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研究生：	謝恩平 Hsieh, En-Ping
論文名稱：	應用八元樹法於銑削力預估之五軸虛擬工具機系統 An Octree Method for Milling Force Prediction in Five-Axis Virtual Machine Tool
指導教授：	李榮顯 Lee, Rong-Shean
學位類別：	碩士 Master
系所名稱：	工學院 - 機械工程學系 Department of Mechanical Engineering
論文出版年：	2013
畢業學年度：	101
語文別：	中文
論文頁數：	127
中文關鍵詞：	八元樹、五軸、銑削力預估、虛擬工具機
外文關鍵詞：	Octree, Five-Axis, Milling Force Predicition, Virtual Machine Tool
相關次數：	點閱：95 下載：8
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在航太、生醫、模具等產業常使用五軸工具機來進行產品開發，由於五軸工具機能提供較大的彈性與變化，並大幅減少加工時間與提升產品精度，是目前工具機產業發展之趨勢。但五軸加工時，工程師為確保加工過程順利，必須反覆測試程式並採用相對保守的加工條件，其目的是為避免撞機或刀具所負荷之銑削力過大導致刀具斷裂等危險，因此本文提出一套預估五軸銑削力之虛擬工具機系統，做為工程師事先檢查加工情況並評估加工參數是否合乎要求的解決方案。
銑削力方面，本文提出結合應用八元樹法之虛擬切削與五軸銑削力模型之演算法，此方法可適用於一般化刀具幾何與五軸運動，隨加工路徑模擬刀具與材料之干涉幾何，並預估其五軸加工之瞬時靜態銑削力。
為模擬實際加工過程，本文提出虛擬工具機系統之架構，並實作出虛擬機台與控制器，虛擬工具機不但具備基本控制器之功能與正確模擬運動之情形外，還可藉由套用符合介面之真實或虛擬控制器比較其差異。
最後，本文以文獻驗證本研究所產生之模擬結果，並證實本文提出之銑削力預估演算法可正確模擬五軸工具機之各種運動形式之瞬時靜態銑削力，具有實際應用之價值。在虛擬工具機系統方面，本文以實際程式比較真實控制器與虛擬控制器之差異，並顯示在虛擬控制器能夠準確模擬運動之情形。

Generally, products for aerospace or mold industries need superior precision. Since the manufacturing processes are difficult and time-consuming in traditional 3-axis machine tool. To improve the accuracy and productivity of the products, the five-axis machine tools are introduced to the manufacturing industries. In five-axis machining, engineers set the operation parameter more cautious to decrease the possibility of tool breakage caused by peak force, which is ineffective and time-consuming. To solve the aforementioned problems, a system to simulate the milling process and to predict milling force is proposed. The contribution of the thesis includes an algorithm connecting between geometric simulation and instantaneous static milling force model in five-axis machining process and a system to monitor the milling force in the five-axis virtual machine tool.
An algorithm combining octree method of geometry simulation with general milling cutter and five-axis semi-discrete milling force model is developed. It presents the cutter-workpiece engagement geometry along tool paths and predicts the milling force at the same time. Moreover, a five-axis virtual machine tool simulation system is developed. It provides basic functions of commercial controllers and presents five-axis motion animation. Furthermore, it presents the comparison with the tool paths via virtual controller and commercial controller.
Finally, the algorithm of milling force prediction is verified by previous literature, and it proved that the result of this thesis is reasonable; and the virtual five-axis machine tool system simulates the entire operation appropriately. As a consequence, the prediction of milling force in five-axis virtual machine tool system is reliable and valuable.

摘要 .................................................................................................................... I
Abstract............................................................................................................. II
誌謝 ................................................................................................................. III
目錄 ................................................................................................................. IV
表目錄 ........................................................................................................... VII
圖目錄 ............................................................................................................. IX
符號說明 ...................................................................................................... XIII
第一章 緒論 .............................................................................................. 1
1-1 前言 .................................................................................................... 1
1-2 文獻回顧 ............................................................................................ 3
1-2-1 五軸工具機 ............................................................................ 4
1-2-2 幾何切削模擬 ........................................................................ 5
1-2-3 銑削力模式 .......................................................................... 13
1-2-4 文獻分析 .............................................................................. 15
1-3 研究目的與範疇 .............................................................................. 19
第二章 基礎理論 .................................................................................... 20
2-1 齊次轉換矩陣 .................................................................................. 20
2-2 適應性八元樹切削模擬演算法 ..................................................... 25
2-3 插補演算法 ...................................................................................... 27
2-3-1 線性軸插補 .......................................................................... 29
2-3-2 旋轉軸插補 .......................................................................... 32
2-4 一般化端銑刀 .................................................................................. 35
2-5 三軸銑削力模式 .............................................................................. 40
2-5-1 刀具座標系與定義 .............................................................. 40
2-5-2 水平進給之三軸銑削力模型 .............................................. 42
2-5-3 斜向進給之三軸銑削力模型 .............................................. 45
2-6 五軸銑削力模式 .............................................................................. 47
2-6-1 直線運動 .............................................................................. 47
2-6-2 旋轉運動 .............................................................................. 49
2-6-3 進給偏轉效應 ...................................................................... 50
2-6-4 斜向進給之五軸銑削力模型 .............................................. 51
2-6-5 五軸銑削力計算流程 .......................................................... 53
第三章 系統核心理論 ............................................................................ 54
3-1 概述 .................................................................................................. 54
3-2 前處理 .............................................................................................. 57
3-3 建立切削範圍表格 .......................................................................... 63
3-4 計算銑削力 ...................................................................................... 67
第四章 虛擬工具機系統架構 ................................................................ 71
4-1 虛擬機台 .......................................................................................... 73
4-2 虛擬控制器 ...................................................................................... 78
4-2-1 外部介面 .............................................................................. 79
4-2-2 基礎架構 .............................................................................. 81
4-3 虛擬工具機銑削力模擬流程 ......................................................... 84
4-3-1 MDI模式 ............................................................................... 84
4-3-2 檔案執行模式 ...................................................................... 85
第五章 結果與討論 ................................................................................ 86
5-1 虛擬工具機之路徑驗證 ................................................................. 86
5-1-1 循圓測試 .............................................................................. 87
5-1-2 鞋模加工 .............................................................................. 88
5-2 銑削力預估之文獻驗證 ................................................................. 93
5-2-1 三軸銑削力驗證 .................................................................. 93
5-2-2 五軸刀具傾擺銑削力驗證 ................................................ 106
5-2-3 五軸同動銑削力驗證 ........................................................ 113
5-3 討論 ................................................................................................ 117
第六章 結論與建議 .............................................................................. 119
6-1 結論 ................................................................................................ 119
6-2 建議 ................................................................................................ 121
參考文獻 ....................................................................................................... 122
                                    

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