薄壁件加工变形误差预估及补偿的集成

摘要/Abstract

摘要：

针对薄壁件数控加工过程中产生的力致变形误差，提出了一种将变形误差预测与误差补偿进行集成的方法。在提出高效的误差计算迭代算法基础上，采用APDL的方式开发了集迭代计算、刀具走刀、材料去除于一体的误差动态仿真程序，实现全过程加工误差的自动计算。借助UG二次开发工具UG/Open开发的应用程序实现了UG和ANSYS之间的数据通信，根据预测变形误差自动修正CAD模型，继而利用UG CAM生成考虑误差补偿因素的加工代码。研究了涉及误差离线预测及补偿的集成方法的多个关键技术。算例表明：误差预测值逼近实验值，精度可靠；集成软件能够自动生成误差补偿的加工代码，实现了误差离线预测和补偿全过程的CAD/CAE/CAM集成，集成程度高。

关键词: 加工误差, 补偿, 薄壁件, 程序集成, 软件接口

Abstract:

A integration method for error prediction and compensation was established to deal with force-induced errors in NC machining of thin-wall parts. An effective mathematical iterative algorithm of errors was built. The dynamic emulation programs of deformation errors integrating with the error iterative algorithm, cutter moving and material removing were designed by using ANSYS parametric design language. Machining errors through the whole machining process might be calculated automatically. Using UG/Open API (secondary development tool in UG), the data communication interfaces between ANSYS and UG were designed. The CAD model was modified automatically according to the deformation errors. Then the NC codes including error compensation were created by UG CAM. Some key techniques for integration of out-line error prediction and compensation were also studied. It is proved in a three-dimensional milling example that the errors predicted by the APDL program are very close to the experimental results and the integrated softwares can generate automatically the NC codes including error compensation. CAD/CAE/CAM integration including out-line error prediction and compensation is effectively realized.

Key words: machining error, compensation, thin-walled workpiece, program integration, software interface

中图分类号:

TH161

乔凯, 舒小平. 薄壁件加工变形误差预估及补偿的集成[J]. 中国机械工程, 2015, 26(21): 2895-2900.

Qiao Kai, Shu Xiaoping. Integration of Machining Error Prediction and Compensation for Thin-walled Workpieces[J]. China Mechanical Engineering, 2015, 26(21): 2895-2900.

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