Development of Virtual Machining System for Obtaining "Know How" on Machining

开发了一种能够模拟切屑形成和刀具损坏等加工过程的虚拟加工系统。使用该系统，机械加工车间的技术人员可以轻松地体验和学习加工现象，而不需要进行艰苦、危险和肮脏的切割实践；由于该系统不需要实际的机床、刀具和被加工材料，因此可以假设任何切割条件和刀具特性，并可以获得虚拟条件下的切割特性。综合开发了包含切屑形成过程和刀具失效预测的切屑形成过程仿真系统，讨论了加工过程中缺少的信息。由于加工表面的残馀应力/应变等特征会影响被加工零件的性能，因此开发了特征预测系统，并提出了控制残馀应力的方法。为了预测切屑的运动规律，对切屑的运动规律进行了分析，提出了切屑运动规律的预测方法，并在此基础上建立了切屑运动预测模型。开发了曲面刀具切屑形成过程和切屑断裂行为之一的仿真系统，通过切屑形成、刀具失效、表面特征和切屑控制等综合仿真系统，可以在不进行任何切割实践的情况下，对任意条件下的切削过程进行体验和研究。由于仿真系统的计算量很大，为了更好地使用仿真系统--虚拟加工系统，开发了一个切屑温度和刀具磨损范围内的收缩或受限仿真系统。通过Easy模拟系统，可以在个人计算机上以机床的形式很容易地体验到切割条件与刀具温度/寿命的关系。

A virtual machining system, which is enable to simulate machining process including chip formation and tool damage, was developed. By using the system a technician in machine shop may experience and study easily the machining phenomenon without hard, dangerous and dirty cutting practice.Since the system does not require the actual machine tool, tool and work material also, any cutting condition and tool characteristics can be assumed and the cutting characteristics under the virtual condition may be obtained. And the obtained cutting characteristics will give the new concept and performance of advanced machine tool.A simulation system on cutting process, in which a chip formation process, prediction of tool failure are included, was synthetically developed and the lacked information in machining to be predicted was discussed.Since a characteristics of machined surface, such as residual stress/strain, will affect the performance of machined element, the prediction system for the characteristics was developed and the method for control the residual stress was also proposed.In order to predict the kinematics of chip, the simulation system of chip formation process by the curved rake faces tool and one of the behavior of chip breakage process were also developed.By using the synthetical simulation system including chip formation, tool failure, surface characteristic and chip control, the cutting process under any arbitral condition can be experienced and studied without any cutting practice.Since the simulation system was huge scale for computation, for more practical usage of the simulation system-virtual machining system-, the shrinked or the limited system within a cutting temperature and tool wear was developed. Through the easy simulation system the relation between cutting condition and tool temperature/life was easily experienced on the personal computer in the machine shape.