接接头进行处理。国内外许多科研机构和机床生产厂家,如上海理工大学附属二厂、法国的拉伊台克公司和吉斯玛公司等,都对无缝钢轨精磨机进行了研究,并设计有产品在生产应用。国内的焊轨厂大多采用进口国外的磨削机床对钢轨焊缝进行处理,而进口设备存在价格高、代价大、操作学习周期长、维修不便和语言障碍等弊端。
面对国内外钢轨焊缝处理的现状,在导师的指导下,产生了一种新的钢轨焊缝磨削的方法,提出数控仿形磨削的无缝钢轨焊缝磨削方案,利用数控插补的原理,以VERICUT数控仿真软件为平台,建立数控钢轨精磨机机床模型,并根据加工对象编写数控加工程序——G-代码。在磨削加工过程中,磨床的打磨头按照数控程序编制的轨迹运行,精确磨出形面。最后,应用VERICUT仿真软件的AUTO-DIFF(自动检测)功能对加工模型的加工质量与设计模型要求的加工质量进行比较检测,应用VERICUT仿真软件的OptiPath(优化)功能,对编写的数控加工程序进行优化。
With the development of railway construction in China, the railway transportation toward in the direction of high-speed, safety, and comfort. The rail is playing an important role as a medium for carrying the rolling stock. The development of the high-speed railway, greatly promoted the continuously welded rails in application of the high-speed railway.
When the standard length of rail is welded into railway in the course of the continuously welded rails processing, there is overlap which appears in the welded joint. It is a critical that conditions the continuously welded rail using in the high-speed railway, about how effective to deal with the overlap.
The traditional means about the overlap of the continuously welded rail are inefficient, obviously, the existing continuously welded rail can not meet the demand for the high-speed railway construction. Therefore, the high automation and apply to workshop production rail grinding equipment is needed for processing of the railway welded joint. Many domestic and foreign research institutions and machine tool manufactures, like University of Shanghai for Science and technology subordinate shopⅡ, Railtech International France company and GEISMAR France company. They researched on the continuously welded rail grinding machine, and there are productions using in practice. Most of the domestic rail welding factory imported the grinding machine tool abroad for processing the overlap of the continuously welded rail, however, there are high price, cost of large, long learning cycle operation, inconvenient maintenance, language barriers and so on disadvantages for the imported machine.
There is a new method for grinding the overlap of the railway, facing to the domestic and international status about the overlap of the railway process. It proposes the application of the concept of the numerical control profile grinding, using numerical control interpolation principles and the VERICUT numerical control simulation software platform, then, refining the model of the numerical control railway grinding machine tool, and programming the G-code according to the processing objects. In the grinding process, the grinding wheel of the grinding machine accordance with the numerical control program to run the track, and precise grind-shaped surface. Finally, compare the surface of the processing model with the design model, by using AUTO-DIFF (automatic detection) which is the function of the VERICUT simulation software, and using OptiPath (optimization) which is the function of the VERICUT simulation software optimize the numerical control program.
在无缝钢轨加工的过程中,将标准长度的钢轨焊接成轨道,在焊接接头的地方,会产生焊瘤,如何高效的处理焊瘤就成为了制约无缝钢轨在高速铁路中应用的关键。
传统的无缝钢轨焊缝处理手段效率低下,显然无法满足无缝钢轨在高速铁路建设中的需求。因此急需高自动化的、适用于车间生产的钢轨打磨设备对钢轨焊接接头进行处理。国内外许多科研机构和机床生产厂家,如上海理工大学附属二厂、法国的拉伊台克公司和吉斯玛公司等,都对无缝钢轨精磨机进行了研究,并设计有产品在生产应用。国内的焊轨厂大多采用进口国外的磨削机床对钢轨焊缝进行处理,而进口设备存在价格高、代价大、操作学习周期长、维修不便和语言障碍等弊端。
面对国内外钢轨焊缝处理的现状,在导师的指导下,产生了一种新的钢轨焊缝磨削的方法,提出数控仿形磨削的无缝钢轨焊缝磨削方案,利用数控插补的原理,以VERICUT数控仿真软件为平台,建立数控钢轨精磨机机床模型,并根据加工对象编写数控加工程序——G-代码。在磨削加工过程中,磨床的打磨头按照数控程序编制的轨迹运行,精确磨出形面。最后,应用VERICUT仿真软件的AUTO-DIFF(自动检测)功能对加工模型的加工质量与设计模型要求的加工质量进行比较检测,应用VERICUT仿真软件的OptiPath(优化)功能,对编写的数控加工程序进行优化。
With the development of railway construction in China, the railway transportation toward in the direction of high-speed, safety, and comfort. The rail is playing an important role as a medium for carrying the rolling stock. The development of the high-speed railway, greatly promoted the continuously welded rails in application of the high-speed railway.
When the standard length of rail is welded into railway in the course of the continuously welded rails processing, there is overlap which appears in the welded joint. It is a critical that conditions the continuously welded rail using in the high-speed railway, about how effective to deal with the overlap.
The traditional means about the overlap of the continuously welded rail are inefficient, obviously, the existing continuously welded rail can not meet the demand for the high-speed railway construction. Therefore, the high automation and apply to workshop production rail grinding equipment is needed for processing of the railway welded joint. Many domestic and foreign research institutions and machine tool manufactures, like University of Shanghai for Science and technology subordinate shopⅡ, Railtech International France company and GEISMAR France company. They researched on the continuously welded rail grinding machine, and there are productions using in practice. Most of the domestic rail welding factory imported the grinding machine tool abroad for processing the overlap of the continuously welded rail, however, there are high price, cost of large, long learning cycle operation, inconvenient maintenance, language barriers and so on disadvantages for the imported machine.
There is a new method for grinding the overlap of the railway, facing to the domestic and international status about the overlap of the railway process. It proposes the application of the concept of the numerical control profile grinding, using numerical control interpolation principles and the VERICUT numerical control simulation software platform, then, refining the model of the numerical control railway grinding machine tool, and programming the G-code according to the processing objects. In the grinding process, the grinding wheel of the grinding machine accordance with the numerical control program to run the track, and precise grind-shaped surface. Finally, compare the surface of the processing model with the design model, by using AUTO-DIFF (automatic detection) which is the function of the VERICUT simulation software, and using OptiPath (optimization) which is the function of the VERICUT simulation software optimize the numerical control program.
引文
[1]孙德茂.数控机床磨削加工直接编程技术.北京：机械工业出版社,2006
[2]杨胜群VERICUT数控加工仿真技术.北京：清华大学出版社,2010
[3]娄锐.数控应用关键技术.北京：电子工业出版社,2005
[4]王先逵.磨削加工.北京：机械工业出版社,2008
[5]李云龙,曹岩.数控机床加工仿真系统VERICUT西安：西安交通大学出版社,2005
[6]周凯.PC数控原理、系统及应用.北京：机械工业出版社,2006
[7]陈俊主编.数控机床编程及应用.北京：北京理工大学出版社,2008
[8]韩宝明,李学伟.高度铁路概论.北京：北京交通大学出版社,2008
[9]黄明吉.虚拟数控技术及应用.北京：化学工业出版社,2005
[10]董志洪.高技术铁路与钢轨.北京：冶金工业出版社,2003
[11]罗敏.典型数控系统应用技术(FANUC篇).北京：机械工业出版社,2009
[12]王爱玲,张吉堂,吴雁.现代数控原理及控制系统.国防工业出版社,2005
[13]傅杰才主编.磨削原理与工艺.湖南：湖南大学出版社,1986
[14]盛晓敏.超高速磨削技术.北京；机械工业出版社,2010
[15]毕承恩,丁乃健.现代数控机床.北京：机械工业出版社,1991
[16]王爱玲,俞士谦.实用数控与编程技术.北京：国防工业出版社,1993
[17]张新义.经济性数控机床系统设计.北京：机械工业出版社,1994
[18]严爱珍主编.机床数控原理俞系统.北京：接线工业出版社,2002
[19]余勤科等.虚拟数控机床及其应用.制造业自动化,2001
[20]杨润党等.虚拟数控加工过程的建模与仿真.机床与液压,2001
[21]Koren Yoram. Computer control of manufacturing systems.New York: McGraw-Hill,1983
[22]Shang-Liang Chen and Wen-Tsai Wang. Computer aided Manufacturing Technologies for Centrifugal Compressor Impellers. Int J Adv Manuf Technol,2001
[23]魏林.基于VERICUT的数控加工仿真系统的研究.沈阳理工大学硕士学位论文,2008
[24]谷鹏.基于VERICUT的非圆齿轮磨床加工仿真系统研究.哈尔滨工业大学硕士学位论文,2009
[25]Donggo Jang,Kwangsoo Kim and Jungmin Jung. Voxel-Based Multi-Axis Manufacturing. Advanced Manufacturing Technology,2000
[26]Liu Xiao-Wei.5-axis NC cylindrical milling of sculptured surfaced. Computer-Aided Design,1995
[27]Kakino Y, Masubara A. High speed and high acceleration feed drive system for NC machine tools. International Journal of the Japan Society for Precision Engineering,1996
[28]Wittenmark B, Middletion R and Goodwin G C.Adaptive decoupling of multivariable systems. International Journal of control,2003
[29]王宏典,张友良.虚拟制造技术及其应用.机械科学与技术,1998
[30]Lee H C, Jeon G J.A neuro-controller for synchronization of two motion axes. International Journal of Intelligent System,1998
[31]Koren Y, Lo C C. Variable-gain cross-coupling controller for counting. Annals of the CIRP,1991
[32]肖田元等.虚拟制造的定义与关键技术.清华大学学报,1998
[33]张铁军,袁哲俊等.虚拟机床加工系统研究.制造技术与机床,1999
[34]张铁军等.虚拟加工系统中机床结构的描述及实现.航空制造技术,2000
[35]http://www.artcnc.cn
[36]D Vragov. Structure Analysis of Machine Tool Layout. Machine and Tooling, 1982
[37]王启义等.基于虚拟制造的数控车削加工仿真技术.大连铁道学院学报,2000
[38]王印芬.三维数控加工仿真的应用研究.北京航空航天大学硕士论文,2000
[39]陈东凡等.虚拟制造中的仿真系统.机械工业自动化,1997
[40]郑善良.磨削基础.上海：上海科学技术出版社,1988
[41]徐圣群,邵时美,王建晨.简明磨工手册.上海：上海科学技术出版社,1987
[42]章富元,方江龙,汤季安.对我国数控技术发展的思考.中国工程机械,1999
[43]李宏胜主编.数控原理与系统.北京：机械工业出版社,1997
[44]李宏胜.现代数控系统的技术特点与发展趋势.制造业自动化,2002
[45]北京发那科机电有限公司.高可靠的BEIJING-FANUC数控系统.中国工程机械,1999
[46]杨学桐,李冬茹.我国数控产业的现状与发展举措.中国工程机械,1999
[47]陆启建,刘明灯.数控技术的新进展.制造技术与机床,2002
[48]毕承恩.现代数控机床.北京：机械工业出版社,1993
[49]李立斌,谢丽丽.高速切削技术与数控机床发展趋势,2003
[50]张伯鹏主编.机械制造及其自动化.北京：人民交通出版社,2003
[51]周凯.虚拟轴数控机床的仿五轴控制.制造技术与机床,1998
[2]杨胜群VERICUT数控加工仿真技术.北京：清华大学出版社,2010
[3]娄锐.数控应用关键技术.北京：电子工业出版社,2005
[4]王先逵.磨削加工.北京：机械工业出版社,2008
[5]李云龙,曹岩.数控机床加工仿真系统VERICUT西安：西安交通大学出版社,2005
[6]周凯.PC数控原理、系统及应用.北京：机械工业出版社,2006
[7]陈俊主编.数控机床编程及应用.北京：北京理工大学出版社,2008
[8]韩宝明,李学伟.高度铁路概论.北京：北京交通大学出版社,2008
[9]黄明吉.虚拟数控技术及应用.北京：化学工业出版社,2005
[10]董志洪.高技术铁路与钢轨.北京：冶金工业出版社,2003
[11]罗敏.典型数控系统应用技术(FANUC篇).北京：机械工业出版社,2009
[12]王爱玲,张吉堂,吴雁.现代数控原理及控制系统.国防工业出版社,2005
[13]傅杰才主编.磨削原理与工艺.湖南：湖南大学出版社,1986
[14]盛晓敏.超高速磨削技术.北京；机械工业出版社,2010
[15]毕承恩,丁乃健.现代数控机床.北京：机械工业出版社,1991
[16]王爱玲,俞士谦.实用数控与编程技术.北京：国防工业出版社,1993
[17]张新义.经济性数控机床系统设计.北京：机械工业出版社,1994
[18]严爱珍主编.机床数控原理俞系统.北京：接线工业出版社,2002
[19]余勤科等.虚拟数控机床及其应用.制造业自动化,2001
[20]杨润党等.虚拟数控加工过程的建模与仿真.机床与液压,2001
[21]Koren Yoram. Computer control of manufacturing systems.New York: McGraw-Hill,1983
[22]Shang-Liang Chen and Wen-Tsai Wang. Computer aided Manufacturing Technologies for Centrifugal Compressor Impellers. Int J Adv Manuf Technol,2001
[23]魏林.基于VERICUT的数控加工仿真系统的研究.沈阳理工大学硕士学位论文,2008
[24]谷鹏.基于VERICUT的非圆齿轮磨床加工仿真系统研究.哈尔滨工业大学硕士学位论文,2009
[25]Donggo Jang,Kwangsoo Kim and Jungmin Jung. Voxel-Based Multi-Axis Manufacturing. Advanced Manufacturing Technology,2000
[26]Liu Xiao-Wei.5-axis NC cylindrical milling of sculptured surfaced. Computer-Aided Design,1995
[27]Kakino Y, Masubara A. High speed and high acceleration feed drive system for NC machine tools. International Journal of the Japan Society for Precision Engineering,1996
[28]Wittenmark B, Middletion R and Goodwin G C.Adaptive decoupling of multivariable systems. International Journal of control,2003
[29]王宏典,张友良.虚拟制造技术及其应用.机械科学与技术,1998
[30]Lee H C, Jeon G J.A neuro-controller for synchronization of two motion axes. International Journal of Intelligent System,1998
[31]Koren Y, Lo C C. Variable-gain cross-coupling controller for counting. Annals of the CIRP,1991
[32]肖田元等.虚拟制造的定义与关键技术.清华大学学报,1998
[33]张铁军,袁哲俊等.虚拟机床加工系统研究.制造技术与机床,1999
[34]张铁军等.虚拟加工系统中机床结构的描述及实现.航空制造技术,2000
[35]http://www.artcnc.cn
[36]D Vragov. Structure Analysis of Machine Tool Layout. Machine and Tooling, 1982
[37]王启义等.基于虚拟制造的数控车削加工仿真技术.大连铁道学院学报,2000
[38]王印芬.三维数控加工仿真的应用研究.北京航空航天大学硕士论文,2000
[39]陈东凡等.虚拟制造中的仿真系统.机械工业自动化,1997
[40]郑善良.磨削基础.上海：上海科学技术出版社,1988
[41]徐圣群,邵时美,王建晨.简明磨工手册.上海：上海科学技术出版社,1987
[42]章富元,方江龙,汤季安.对我国数控技术发展的思考.中国工程机械,1999
[43]李宏胜主编.数控原理与系统.北京：机械工业出版社,1997
[44]李宏胜.现代数控系统的技术特点与发展趋势.制造业自动化,2002
[45]北京发那科机电有限公司.高可靠的BEIJING-FANUC数控系统.中国工程机械,1999
[46]杨学桐,李冬茹.我国数控产业的现状与发展举措.中国工程机械,1999
[47]陆启建,刘明灯.数控技术的新进展.制造技术与机床,2002
[48]毕承恩.现代数控机床.北京：机械工业出版社,1993
[49]李立斌,谢丽丽.高速切削技术与数控机床发展趋势,2003
[50]张伯鹏主编.机械制造及其自动化.北京：人民交通出版社,2003
[51]周凯.虚拟轴数控机床的仿五轴控制.制造技术与机床,1998