走心車銑複合機實體切削模擬暨切削參數最佳化系統開發;Development of a Swiss-Type Turn-Mill Machine Tool Solid Cutting Simulation System with Cutting Parameters Optimization

[[abstract]]為因應汽車、航太、醫療產業的複雜化、客製化及多樣化零組件加工，車銑複合機將在工具機產業扮演著重要角色，透過結合車削加工、銑削加工與只需一次加工前準備動作等特色，成為主要用來加工複雜零組件的工具機。車銑複合機應用在加工批量、精密且小型零件，大多以走心車銑複合機為主，其特色為具有多軸向及雙系統等；這些特色雖然能提高加工效率，但操作過程複雜且容易發生刀具與工件產生干涉現象，導致走心車銑複合機的學習時間曲線拉長，加工產業之技術人員人力資源產生斷層及技術流失的現象。因此本研究將開發一融入切削物理量的輔助教學加工模擬系統，使用OpenGL為基礎的API建構虛擬工具機及實體切削模擬模組，並以Visual Studio 2013的系統開發環境開發虛擬人機介面模組、碰撞警示模組、NC解譯及插補模組、切削力預估模組，改善切削參數模組等功能，協助技術人員了解、練習、熟悉走心車銑複合機的加工操作過程，最後經由實際教學案例之加工流程操作與模擬，透過複合的加工方法(車、銑、鑽、切斷加工)，模擬切削出加工範例工件。市面上在加工方面主要利用CAM軟體來設計產品、產生加工程式與實體切削模擬，利用整機模擬軟體如VERICUT來驗證加工程式，利用切削參數最佳化軟體如MACHPRO來改善切削參數，本研究透過整合以上軟體的整機模擬功能、常用之CNC控制器功能、實體切削模擬功能、碰撞偵測功能、以及預估切削力與穩態切削圖為主的改善切削參數功能，並且開發讓使用者操作的虛擬人機介面功能，經由上述之功能模組的整合，成功完成目前市面上沒有，但是加工應用端迫切需要的走心車銑複合機教育訓練系統，並達成改善切削參數之目的。 In order to adapt to the customization and diversification of complex parts processing in automobile, aerospace and medical industry, turn-mill machines are playing increasingly more and more important role in the machine tool industry, which has become the mainstream machine tool of machining complex parts in one set-up with combination of turning and milling machining.Swiss-Type turn-mill machines, which are capable of multi-axis machining and controlling two independent system, are widely used in machining lots of small precision parts in turn-mill machines. However, due to the complex operations and high risk of tool-workpiece collisions, learning curve of Swiss-Type turn-mill operations is comparatively very long.This research has therefore developed a 3D machining simulation system in assisting instructions with the integration of physical effects. The functions of cutting simulation and virtual machine tool movements have been developed for the simulation of actual movement and machining of machine tool by an OpenGL-based API. The developed functions include virtual human machine interface, collision detection, NC interpreter, NC interpolator, cutting force calculation and cutting parameters improvement suggestions have been implemented by Visual Studio C#.In manufacturing, CAM software such as Mastercam are widely used to design products and generate NC programs, machine simulation software such as VERICUT are generally used to verify NC path and avoid collisions, optimization of cutting parameters software such as Machpro are used to improve cutting parameters. In conclusion, this research has successfully developed a virtual human machine interface to integrating the functions of machine simulation, CNC controller, cutting simulation, collision detection, and base on cutting force and stability lobe diagram to suggest improved cutting parameters. The developed system can also be used to assist the learning and training of a complex Swiss-Type turn-mill machine