Research And Realization On Key Technologies About Multi-axis Milling Simulation And Optimization Of Cutting Paramters

The virtual manufacturing is a highly informative manufacturing technology since the 1980s. As the research hotspot of virtual manufacturing, the NC simulation system has received extensive concern of academia and manufacturing at home and broad. The NC simulation system simulates the machining process in the computer before actual machining, and it has been the main technique method of machining. The NC simulation system reduces the production cost, improves the processing efficiency, and optimizes the machining process.As the existing NC simulation softwares are short of predicting the cutting force and optimization of cutting parameters and the price of business software is high, a multi-axis milling simulation system based on the authenticity and real-time features of virtual manufacturing system is designed in this paper. Having combined the superiority of C++on the programming language and the interactivity of ACIS/HOOPS geometric modeling platform, the system finally achieves the functions such as milling machining simulation, parameters extraction and cutting force prediction. Based on the cutting force, the cutting parameters are optimized.In the paper, the following aspects are studied and researched:1. To realize the geometric simulation of milling and extract the tool parameters in physical simulation, the geometric model of end mill which contains exact contour and curved edges is established. The tool swept volume is studied based on the characteristic of multi-axis milling and the geometric model of end mill. The paper puts forward a new method of building the tool swept volume. The new method ensures the solving is accurate and efficient, and the method also deals with complex tool scanning path.2. To realize the multi-axis milling simulation dynamically, the paper uses TDM solid modeling method to achieve the Boolean operation between blank and tool swept volulme. This part is the research emphasis, and the TDM solid modeling method has simple data structure, less calculated amount and high efficiency.3. The material removal volume and axial cutting depth can be achieved based on the solid milling process simulation, at the same time the cutting force model is studied in the paper. The cutting force of milling process could be predicted. Then the optimization of cutting parameters can be accomplished according to the cutting force.4. Based on virtual machining process simulation, a multi-axis milling simulation system is developed in C++, ACIS R23 and HOOPS 1919. The system achieves the definition of milling parameters, milling process simulation, output of machining parameters, cutting force prediction and optimization of cutting parameters. The system lays the foundation for the research of the multi-axis freeform surface machining simuation and parameters optimization system.