Next Generation Machining Simulation Technologies for Complete and Efficient Process Validation

加工仿真是现代数控加工的基础。它用于验证CNC机床执行的加工命令是否正确生成，并能够正确生产所需的零件几何形状。错误的加工命令会产生有缺陷的零件，或者更糟的是，由于碰撞而损坏机器，导致生产力和利润的重大损失。拟议研究计划的长期目标是开发对创建完整，高效和准确的虚拟加工系统至关重要的技术。然后，在物理CNC机床上实施之前，可以在虚拟仿真环境中验证计划的加工过程。准确性是这种模拟的关键要求。高效的仿真执行同样至关重要，因为模拟几何复杂零件的加工过程可能会花费大量时间。然而，现有的技术还没有克服这些挑战。它们要么产生不准确的结果，要么在处理过程中非常缓慢。此外，它们仅提供部分仿真解决方案-用于加工零件几何形状或碰撞检测。在接下来的五年里，我和我的学生将开发一个完整的5轴铣削加工仿真解决方案，同时考虑过程中的工件建模和碰撞检测。我们将使用多级体素建模方法最大限度地提高加工仿真效率，以便在几分钟内完成精确的仿真，而不是几小时甚至几天。我们的研究团队作为CNC加工研究的领导者在全球享有盛誉。凭借我们在CNC加工和产品建模方面的专业知识，我们开发了一种新颖的、正在申请专利的几何建模方法，可以准确高效地计算加工零件的几何形状。我们将在此基础上，开发一个统一的，高效的和准确的几何建模方法，一个完整的加工过程仿真系统，包括刀具-工件碰撞检测和刀具-机床碰撞检测。两名博士生，四名硕士生，五名本科生和一名兼职研究员将接受培训，以建立拟议的五轴铣削仿真系统。我已经制定了一个招聘计划，通过接触UBC的女本科生来吸引女学生加入团队。我鼓励学生参加UBC的公平，多样性和包容性培训课程，以提高认识，并帮助在我的实验室创造一个包容性的研究环境。加拿大航空航天和汽车工业的年销售额为1126亿美元，在数控加工方面投入了大量资金，每年使用数控机床生产数百万个零件。拟议的研究将使这些制造商受益，使他们能够快速开发和验证CNC加工工艺，并生产高质量的加工零件。

Machining simulation is essential to modern Computer Numerical Control (CNC) machining operations. It is used to validate whether the machining commands to be executed by a CNC machine tool are generated without errors and able to produce the desired part geometry correctly. Erroneous machining commands produce defective parts, or worse, damage the machines due to collision, leading to a major loss of productivity and profits. The long-term objective of the proposed research program is to develop enabling technologies that are fundamental to the creation of a complete, efficient and accurate virtual machining system. Planned machining processes can then be validated in the virtual simulation environment prior to the implementation on a physical CNC machine tool. Accuracy is a crucial requirement of such simulation. Efficient simulation execution is equally critical as simulating the machining process of a geometrically complex part can take an enormous amount of time. However, the existing technologies have not overcome the challenges. They either produce inaccurate results or are extremely slow in processing. Moreover, they only offer partial simulation solutions - for either machined part geometry or collision detection. In the next five years, my students and I will develop a complete machining simulation solution for 5-axis milling that considers both in-process workpiece modeling and collision detection. We will maximize the machining simulation efficiency using a multi-level voxel modeling method so that an accurate simulation can be completed in minutes instead of hours or even days. Our research group has a worldwide reputation as a leader in CNC machining research. With our expertise in both CNC machining and product modeling, we have developed a novel, patent-pending geometric modeling method to compute the machined part geometry with both accuracy and efficiency. We will build on this method to develop a unified, efficient and accurate geometric modeling method for a complete machining process simulation system that covers both tool-workpiece collision detection and tool-machine collision detection. Two PhD students, four Master's students, five undergraduate students and a part-time research associate will be trained to build the proposed 5-axis milling simulation system. I have developed a recruitment plan to attract female students to join the team by reaching out to female undergraduate students at UBC. My students are encouraged to attend the equity, diversity and inclusion training sessions at UBC to increase awareness and help create an inclusive research environment in my lab. Canadian aerospace and automotive industries, with $112.6B/year in sales, have invested substantially in CNC machining and produced millions of parts annually using CNC machine tools. The proposed research will benefit these manufacturers and enable them to quickly develop and validate the CNC machining processes and produce high-quality machined parts.