Research On Technology Of Milling Force Simulation For Virtual Manufacturing

An ever-increasing emphasis is being placed on market demand and fierce global industrial competition for manufacturing enterprise to survive and develop, and with the rapid technology advance in computer, virtual manufacturing is developed with the demands. Virtual machining process simulation is a key basic technology for virtual manufacturing, and plays an important role. It predicts and optimize effectively to all kinds of machining information in process system composed of machine tools, workpiece, cutters and clamps, so that it can help realizing the real intelligent machining process. Furthermore, it is a fundamental way to research deeply mechanism of the machining process. Virtual machining simulation is mainly consisted of two parts, geometry simulation and physical simulation. The research on physical simulation is not deep due to the complex mechanism of cutting and the difficulty in modeling. But the consideration of physical factors and prediction in cutting quality is necessary and important on virtual manufacturing research.The main purpose of this dissertation is to research on milling force simulation and to develop virtual milling process simulation system, according to existing achievements.Chapter 1 is the introduction of this dissertation, firstly virtual manufacturing technology is summarized and the background and existing achievements of this topic are introduced. Based on introduction, the main contents of this dissertation are determined.In chapter 2, at first, the discussion of cutting force analysis modeling is made. Based on the orthogonal cutting, the oblique cutting force model is set up and regarding milling process as the object, the milling force model is set up.Chapter 3 is the key content of this paper, It presents a systematic method for determining the coefficients in a three-dimensional mechanistic cutting force model with the consideration of size effect. With the methods of the experiments combined with analysis, the systematic model of milling force prediction is validated accurately.In chapter 4, the model of cutting process simulation is obtained and a discrete model of work piece is set up using the data structure of constraint quarter-tree based on Z-Map, which is the innovation of this paper. Meanwhile four representative transient cuts in two-dimensional pocket milling are introduced.In chapter 5, the virtual milling process simulation system is developed based on object-oriented method. It can simulate four representative transient cutting process in milling from geometry, and validate the simulation accurately using the model of milling fore prediction.Finally, the research contents of this dissertation have been summarized and the prospect of milling force simulation for virtual manufacturing has been opened up.