臺灣博碩士論文加值系統

因應當今對於加工產品高精度、高複雜度的要求，多軸加工技術已成為航空、模具等注重加工品質的產業發展趨勢。對於擁有傾斜平面及容易發生加工干涉的工件，能夠更加凸顯其具備旋轉軸的優勢，透過調整刀具軸向可以進行干涉避讓、傾斜平面定位，不僅增加了加工精度與安全性，也可以節省多次裝卸定位工件所需的時間，但也提升了刀具路徑編程的複雜程度。現今大多數的加工需求，以人工方式進行路徑編程相當困難，須使用CAD/CAM軟體，目前常用的CAD/CAM軟體雖然各項功能趨於完善，但授權費用昂貴，且軟體中許多功能可能使用不到，應用方面也不易根據使用者的需求更改操作流程，雖然部分軟體有提供二次開發，但開發門檻較高，因此只能被動的適應各家廠商軟體的使用方式。
本研究基於ModuleWorks的函式庫進行多軸加工模擬系統開發，函式庫中各項功能模組為獨立，可依照使用需求調整實現方式。以Visual Studio C#與OpenGL建立使用者介面，工具機的圖形採用STL的格式，透過三角網格的方式進行渲染，矩陣堆棧的分層可使各軸的移動情形依照現實工具機的軸向關係分為獨立或者同時運動，再將各個軸向的移動值設為變數，使用者便可透過介面控制工具機的軸向移動。工件的圖形則採用IGES的格式，將表面轉換為網格形式，OpenGL的投影函式可將座標點由三維空間轉換至二維螢幕座標系，再結合滑鼠的動作，可選取工件上的曲面、曲線與點特徵，以便編程時指定加工區域或是驅動特徵。路徑編程、切削與機台模擬、碰撞檢測、後處理等功能則是透過函式庫中的各種類別實現，調用類別中的函式便可獲得計算後的結果，再透過座標系的偏置，可呈現工具機進行加工模擬的情形。
將工件圖形載入至本研究開發之加工模擬系統，可進行路徑編程、加工模擬與後處理，為了驗證系統所輸出的NC程式，使用商用模擬軟體VERICUT進行驗證，包括RTCP與非RTCP的兩種路徑輸出方式，並以真實的五軸工具機進行加工測試。經由模擬與實驗測試，驗證本研究發展的系統之正確性。

In response to the requirements of high precision and high complexity of machined products, multi-axis machining technology has become the development trend of aviation, mold and other industries that pay attention to machining quality. For workpieces with inclined planes and prone to machining interference, the advantage of rotary axis is highlighted as it can avoid interference and fix position on an inclined plane by adjusting the axial direction of the tool, which not only increases the machining accuracy and safety, but also saves the time required for reclamping operations. However, it can also increase the complexity of tool path programming relatively. Most of today's processing needs is quite difficult to program the path manually and CAD/CAM software must be used. Although the functions of CAD/CAM software are near perfection at present, the authorization cost is expensive. Since many functions in the software may not be used, it is not easy to change the operation process according to the needs of users. Despite its flexibility for secondary programming, the development threshold is relatively high. Therefore, the user can only adapt to the use of software.
This research was based on ModuleWorks function library to develop multi-axis machining simulation system. The functional modules in the function library were all independent, and the implementation could be adjusted according to the user requirements. The user interface was established with Visual Studio C# and OpenGL. The graph of the machine tool adopted STL format and was rendered by mesh segmentation. The layering of matrix stack allowed the movement of each axis proceed independently or simultaneously according to the axis relationship of actual machine tool, where the movement value of each axis is set as a variable, and the user could control the axis movement of the machine tool through the interface. The graphics of the workpiece adopted IGES format, which transforms the surface into grid form. The projection function of OpenGL would transform the coordinate points in three-dimensional space to two-dimensional coordinate system on screen. The curved surface, the curves and point features on the workpiece could be selected with the use of mouse, so as to specify the machining area or driving features when programming. Path programming, cutting and machine simulation, collision detection, post-processing and other functions were achieved through various categories of the function library. The calculated results were obtained by calling the functions in the categories, and then the machining simulation of the machine tool could be presented through the transformation of the coordinate system.
The workpiece graphics were loaded into the machining simulation system developed in this research, which can be used for path programming, machine simulation and post-processing. In order to verify the generated NC program including RTCP and non-RTCP path modes, the commercial simulation software VERICUT was used. The machining test was carried out with a real five-axis machine tool. Through simulation and experimental test, the correctness of the developed system in this study was verified.

摘要...i
Abstract...ii
誌謝...iv
目錄...v
表目錄...vii
圖目錄...viii
符號說明...xi
中英文對照表...xii
第一章 緒論...1
1.1 研究背景與目的...1
1.2 文獻回顧...2
1.2.1 工具機模擬...2
1.2.2 後處理...3
1.2.3 導入外部函式庫...4
1.3 研究方法...5
1.4 論文架構...8
第二章 相關技術...9
2.1 使用軟體介紹...9
2.1.1 Microsoft Visual Studio...9
2.1.2 Vericut...10
2.1.3 Mathematica...10
2.1.4 hyperMILL...11
2.2 ModuleWorks...12
2.3 圖形格式...12
2.3.1 STL...12
2.3.2 IGES...13
2.4 OpenGL...15
2.5 Modern OpenGL...16
2.6 五軸工具機後處理...17
2.7 線性化插補...19
2.8 尤拉角轉換...22
第三章 程式模組開發...24
3.1 系統架構...24
3.2 系統具備功能...25
3.3 載入工件與機台模型...26
3.4 OpenGL圖形顯示...28
3.5 圖形選取...36
3.6 加工路徑編程...37
3.7 切削模擬...40
3.8 碰撞偵測...45
3.9 過切餘量...49
3.10 後處理...50
第四章 程式功能介紹...52
4.1 系統介面...52
4.2 系統使用流程...57
4.3 異常檢視...61
4.4 刀具路徑編程...64
4.4.1 加工參數...64
4.4.2 編程範例...71
第五章 結果與討論...80
5.1 斜平面座標系轉換驗證...80
5.2 ModuleWorks後處理驗證...83
5.2.1 參數方程式驗證...83
5.2.2 VERICUT驗證...85
5.3 ModuleWorks插補與線性插補對照...88
5.4 實際加工測試...90
5.4.1 問題排除...91
5.4.2 模擬與實際對照...93
5.4.3 尺寸量測...96
5.5 圖形可視化...97
5.5.1 可視化方式...97
5.5.2 ModernOpenGL...97
第六章 結論與未來展望...101
6.1 結論...101
6.2 未來展望...102
參考文獻...103
附錄一 路徑計算依據及樣板...105
附錄二 刀軸傾擺方式...110
Extended Abstract...112

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