基于刀具空间包围体算法的数控切削仿真

采用计算刀具空间包围体和刀具旋转体的方法来对仿真过程中的有效切削计算进行判断,刀具在一般运动情况下所占空间包围体的计算公式可由刀具的长度、半径以及刀具在任意时刻的刀位点、刀轴矢量来共同推导;刀具的旋转体范围可以通过刀具在当前时刻的刀轴矢量、母线方程以及刀具的半径、长度进行计算.该方法已经成功应用到基于OpenGL的VC6.0环境下所开发的五轴数控仿真系统中,实验结果表明,该方法能够提高有效切削率和减少切削计算耗时.     

Hybrid cutting simulation via discrete vector model

Geometric cutting simulation and verification play an important role in detecting NC machining errors in mold and die manufacturing, thereby reducing the correcting time and cost on the shop floor. According to workpiece model, current researches may be categorized into view-based, solid-based, and discrete vector-based methods. Each methodology has its own strengths and weaknesses in terms of computing speed, representation accuracy, and its ability to perform numerical inspection. This paper proposes a cutting simulation methodology via a hybrid workpiece model which consists of the general discrete vector model and its simplified model. Workpiece modeling scheme, cutting simulation via tool swept surface modeling and vector intersection, and some case studies of mold and die machining are presented in this paper.     

End mill design and machining via cutting simulation

This paper describes a design process for an end mill. A solid model of the designed cutter is constructed together with the computation of the cutter’s geometry, wheel geometry, and wheel positioning data for fabricating end mills with the required cutter geometry. The main idea of the process is to use the cutting simulation method to obtain the machined shape of an end mill by using Boolean operations between a given grinding wheel and a cylindrical workpiece (raw stock). The major design parameters of a cutter, such as rake angle and inner radius, can be verified by interrogating the section profile of its solid model. This study investigates the relationship between various dimensional parameters and proposes an iterative approach to obtain the required geometry of a grinding wheel and cutter location (CL) data for machining an end mill that satisfies the design parameters. This research was implemented using a commercial computer aided design (CAD) system with API function programming and is currently used by a commercial tool maker in Korea. It can eliminate the need to produce a physical prototype during the design stage and can be used in virtual cutting tests and analyses.     

Real‐time cutting simulation of meshless deformable object using dynamic bounding volume hierarchy

This paper proposes a novel method for a real‐time cutting simulation of deformable objects using meshless method. The method utilizes a rapid refinement of topological relations among the simulation nodes of meshless deformable objects. Topological relations are defined as an undirected graph based on a visibility criterion. The graph connects the adjacent nodes that lie within a support of each node. The topological relations are refined by removing the edges of the graph that is intersected by the cut surface during the cutting simulation. Our approach utilizes a bounding volume hierarchy (BVH) to accelerate the computation of the intersection test. The BVH reconstruction algorithm is proposed to account for the cases where pieces of the object are completely cut out from the object. Algorithms to examine the connectivity among simulation nodes and accordingly reconstructing the BVH using two‐level BVH are presented. The proposed approach achieves real‐time cutting simulation of deformable objects through the rapid refinement of the topological relation. In addition, the computational performance of the cutting procedure is preserved during the entire simulation, thanks to the real‐time reconstruction of the BVH. Copyright © 2012 John Wiley & Sons, Ltd.     

数控管切割机三维仿真加工若干问题的研究

为解决检验数控管切割机加工工艺合理性的问题,基于OpenGL 和3DSMax 平台,并在OpenGL 中通过参数驱动导入的3DS 静态模型,实现了加工过程和结果的三维 动态演示。同时相对于传统的利用碰撞检测技术再现切割后管材的相贯线形状,提出了改进 的数学模型,新算法通过了快速性、准确性等的验证。     

煤岩刨削中的刨刀受力有限元模拟研究

建立刨煤机刨刀刨削煤层的三维模型,利用有限元分析软件LS-DYNA,模拟刨刀刨削煤层的过程。通过研究,得到了刨削速度、刨刀刨削阻力等的时间历程曲线,分析了不同刨削深度、刨刀间距和刨刀宽度对刨削阻力的影响。     

Mesh cutting during real-time physical simulation

The ability to cut through meshes in real-time is an essential ingredient in a number of practical interactive simulations. Surgical simulation, cloth design, clay sculpting and many other related VR applications require the ability to introduce arbitrary discontinuities through models to separate, reposition, and reshape various pieces of the model as needed for the target application. In addition, in order to provide the necessary realism for these applications, model deformations must be computed from an underlying physically-based model—most commonly a continuum-based finite element model.In this work, we present a method for representing and computing, at interactive rates, the deformations of a mesh whose topology is being dynamically modified with multiple virtual tools. The method relies on introducing controlled discontinuities in the basis functions used to represent the geometry of deformation, and on fast incremental methods for updating global model deformations. The method can also generate the forces needed for force rendering in a haptic environment. The method is shown to scale well with problem size (linearly in the number of nonzeros of the Cholesky factor) allowing realistic interaction with fairly large models.     

Analytic construction and analysis of spiral pocketing via linear morphing

In numerical control, pocketing is a widely extended machining operation with different industrial applications. Conventional strategies (directional and contour parallel) provide a uniform material removal rate, but they show discontinuities and undesirable stops. However, smooth spiral paths overcome discontinuities, although the removal rate is not constant, and their implementation is complex. In order to provide an in-between solution, our algorithm embeds an Archimedean spiral into a linear morphing definition of the pocket. The solution is smooth, simple, analytic, and leads to a B-spline curve. Different tests were performed to compare the proposed spiral to other conventional and spiral strategies. To study the influence of the tool-path geometry, we computed engagement angle and feed direction, and measured force and time. The results demonstrate that our spiral is a committed, analytic and easy to compute solution.     

基于LS-DYNA刨刀刨削煤岩的模拟研究

利用有限元分析软件LS-DYNA,建立刨煤机刨刀刨削煤层的三维模型,模拟刨刀刨削煤层的动态过程。研究中,获取了刨刀刨削阻力、应力分布等时间历程曲线,分析了刨刀不同刨削深度、刨刀间距和刨刀宽度对刨削能耗的影响。     

Parallel simulation of DEDS via event synchronization

In this paper we use the event synchronization scheme to develop a new method for parallel simulation of many discrete event dynamic systems simultaneously. Though a few parallel simulation methods have been developed during the last several years, such as the well-known Standard Clock method, most of them are largely limited to Markovian systems. The main advantage of our method is its applicability to non-Markovian systems. For Markovian systems a comparison study on efficiency between our method and the Standard Clock method is done on Connection Machine CM-5. CM-5 is a parallel machine with both SIMD (Single Instruction, Multiple Data) and MIMD (Multiple Instruction Multiple Data) architectures. The simulation results show that if event rates of Markovian systems do not differ by much then both methods are compatible but the Standard Clock method performs better in most cases. For Markovian systems with very different event rates, our method often yields better results. Most importantly, our simulation results also show that our method works as efficiently for non-Markovian systems as for Markovian systems.     

正交切削加工过程仿真

为优化正交切削加工参数,采用弹-塑热耦合有限元方法,建立正交切削加工有限元模型.应用DEFORM软件,模拟出45号钢件切削过程中变形区内温度、应力、应变以及切削力的分布,采用自适应网格重划技术避免大塑性变形引起的网格畸变.该仿真结果能对切削加工参数的选择及实际的切削加工提供指导.     

单晶金属AFM切削过程的分子动力学模拟

使用三维分子动力学方法模拟了基于AFM针尖的不同结构(FCC,BCC)的单晶金属(铝,铁,铜,镍)的纳米切削过程,研究了单晶金属延展性能对切削过程工件材料变形的影响。使用Morse势计算工件原子之间,工件原子和刀具原子之间的相互作用。观察和分析了切削过程中切屑形成,工件变形区域,以及系统势能变化。模拟结果显示单晶金属延展性能对基于AFM的纳米切削过程有显著影响。     

一种有效的求解一维下料问题的启发式算法

使用了一种改进的顺序启发式算法,在排样方式的生成过程中不断修正当前排入毛坯的价值,使之趋于合理,依次选取求解背包函数获得的最大单位价值的排样方式组成当前排样方案,迭代调用该过程多次,最终选取最优的排样方案。在保证较高材料利用率的同时考虑减少排样方式,增加最后一根材料余料长度等多个优化目标。通过多组实验结果比较,证实了算法的有效性。     

Algorithms for 3D guillotine cutting problems: Unbounded knapsack, cutting stock and strip packing

We present algorithms for the following three-dimensional (3D) guillotine cutting problems: unbounded knapsack, cutting stock and strip packing. We consider the case where the items have fixed orientation and the case where orthogonal rotations around all axes are allowed. For the unbounded 3D knapsack problem, we extend the recurrence formula proposed by [1] for the rectangular knapsack problem and present a dynamic programming algorithm that uses reduced raster points. We also consider a variant of the unbounded knapsack problem in which the cuts must be staged. For the 3D cutting stock problem and its variants in which the bins have different sizes (and the cuts must be staged), we present column generation-based algorithms. Modified versions of the algorithms for the 3D cutting stock problems with stages are then used to build algorithms for the 3D strip packing problem and its variants. The computational tests performed with the algorithms described in this paper indicate that they are useful to solve instances of moderate size.     

Heuristic for the two-dimensional arbitrary stock-size cutting stock problem

A heuristic is presented for the two-dimensional arbitrary stock-size cutting stock problem, where a set of rectangular items with specified demand are cut from plates of arbitrary sizes that confirm to the supplier’s provisions, such that the plate cost is minimized. The supplier’s provisions include: the lengths and widths of the plates must be in the specified ranges; the total area of the plates with the same size must reach the area threshold. The proposed algorithm uses a pattern-generation procedure with all-capacity property to obtain the patterns, and combines it with a sequential heuristic procedure to obtain the cutting plan, from which the purchasing decision can be made. Practical and random instances are used to compare the algorithm with a published approach. The results indicate that the trim loss can be reduced by more than half if the algorithm is used in the purchasing decision of the plates.     

螺旋锥齿轮数控切削仿真系统研究

针对目前螺旋锥齿轮切削仿真系统独立性差、仿真速度慢、精度低、很难实现实时仿真等问题, 提出了刀具和轮坯进行布尔运算的一种新方法,即将螺旋锥齿轮加工区域层片分割后与刀具切削面求交的方法,在此基础上研究了切削过程的可视化及其实现,并基于虚拟现实技术开发出了螺旋锥齿轮数控加工仿真系统,介绍了该仿真系统的整体结构、各个模块的作用以及实现的流程。仿真实例验证了核心算法和仿真系统的正确性和有效性。     

Hybrid heuristic algorithm for two-dimensional steel coil cutting problem

This paper is concerned with the problem of two-dimensional cutting of small rectangular items, each of which has its own deadline and size, from a large rectangular plate, whose length are more than one thousand times its width, so as to minimize the trim loss and the reduction of the times of clamping and changing speed are also concerned. This problem is different with the classical two-dimensional cutting problem. In view of the distinguishing features of the problem proposed, we put forward the definition of non-classical cutting, that is to say, put a series of items on the rectangular plates in their best layout, so as to enhance utility and efficiency at the same time. These objectives may be conflicting and a balance should be necessary, so we present a Hybrid Heuristic Algorithm (HHA), consisting of clustering, ordering, striping and integer programming etc. We demonstrate the efficiency of the proposed algorithm through the comparison with the algorithm we studied before.     

无嫉妒蛋糕分配中的谎言

对于给定的任意一个蛋糕分配算法,研究了玩家能从谎报中获取多大的利益。考虑两种类型的玩家：风险寻求玩家和风险厌恶玩家,并且把玩家的价值密度函数限制为分段常数。证明了风险寻求玩家和风险厌恶玩家均不能从谎报中获取更多利益。但如果只允许算法在蛋糕上切[n-1]刀,证明了玩家通过谎报能够拿到多出[Θ(n)]倍的利益。     

CO_2激光器加工晶圆切缝控制工艺研究

晶体硅是当前最重要的半导体材料,主要用于微电子技术。随着微电子技术的发展,对晶圆的切割技术要求越来越高,而在实际切割中,对晶圆的切割十分注重于晶圆的切割宽度,以降低晶圆损耗。研究CO2激光切割机的脉宽、频率以及切割速度对晶圆切割宽度的影响,从而达到高效率、小宽度、高标准的激光切割加工。