Virtual Machining of High Speed Mechining and Its Application to Machining System

高速加工是一种极具发展前景的加工技术，可实现高经济生产和高质量加工。此外，它有望成为一种无需研磨或抛光即可完成产品的技术。然而，高速加工可能只在某些特定的加工领域有效。没有提出和发现探索这些领域的战略。因此，利用计算机仿真技术进行虚拟加工，可以有效地评价高速加工的性能，具有优化加工工艺的潜力。在本研究中，首先发展了由不同工作材料和切削条件组合引起的不同刀具和切屑形状加工的各种类型的建模，以阐明不同形状的有限元方法和有限差分方法的加工现象。所考虑的切屑形成有连续的、不连续的和锯齿状的。在二维加工中，刀具类型为平面和槽，而在三维切削中，则考虑单点刀具和立铣刀。然后将虚拟加工方法应用于刀具几何形状的优化。在此应用中，通过切削温度、刀面应力、刀具变形、切屑变形和断裂，阐明了刀具几何形状对刀具磨损、刀具断裂和切屑控制的影响。然后确定了给定切削条件下的优化刀具几何形状和给定刀具几何形状下的优化切削条件。研究了通过虚拟加工方法实现切削状态监测与切削作业规划的集成。

High speed machining is one of promising technologies that will yield high economical production and high quality of the machined elements. Moreover, it is expected as a technology which can finish the product without the processes of grinding or polishing. However, high speed machining may be effective only in some particular areas of machining. No strategy for exploring such areas has been proposed and found. Thus the performances of high speed machining should be effectively evaluated by the virtual machining with the aid of computer simulation, which has a potential for optimizing machining operations.In this research the various types of modiling of machining with different tools and chip formations, which caused by different combinations of work materials and cutting conditions, were first developed for clarifying the machining phenomena using finite element methods with different formations and finite difference method. The chip formations considered are continuous, discontinuous and serrated. The types of tools are flat and grooved in two dimensional machining, while a single point tool and an endmill are considered in three dimensional cutting.Next the virtual machining methods are applied to the optimization of tool geometry. In this application the influences of tool geometry on tool wear, tool breakage and chip control were clarified by using cutting temperature, stresses on the tool face, tool deformation, and chip deformation and breakage. Then the optimized tool geometry for given cutting conditions and the optimized cutting conditions for given tool geometry were determined. The integration of cutting condition monitoring and cutting operation planning through the virtual machining method was investigated.