A Voxel-Based End Milling Simulation Method to Analyze the Elastic Deformation of a Workpiece
A Voxel-Based End Milling Simulation Method to Analyze the Elastic Deformation of a Workpiece
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基于体素的立铣仿真方法分析工件的弹性变形
DOI：
10.1115/1.4055794
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发表时间：
2022
期刊：
影响因子：
--
通讯作者：
Shirase Keiichi
中科院分区：
文献类型：
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作者：
Kaneko Kazuki;Shimizu Jun;Shirase Keiichi
提出了一种分析端铣加工过程中工件弹性变形的新方法。这种方法的优点之一是可以很容易地将其与基于体素的铣削仿真相结合，后者通常用于预测切削力，并预测由于工件偏转而导致的加工误差。该方法将工件离散化，用体素与相邻的体素通过梁单元连接起来。虽然有限元法（FEM）通常用于变形分析，但是其需要大量时间来分析变形。相比之下，所提出的方法不需要太多的时间重新网格化，因为工件形状的变化是通过去除体素表示的，并且刚度矩阵可以很容易地从形状变化之前获得的刚度矩阵更新。通过使用粗体素进行初步分析并估计解的初始值，我们的方法还减少了确定变形所需的迭代次数。将该方法集成到基于体素的切削力预测方法中，模拟切削力引起的工件变形。因此，使用体素模型无缝地预测切削力和由此产生的工件偏转。验证实验结果表明，分析的工件变形与测量的变形大致一致。我们未来的工作是预测工件弹性变形引起的加工误差的基础上，并结合我们以前的工作，由刀具的弹性变形引起的加工误差的预测。
A new method to analyze the elastic deformation of a workpiece during end milling is proposed. One of the advantages of this method is the possibility of easily combining it with a voxel-based milling simulation, which is often used to predict cutting force, and to predict machining error due to workpiece deflection. With this method, the workpiece is discretely represented by voxels connected to their neighboring voxels with beam elements. Although the finite element method (FEM) is generally used for deformation analysis, it requires substantial time to analyze the deformation. In contrast, the proposed method does not require much time for remeshing, as the workpiece shape change is represented by removing voxels, and the stiffness matrix can be easily updated from the stiffness matrix obtained before the shape change. By conducting the preliminary analysis using coarse voxels and estimating the initial value of the solution, our method also reduces the number of iterations required to determine the deformation. The proposed method was integrated into the voxel-based cutting force prediction method in order to simulate the workpiece deformation caused by the cutting force. Therefore, the cutting force and the resulting workpiece deflection are seamlessly predicted using a voxel model. The results of a verification experiment showed that the analyzed workpiece deformation was in rough agreement with the measured deformation. Our future work is to predict the machining error induced by the workpiece elastic deformation based on this method and to integrate it with our previous work on the prediction of machining error induced by elastic deformation of the tool.