基于物理学的铣削过程仿真关键技术

Key technologies of physics-based milling process simulation

为了预测零件加工变形,基于铣削加工有限元理论,构建了基于物理学的铣削加工过程仿真环境,研究了刀位轨迹离散、材料去除、网格自适应生成及动态网格数据维护等关键技术的处理.针对刀具的每次进给运动,系统自动检测刀具和工件毛坯网格相交的区域,通过网格自适应求精、粗化和删除以及有限元分析计算,模拟真实的铣削加工过程.该仿真环境可综合考虑加工参数、刀具路径等因素对零件加工变形的影响,优化加工工艺,保证加工精度.

In order to predict the machining deformation of workpiece, a prototype version of physics-based simulation environment was developed based on the finite element theory of milling process. The key problems concerned with the finite element model （FEM） simulation system, such as tool-path discretization, material removal, adaptive mesh generation, dynamic mesh data management, etc, were studied deeply. With each incremental motion of the cutter, the system detects the intersection region between the cutter and the finite element mesh, and simulates the actual machining process in a step-by-step manner by mesh adaptive refinement, coarsening, deletion and finite element calculation. The system can optimize milling process and guarantee machining accuracy, taking into consideration multiple factors affecting distortion such as machining parameters, tool path and so on.