臺灣博碩士論文加值系統

近年來許多醫療器材、航太零組件、汽車元件及模具均具有高精度及複雜的空間幾何形狀的需求，使得五軸加工日趨重要，但也因為五軸工具機的自由度大及精度較高，機器承受不起碰撞，所以五軸工具機在執行切削工作前都需要先做切削模擬之測試。有鑑於此，本論文設計出可供機構運動模擬之五軸工具機模型，並利用此機器模型來執行NC刀具路徑之電腦模擬。首先由Pro/ENGINEER設計出五軸工具機的機構模型，並利用Pro/ENGINEER之Pro/Toolkit及Visual C++之MFC為核心程式來開發輔助工具，經由輔助工具讓使用者了解到五軸工具機各軸機構模擬之情形，接下來由PowerMILL設計工件模型及五軸加工NC碼，再經由VERICUT NC切削加工模擬軟體整合前兩者之資料並建立刀具資料後，即可開始進行五軸切削模擬，透過這樣的方式將Pro/ENGINEER、PowerMILL及VERICUT三種軟體中的五軸工具機資料整合為一，讓使用者可以了解五軸工具機的機構運動模擬之情形及切削模擬之結果，也讓使用者在NC加工程式設計完成後可以更簡易、更快速的得到切削模擬之結果。

In recent years, many medical equipments, aerospace components, automobile parts, and moulding devices require a high degree of precision and very complex geometries. This has made five axis machining increasingly important. Due to higher degrees of freedom and better precision associated with five-axis machines, they are susceptible to impacts. Therefore, prior to commencement of the cutting process, five-axis machines must first undergo cutting simulations as a test for impacts. In light of this, this study proposes a five-axis machine model that is capable of motion simulation, and applies this model to the simulation of an NC tool path. A model of the five-axis machine is first developed in Pro/ENGINEER. Supporting tools are also developed using core programs including Pro/ENGINEER’s Pro Toolkit and MFC in Visual C++. With the supporting tools, users can understand the modelled behaviours of each axis in the machine. PowerMILL is used alongside the design workpiece model and NC program. Once information in both models is combined using NC cutting simulation in the software VERICUT, the five-axis cutting simulation can begin. In this way, model data for five-axis machines in all three software programs (Pro/ENGINEER, PowerMILL, and VERICUT) is integrated to provide users with an understanding of motion simulation of five-axis machines and the results of cutting simulation. The designed NC program facilitates easy and rapid delivery of the simulation results to users.

中文摘要 II
ABSTRACT III
誌謝 IV
目錄 V
第一章 緒論 1
1.1 研究背景及動機 1
1.2 研究目的 3
1.3 研究範圍 4
1.4 研究方法 5
1.5 論文架構 6
第二章 文獻探討 8
2.1 五軸加工之文獻 8
2.2 切削模擬及機構設計之文獻 10
2.3 文獻回顧之心得 11
第三章 五軸工具機機構運動之電腦模擬 13
3.1 五軸工具機的型式及分類 13
3.2 Top-down design簡介 19
3.3 五軸工具機之機構設計 20
3.3.1. 以Top-down design建立機構模型 21
3.3.2. 機構模型同步變更之說明 34
3.3.3. 機構組裝及組件參數之介紹 38
3.4 五軸工具機機構運動之電腦模擬輔助工具 46
3.4.1 指定機型模組 48
3.4.2 五軸機構模擬模組 55
3.4.3 檔案轉存模組 59
3.4.4 資料清除模組 61
第四章 五軸工具機NC加工之電腦模擬 62
4.1 五軸工具機資料之整合 62
4.1.1 在VERICUT定義五軸工具機之結構 63
4.1.2 匯入機構模型之STL資料 65
4.1.3 建立或匯入工件模型 69
4.1.4 匯入NC程式 75
4.1.5 刀具資料及刀具座標系之整合 76
4.1.6 工作座標系之定義 81
4.2 五軸工具機NC加工之模擬 82
第五章 系統的運作與實例 87
5.1 系統之運作流程 87
5.2 實例一 89
5.3 實例二 96
第六章 結論及未來研究方向 103
6.1 結論 103
6.2 未來研究方向 104
參考文獻 106
作者簡介 109

1.林清安，Pro/ENGINEER Wildfire 2.0 零件組立與產品設計，知城 數位科技股份有限公司，台北市，2004
2.林清安，Pro/ENGINEER Wildfire 3.0 動態機構設計與模擬，旗標 出版股份有限公司，台北市，2006
3.林晴比古，Visual C++ 2005學習講義，博碩文化股份有限公司，台北，2007
4.李世國，Pro/TOOLKIT程序設計，機械工業出版社，北京，2003
5.王文波，Pro/E Wildfire 4.0 二次開發實例解析，清華大學出版社，北京，2010
6.Parametric Technology Corporation. Pro/ENGINEER Wildfire 4.0 Pro/TOOLKIT Users Guide, MA, USA, 2008.
7.Yoshimi Takeuchia and Takahiro Watanabe, “Generation of 5-Axis control collision-free tool path and post-processing for NC data”, Annals of the ClRP, Vol.41, No.1, 1992, pp. 539-542.
8.A. Rüegg and P. Gygax, “A generalized kinematics model for three to five axis milling machines and their implementation in a CNC”, Annals of the ClRP, Vol.41, No.1, 1992, pp. 547-550.
9.Sakamoto Shiquhiko and Inasaki Ichiro, “Analysis of generating motion for five-axis machining centers,” The Japan Society of Mechanical Engineers, Vol. 59, No. 561, 1993, pp. 1553-1559.
10.R. S. Lee and C. H. She, “Developing a postprocessor for three types of five-axis machine tools,” International Journal of Advanced Manufacturing Technology, Vol.13, 1997, pp. 658-665.
11.Chen-Hua She and Chun-Cheng Chang, “Development of a five-axis postprocessor system with a nutating head,” Journal of Materials Processing Technology, 187-188, 2007, pp. 60–64.
12.Chen-Hua She and Zhao-Tang Huang, “Postprocessor development of a five-axis machine tool with nutating head and table configuration,” International Journal of Advanced Manufacturing Technology, Vol. 38, 2008, pp.728–740.
13.Mahbubur Rahman, Jouko Heikkala and Kauko Lappalainen, “Modeling, measurement and error compensation of multi-axis machine tools. Part I: theory,” International Journal of Machine Tools and Manufacture, Vol. 40, No. 10, 2000, pp. 1535–1546.
14.Fusaomi Nagata, Yukihiro Kusumotob and Keigo Watanabe, “Intelligent machining system for the artistic design of wooden paint rollers,” Robotics and Computer-Integrated Manufacturing, Vol. 25, No. 3, 2009, pp. 680-688.
15.Chen-Hua She and Rong-Shean Lee, “A postprocessor based on the kinematics model for general five-axis machine tools,” Journal of Manufacturing Processes, Vol. 2, No. 2, 2000, pp. 131-141.
16.S. Ashmall, “Post-processors for general purpose N.C. processor,” Proceedings of the Institution of Mechanical Engineers, Vol. 186, No. 25, 1972, pp. 551-556.
17.Chen-Hua She and Chun-Cheng Chang, “Design of a generic five-axis postprocessor based on generalized kinematics model of machine tool,” International Journal of Machine Tools and Manufacture, Vol.47, 2007, pp.537-545.
18.Anna Puig, Lluis Perez-Vidal, Dani Tost, “3D simulation of tool machining”, Computers & Graphics, Vol.27, No.1, 2003, pp.99-106
19.E. Budak, E. Ozturk, L.T. Tunc, “Modeling and simulation of 5-axis milling processes”, CIRP Annals - Manufacturing Technology, Vol.58, No1, 2009, pp.347-350
20.楊勝群，VERICUT數控加工仿真技術，北京，清華大學出版社
21.王俊程，「鑄造模具2D參數化設計系統之開發」，國立台灣工業技術學院機械工程技術研究所碩士論文，台北，1996
22.楊欣瑜，「導光板之參數化塑膠模具設計」，國立台灣科技大學機械工程研究所碩士論文，台北市，2007
23.呂秉澄，「登山自行車之Top-down Design」，國立台灣科技大學機械工程研究所碩士論文，台北市，2009
24.黃寶翰，「具擴充性之特徵管理系統的Pro/Toolkit程式開發」，國立台灣科技大學機械工程研究所碩士論文，台北市，2011
25.簡孟樹，PowerMILL 2-5軸高速加工CAM系統教育訓練手冊，文魁資訊股份有限公司，台北市，2007
26.鄭正東，「五軸控制MC結構及其運用技術」，機械技術，1996年2月，pp.98-100