基于数控加工仿真平台的工艺参数优化系统的研究

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摘要

本文针对数控系统中所集成的加工仿真模块功能单一、不能满足多种加工形式

的仿真需求，根据开放式数控系统的软硬件特性，提出一种可与开放式数控系统

集成的数控加工仿真方案，即根据加工仿真需求，通过对数控系统软件的二次开

发和集成，扩展数控系统中加工仿真模块的功能。同时为了完成常用工艺参数的

存储和工人经验数据的收集，集成一个面向机床的切削加工工艺参数库。在此基

础上，研究了数控程序中工艺参数的自动处理方法。

数控加工的图形仿真能够对实际加工过程进行验证，能有效的减少加工事故，

因而得到广泛的应用。本文设计了程序所需的数据结构和基本运算库，分析了数

控程序的翻译方法，完成了数控程序中刀具轨迹、进给速率和主轴转速等信息的

提取。根据数控铣床的加工特性，建立工件和刀具的数学模型，设计了加工仿真

算法，结合 OpenGL 和Open Inventor，设计开发了数控加工的图形仿真系统，完

成了刀具轨迹的验证和切削过程的仿真，并能记录切削过程中各个状态下的主轴

转速、进给速率、刀具切削宽度和切削深度。

数控机床操作工人一方面需要查询常用的工艺参数，另一方面，他们的在生产

中所积累的经验数据对生产具有重要的指导意义。本文设计了一个面向机床的数

控加工工艺参数数据库，根据机床的加工特性存储常用的参数，将其集成到数控

系统软件中，使得工人能够在数控机床的操作面板上就能完成工艺参数的查询，

并提供数据录入功能，用来完成经验数据的收集。

数控程序中工艺参数的科学性和可靠性将直接影响到产品的质量、生产成本等

关键指标，因而对工艺参数合理的选取和优化具有重要的现实意义。本文根据加

工仿真过程所获得的主轴转速、进给速率、刀具切削宽度和切削深度信息，对数

控程序中进给速率的自动分配方法进行研究，提出了以单位时间内刀具所允许切

削的材料的体积为依据，为数控程序分段分配进给速率的方法，实现了进给速率

的自动优化分配。

最后通过一个加工实例，验证了仿真系统各个模块的功能，通过分析比较，证

明本文提出的进给速率分配策略有效性，同时发现了系统的不足，并提出了改进

方向。

关键词：加工仿真工艺参数数据库进给速率优化 LEX 与YACC

ABSTRACT

Aiming at the NC system soft-ware’s deficiency of being unsatisfactory to different

needs of simulation, according to the hardware and software architecture, a solution of

integrating a user-developed simulation system with NC system soft-ware is presented.

Meanwhile, in order to store the cutting machining processing technic parameters and

collect the empirical data of machine operators, a database is also integrated. Base on

the simulation system and the database, the auto-process of NC program is studied.

The computer graphic simulation of NC cutting machining which can verify the

cutting process accurately and prevent accidents, is widely used. The data structures and

algorithms needed during the development of system are designed in the paper, and the

NC program interpreting method is analyzed, so the CLP (cut location point), feed-rate,

spindle-speed and other information contained in the NC program can be extracted.

According to the machining features milling, the mathematic model of work piece and

tools is built, and the simulation algorithm is designed, with the support of OpenGL and

Open Inventor, the tool track verification and cutting process simulation is completed,

and the process technic parameters during the process can be recorded automatically.

The main subject of the paper is to build a numerical control (NC) machining

simulation system that can be integrated with Open-NC-system, based on which a

machine-oriented cutting machining processing technology database is constructed, in

order to implement the NC program verification, front-line manufacturing experiential

data extraction, machining parameters auto-process.

NC machine tools operators often have to query common used parameters and

their empirical data is also of great significance to production. A machine tool oriented

cutting process technic parameters database that can be integrated with NC system

software is designed according to the milling features, so that the operators can query

the information they need just on the control panel of NC system and the empirical data

can also be collected.

The scientificalness and reliability of the cutting process technic parameters in NC

program determine the product quality, production cost and other key factors, so the

selection and optimization of the process technic parameters in NC program is very

important. Based on the information, such as feed rate, spindle-speed, cut-depth and

cut-width of tool, which are gotten from the simulation process, the auto-process

method of feed-rate is studied, and a strategy based on the amount of material removed

in a time unit, of automatically calculating and inserting improved feed rates where

necessary into the NC program is presented, and the auto-distribution of feed-rate is

completed.

Finally, an example is presented to demonstrate the good performance of graphic

machining simulation system. According to analytical comparison, the validity is

proved. Meanwhile, the deficiencies of the system are discovered, and the later work of

this paper is pointed out.

Key Word: Machining simulation, Process technic parameters

database, Feed-rate optimization, LEX and YACC

中文摘要 ...........................................................................................................................1

ABSTRACT .....................................................................................................................2

第一章绪论 ........................................................ 1

§1.1 背景和意义......................................................................................................................1

§1.2 数控加工仿真系统和切削参数优化的发展现状................................................ 2

§1.2.1 数控加工仿真系统的发展现状 ...............................................................2

§1.2.2 工艺数据库和切削参数优化的发展现状 ...............................................3

§1.3 本课题的主要工作.......................................................................................................4

第二章系统分析和系统结构设计 ...................................... 7

§2.1 需求分析.......................................................................................................................... 7

§2.1.1 数控加工的图形仿真 ...............................................................................7

§2.1.2 工艺参数数据库和数控代码的处理 .......................................................8

§2.2 系统的结构设计与实现...............................................................................................9

§2.2.1 数控代码的解析 .......................................................................................9

§2.2.2 数控加工过程的图形仿真 .....................................................................10

§2.2.3 数控加工工艺参数数据库和数控程序的处理 .....................................11

§2.3 开发平台和开发工具................................................................................................. 12

§2.3.1 语法分析器生成工具 ............................................................................12

§2.3.2 开放式图形程序接口 ............................................................................13

第三章数控代码的解析 ............................................. 15

§3.1 数控代码解析概述......................................................................................................15

§3.2 数控代码解析器工作流程........................................................................................16

§3.2.1 编译器工作的一般流程 .........................................................................16

§3.2.2 目标代码格式 .........................................................................................17

§3.2.3 与语法生成器的结合 .............................................................................18

§3.3 数控程序解析器的功能分析................................................................................... 19

§3.3.1 数控程序的一般结构 .............................................................................19

§3.3.2 数控代码解析器原型的功能要求 .........................................................20

§3.4 数控程序解析器的实现.............................................................................................22

§3.4.1 巴库斯范式(BNF)简介 ...........................................................................22

§3.4.2 数控程序中基本语言元素的识别 .........................................................23

§3.4.3 变量和变量的常数赋值的实现 .............................................................26

§3.4.4 表达式的实现 .........................................................................................27

§3.4.5 控制语句的实现 .....................................................................................30

§3.4.6 语义分析简述 .........................................................................................31

第四章数控加工过程的仿真 ......................................... 33

§4.1 数控加工仿真的概述................................................................................................. 33

§4.2 仿真系统的基本模块................................................................................................. 33

§4.2.1 数据结构和几何运算库 .........................................................................33

§4.2.2 图形场景建立 .........................................................................................35

§4.3 数控程序和刀具的管理.............................................................................................36

§4.3.1 数控程序的管理 .....................................................................................36

§4.3.2 刀具模型和刀具库 .................................................................................37

§4.3 加工仿真过程的实现................................................................................................. 39

§4.3.1 工件模型 .................................................................................................39

§4.3.2 干涉点的筛选 .........................................................................................41

§4.3.3 节点高度值 Z 的计算............................................................................43

§4.3.4 工艺参数的提取 .....................................................................................44

§4.3.5 工件模型的 Open Inventor 实现.........................................................45

§4.3.6 加工仿真过程的流程 .............................................................................46

§4.4 加工仿真实例...............................................................................................................47

第五章工艺参数数据库和工艺参数优化 ............................... 52

§5.1 切削工艺参数数据库和工艺参数优化概述........................................................52

§5.2 切削工艺参数数据库的建立................................................................................... 53

§5.2.1 数据库的功能和结构分析 .....................................................................53

§5.2.2 数据库的管理 .........................................................................................55

§5.2.3 输入和输出数据的处理 .........................................................................56

§5.3 进给速率 F 的优化选取.............................................................................................58

§5.3.1 切削工艺参数优化的简述 .....................................................................58

§5.3.2 进给速率优化的策略 .............................................................................58

§5.3.3 进给速率 F 的约束条件和影响因子 .....................................................59

§5.3.4 进给速率 F 的优化选取方法 .................................................................61

§5.3.5 加工实例 .................................................................................................63

第六章结论和展望 ................................................. 68

参考文献 ............................................................ 69

在读期间公开发表的论文和承担科研项目及取得成果 ...................... 72

致谢 .............................................................. 73

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摘要：

摘要本文针对数控系统中所集成的加工仿真模块功能单一、不能满足多种加工形式的仿真需求，根据开放式数控系统的软硬件特性，提出一种可与开放式数控系统集成的数控加工仿真方案，即根据加工仿真需求，通过对数控系统软件的二次开发和集成，扩展数控系统中加工仿真模块的功能。同时为了完成常用工艺参数的存储和工人经验数据的收集，集成一个面向机床的切削加工工艺参数库。在此基础上，研究了数控程序中工艺参数的自动处理方法。数控加工的图形仿真能够对实际加工过程进行验证，能有效的减少加工事故，因而得到广泛的应用。本文设计了程序所需的数据结构和基本运算库，分析了数控程序的翻译方法，完成了数控程序中刀具轨迹、进给速率和主轴转速等...

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