Cross wedge rolling is a high-efficiency, low-cost, and environmentally friendly method for forming shaft parts. It is an essential component of modern advanced manufacturing technologies. As the complexity of parts processed through this technique increases, the design and production of cross wedge rolling dies have become a critical challenge in ensuring accurate and successful part formation.
Virtual Machining (VM) has long been a focal point in CAD/CAM research both domestically and internationally. By utilizing VM technology, engineers can simulate the entire cross wedge rolling process on a computer before actual machining begins. This allows for the evaluation of moldability, significantly improving the success rate of the die, reducing development time, lowering costs, and ensuring higher quality outcomes.
Traditionally, the process of designing and manufacturing cross wedge rolling dies involves several stages: first, the designer creates the mold based on specifications; then, the technician generates the CNC program; finally, the design and code are verified through trial cutting. This approach not only prolongs the development cycle but also increases expenses. In contrast, virtual machining enables the simulation and evaluation of the die in a digital environment, eliminating reliance on experience and enhancing precision.
The architecture of the Virtual Machining System (VMS) for cross wedge rolling consists of multiple layers. The underlying support layer includes hardware, operating systems, databases, and CAD/CAM software. The application layer comprises modules such as Modeling and Simulation (MEM), Automatic Programming (AP), NC Code Recognition (INCC), and Machining Process Simulation (SMP). The implementation concept layer integrates advanced manufacturing principles like Concurrent Engineering (CE) and Virtual Manufacturing (VM), which are crucial for the effective operation of VMS.
The flowchart of the cross wedge rolling die manufacturing process outlines the steps to create a realistic virtual machining environment that mirrors real-world conditions. This environment includes models of the machine tool, fixtures, and tools. For simplicity, non-essential components can be omitted while still capturing the necessary geometric and functional features.
The Automatic Programming Module (APM) plays a vital role in the system. It extracts relevant geometry and process information from the die design, generates a machining process file, and translates it into NC code for the machine tool. This module bridges the gap between design and manufacturing by converting design features into meaningful machining features through feature matching and set operations.
The NC Code Recognition Module (INCCM) analyzes the NC program to extract motion and state-related data, generating an intermediate simulation file. Preprocessing tasks involve removing unnecessary elements and checking for lexical and grammatical errors. The system also translates G codes, M codes, F codes, S codes, and T codes to accurately represent the machine's movements and settings.
The Machining Process Simulation Module (SMPM) simulates the material removal process by performing Boolean subtraction between the tool scan and the workpiece. It detects interference and collisions, including local gouging and global collision, which can damage the workpiece or the machine itself. The system alerts users when such issues occur, ensuring safe and accurate simulations.
One of the key objectives of the simulation is to verify whether the machined surface remains within the desired tolerance. By comparing the NC program with the ideal model, the system provides detailed feedback on undercuts, overcuts, and accuracy levels.
In conclusion, virtual machining for cross wedge rolling dies holds significant practical value and research potential. This paper presents the architecture and implementation of the VMS, laying the foundation for its future development and application. However, current systems do not account for factors like cutting forces, tool wear, and vibration. Future improvements should integrate these elements to enhance the realism and reliability of the simulation.
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