数字化设计是数控机床设计技术的发展趋势，也逐渐成为机床企业提升产品质量、降低生产周期和成本的重要技术手段。在机床设计阶段通过仿真分析整机静动刚度，并进一步对机床设计进行优化，是机床数字化设计的重要内容之一。目前国内数控机床企业对整机静动刚度的分析，由于缺乏统一的建模分析规范和专用的机床静动刚度分析工具，使得分析周期长，且分析结果可信度低，制约了机床数字化设计技术的进一步发展。本文针对机床数字化设计中存在的上述问题，结合其对整机静动刚度仿真分析效率和仿真精度的综合要求，设计开发了机床整机静动刚度数字化分析工具，重点研究了仿真分析模型简化方法、关键尺寸批量参数化建模方法及结合面自动化建模方法等三项关键问题，设计了相应的算法，并利用Pro/E和ANSYS Workbench的二次开发功能，对该工具进行了软件实现和应用验证。针对仿真模型的简化问题，提出了一套基于闭合力学系统和受力流的模型简化方法，并针对不同的机床系统部件提出了相应简化策略。为验证模型简化方法的有效性，并对不同简化策略进行量化对比，论文还提出了模型简化有效性评价指标。实例分析表明，该模型简化方法可在保证分析精度的同时，大幅降低仿真分析时间。为实现整机静动刚度分析的自动建模，本文根据所提出的模型简化方法，设计了针对微小部件，圆倒角和小孔的识别与删简算法，关键部件特征尺寸批量参数化算法，以及结合面自动化辅助建模算法，为分析工具软件的开发奠定基础。依据数控机床整机静动刚度分析规范，设计了分析工具软件的实现架构。基于上述关键技术和算法研究成果，利用Pro/E的VBAPI二次开发模块及ANSYS Workbench脚本驱动二次开发功能，实现了机床整机模型简化、自动建模以及机床静动刚度定制化分析模版的开发，并对一台高精度数控磨床进行了软件应用验证，分析结果具备了较高的分析效率和精度，为机床的静动刚度优化奠定了基础。本文首先针对数控机床数字化设计的研究现状，回顾了其静动刚度分析的规范和现有的分析工具研发情况，明确了现有研究和实际应用间所存在的问题——缺乏模型简化规范，缺乏模型简化方法及结合面自动化辅助建模算法，现有通用FEM软件无法满足机床静动刚度分析需求等，并结合课题要求，明确了分析工具的设计背景和目标，并设计了其整体实现架构。
Digital design is the trend of NC machine tool design technology and becoming a critical method for enterprise to improve product quality, reduce production cycle and cost. Analyzing the static and dynamic behavior of machine tool by using simulation method at the stage of design plays an important role in machine tool digital design, which affects the further optimization of it. Nowadays, due to the shortage of consistent machine tool analysis standard and specific analysis software of static and dynamic stiffness, many enterprises are facing the problems such as long analysis cycle, low accuracy of analysis results etc., that limit the development of machine tool digital design technology. This paper focused on the above existing problems and then designed one kind of software tool for the analysis of static & dynamic stiffness aimed at the whole machine tool. Specific to the main issues – higher analysis efficiency and higher analysis accuracy – this paper focused on the model simplification method, key geometry serial parameterization method and joint surface automatic modeling method, finally using the secondary development functions of Pro/E and ANSYS Workbench this software tool was developed.Aimed at the model simplification issue a simplification method based on force circle and force flow was proposed. It distinguished parts into different categories with different simplification methods by considering the effects on static & dynamic stiffness of machine tool. For further comparison of different simplifications an index of model simplification effectiveness was created. Via some case study, this method could guarantee the accuracy of analysis and simultaneously reduce the time of analysis.Based on the above methods several algorithms focusing on tiny part/ chamfer & round/ hole feature identification and deleting, serial parameterization of key geometry and automatic modeling of joint surface were designed, which provided a possibility for the further software development.Referred to the analysis standard a software entire developing structure was proposed. Using the VBAPI of Pro/E and script-driven secondary development function of ANSYS Workbench, a model simplification tool and a customized simulation template were developed. This software tool was then tested by conducting an application verification on a high-precision grinding machine tool, which was proved to have a relative high analysis efficiency and accuracy. The result provided a reference for the further automatic optimization of NC machine tool design.This paper first did a brief review of current research of NC machine tool digital design, analysis standard of static & dynamic stiffness and certain software tool. The main focusing problems are model simplification standard, model simplification method and joint surface semi-automatic modeling algorithms etc. Based on the review, the application background and target of this software tool was clearly understood and simultaneously the entire software procedure was established.
