Study On The Key Technologies Of Pre-treatment Of Milling Simulation With Abaqus And Redevelopment

The technology of "birth-death elements" can effectively solve the problem that physical simulation is difficult to simulate the actual machining process.However,this method still exists some problems,such as huge workload to do,not accurately set elements death and the bad combination of physical simulation and geometric simulation,etc.This paper studied the key technologies of pre-treatment of milling simulation based on Abaqus "birth-death elements",such as dispersing tool path,establishing cutter swept volume,setting elements death and loading milling force.As a result,we can automatically and accurately set " birth-death elements" and load the milling force according to the tool geometry and tool path.This can greatly improved the accuracy and practicability of this simulation method.The main work and results are summarized as follows:(1)Reading and dispersing NC milling tool path from UG through the Python language programming.Raising the six-parameter tool model and establish the tool swept volume through the principle of tool swept volume modeling based on Gauss mapping.This can strenghthen the combination of physical simulation and geometric simulation.(2)Setting the elements death according to the tool swept volume through the parity discrimination method;computing the milling forces in X,Y,Z directions according to the tool path and loading them on "birth-death elements" in order to simulate the effect of milling force between workpiece and tool during the milling process.(3)Based on the study on the key technology of the pre-treatment,establishing an Abaqus plug-in for three-axis milling simulation.This plug-in can be applied to various of workpieces,tools and milling processings.(4)The pre-treatment of the typical thin-walled workpiece milling simulation is carried out through the plug-in.Machining the thin-walled parts and measure deformation.The simulation results and the machining results are compared to verify the correctness of the pre-treatment key technologies and the pre-treatment plug-in.