基于粒子有限元法的金属切削工艺仿真软件研究

Research on Simulation Software of Metal Cutting Process Based on Particle Finite Element Method

金属切削是一个复杂的工艺过程,包含了复杂的瞬态热力耦合自由边界问题。开发金属切削工艺仿真软件时,首先采用粒子有限元法开发了切削力学求解器,其次采用生死单元法开发了材料去除残余应力和变形求解器,最后在求解器的基础上进一步开发完整的工艺仿真软件。金属切削工艺仿真软件是一个复杂的系统,包括工艺研发和生产现场两个部分。其中,工艺研发包括切削机理计算与材料去除残余应力和变形计算。生产现场包括工艺MBSE、机床系统仿真和前后处理,其中前后处理的研发难度不亚于求解器。开发金属切削工艺仿真软件的最大难点是成本和周期。通过研究开源软件的核心技术,验证了基于开源软件可以有效降低开发成本和周期,并可以达到工业级软件的水平。该软件建立了统一的几何模型和物理模型的数据结构,建立了统一的数据可视化引擎。此外,还介绍了仿真软件系统集成的3个核心技术。

Metal cutting is a complex process,which includes complex transient thermal mechanical coupling free boundary problems.In the development of metal cutting process simulation software,firstly,the particle finite element method is used to develop the cutting mechanics solver,secondly,the life and death element method is used to develop the material removal residual stress and deformation solver,finally,the complete process simulation software is further developed based on the solver.Metal cutting process simulation software is a complex system,including process development and production site.Among them,process development includes cutting mechanism calculation and material removal residual stress and deformation calculation.The production site includes process MBSE,machine system simulation and pre-processing and post-processing.The research and development of pre-processing and post-processing is no less difficult than solver.The most difficult point in developing simulation software of metal cutting process is cost and cycle.By studying the core technology of open source software,it is verified that based on open source software can greatly reduce the development cost and cycle,and can reach the level of industrial software.The software establishes a unified data structure of geometric model and physical model,establishes a unified data visualization engine.In addition,three core technologies of simulation software system integration are introduced.