【作者】 纪一郎；

【导师】 冯平法；

【作者基本信息】 清华大学 ， 机械工程， 2009， 硕士

【摘要】 虚拟制造技术在制造行业中得到了广泛的应用,切削物理仿真属于虚拟制造技术范畴,对制造技术的发展有重要的意义。但限于技术水平等因素,目前物理仿真技术局限于简单零件切削模拟,复杂结构零件的切削过程物理仿真仍然是一个难点。本文将二维切削模型仿真与三维实体模型仿真方法相结合,实现了复杂结构零件切削过程的模拟。文中介绍了切削仿真的关键技术及实现方法,研究了将各种类型切削加工抽象简化为二维切削模型的方法,以及三维实体模型加载方式和仿真结果分析方法。搭建了切削实验平台,研究材料Al6061-T6的切削性能,与仿真结果相比较,验证了仿真方法的有效性。仿真了一款磁盘驱动架零件的切削过程,分析零件及刀具在切削力、切削热作用下应力分布及变形状况,从而评价切削工艺的合理性。本文研究了基于切削物理仿真的工艺优化方法,详述了多因素多水平条件下系统化的仿真实验设计方法。针对磁盘驱动架切削加工过程,根据物理仿真计算结果对切削参数及刀具几何参数进行优化,使用优化参数加工所得产品质量有较大的提高。此外,针对生产中的刀具折断问题进行分析,找出问题的原因,给出了刀具和切削参数优化方案,降低了刀具的折断率。更多还原

【Abstract】 Cutting process physical simulation belongs to the virtual manufacturing technology which is widely used in manufacturing industry. It is meaningful to the improvement of manufacturing technology. But restricted by technical level and other factors, physical simulation is only used for ordinary parts cutting. There still have difficulties in realizing the physical simulation of complex parts cutting process.This paper develops a method to realize physical simulation of complex parts cutting process by integrating 2D and 3D cutting model simulation technique. It introduces the key techniques and realizing mechanism. Method of abstracting ordinary cutting types to 2D cutting model is researched. It also develops 3D model loading and result analysis method.Cutting experiment platform is established for studying the cutting property of Al6061-T6. Compared with the simulation results, it proves that the simulation method is reliable. A hard disk drive part cutting progress is simulated to analysis the stress distribution and overall deformation under the effect of cutting force and heat. The result can be used to evaluate the cutting technique.A cutting technique optimization method based on the physical simulation is introduced. The paper describes a systematic experiment method used for influencing factors that have several different values. The cutting parameters and tool geometry of hard disk drive part is optimized, and the products quality is greatly improved. Besides, the paper analyzes a tool break problem and gives a helpful solution to reduce the risk.更多还原