Construction And Validation Of Non-ideal Surface Model For Barrel Finishing Process Simulation

As a key technology to improve the surface quality of parts,barrel finishing technology can effectively improve the service performance,reliability and service life of products.It is one of the methods commonly used in the research on the optimization technology of barrel finishing process to predict the finishing effect and optimize the process parameters by computer simulation.However,there is often a certain gap between the computer simulation results of barrel finishing and the actual processing results.The author analyzes that in the study of geometric contact model,the ideal smooth surface model is mostly used for the machined workpiece model,and the actual microscopic surface morphology information of the workpiece is ignored,so that the contact model used in the simulation is different from the actual contact condition,which may lead to distortion of the simulation results.Therefore,this paper studies the non-ideal model construction of the surface model of barrel finishing and the fine simulation method of barrel processing based on this model.The main research contents are as follows:(1)A method of constructing non-ideal surface model is proposed.Based on the application criterion of barrel finishing,the non-ideal surface model including geometric model,surface quality model and surface performance model is created by object-oriented modeling method,which provides a reference for multi-index comprehensive characterization of surface quality of parts.Secondly,the expression and management method of non-ideal surface model information is studied,and the expression and management of the correlation between geometric model and surface quality information are realized.An integrated application framework of non-ideal surface model based on XML is proposed,and the St AX standard programming interface specification is used to parse the XML file,so as to realize the effective transmission of various data between different systems.Finally,taking the composite processing technology of a satellite part as an example,the non-ideal surface model of the part is constructed to realize the expression and integrated application of the non-ideal surface model of the part,which proves the feasibility and effectiveness of the proposed method.(2)The three-dimensional geometric morphology of the non-ideal surface model was studied.In order to obtain the original surface morphology data of the barrel finishing parts,the Ze Gage Plus white light interferometer was used to collect the surface data of the parts,and the data were processed by the wavelet analysis method.The wavelet soft threshold denoising method was selected to denoise the collected original morphology data.Based on db3 wavelet,the multi-resolution analysis of the de-noising surface morphology data is carried out,and the seven-layer fractal data is extracted.The 3D reconstruction method of surface topography data was studied.The 3D reconstruction results of original data and parting topography data by ball rolling method and Poisson reconstruction method were compared.The Poisson reconstruction method with closed and fine reconstruction surface was selected as the reconstruction method for generating the geometric morphology of the non-ideal surface to complete the construction of the real morphology of the non-ideal surface model.(3)The fine simulation method based on the non-ideal surface model is studied and applied.The contact model of the discrete element method to simulate the grinding and finishing process is analyzed.The Hertz-Mindlin with Archard Wear contact model is selected as the mechanical contact model in the fine simulation.The pretreatment method of the non-ideal surface model applied to the fine simulation is studied.According to the actual processing parameters,the initial conditions and boundary conditions of the fine simulation in the EDEM simulation software are determined.Through the actual processing experiments,the difference between the fine simulation and the non-fine simulation and the surface of the parts after the actual processing is compared.It is concluded that the fine simulation is more effective than the nonfine simulation.