251 lines
11 KiB
C#
251 lines
11 KiB
C#
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using CaeKnowledge.Data;
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using System;
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using ToolPathParser;
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namespace CaeCuttingForce.ToroidalCutter
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{
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public class LineForce
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{
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private const double PI = Math.PI;
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private const double h1 = 0.006; // h1
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private const double da = 0.006; // da
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public void CalculateCuttingForce(int direction, ToolPosition position, CuttingForceCoefficients coefficients, ToolParameters toolParams)
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{
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// 刀具参数
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int N = toolParams.NumberOfTeeth; // 刀齿数 N
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double D = toolParams.ToolRadius * 2; // 刀具直径
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double i0 = toolParams.HelixAngle; // 刀具螺旋角
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double R_bull = toolParams.ArcRadius; // 环形圆弧半径(mm)
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double Ap = position.AxialDepth; // 轴向切削深度 Ap
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double Ae = position.RadialDepth; // 径向切削深度 Ae
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double nrot = position.SpindleSpeed; // 主轴转速 n
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double fd = position.FeedRate; // 进给速度 fd
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// 计算中间变量
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double Theta_pit = 2.0 * PI / N; // 齿间角(rad)
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double i0_rad = i0 * PI / 180.0; // 螺旋角转换为弧度
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double Rr = D / 2.0 - R_bull; // 径向偏移量(mm)
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double stj = fd / (N * nrot); // 每齿进给量(mm/tooth)
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// 计算切入角和切出角
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double Theta_st = Math.Acos(Ae / (D / 2.0) - 1.0); // 切入角(rad)
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double Theta_ex = PI; // 切出角
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// 积分步数计算
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int K_angle = (int)Math.Floor(2.0 * PI / h1); // 角向积分步数
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int L_axial = (int)Math.Round(Ap / da); // 轴向积分步数（四舍五入）
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L_axial = Math.Max(L_axial, 1);
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// 初始化结果数组
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double[] Fx = new double[K_angle];
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double[] Fy = new double[K_angle];
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double[] Fz = new double[K_angle];
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double[] Fx_global = new double[K_angle];
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double[] Fy_global = new double[K_angle];
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double[] Fz_global = new double[K_angle];
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// 环形刀轴向几何参数数组
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double[] r_z = new double[L_axial]; // z处的刀具半径
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double[] kappa_z = new double[L_axial]; // z处的轴向浸入角(rad)
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double[] psi_z = new double[L_axial]; // z处的径向滞后角(rad)
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double[] db_z = new double[L_axial]; // z处的微元切削宽度(mm)
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double[] ds_z = new double[L_axial]; // z处的微元刃口长度(mm)
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double[] tool_helixangel_z = new double[L_axial];// z处的螺旋角(rad)
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// 辅助数组
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int M = L_axial * N * K_angle;
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double[] h = new double[M];
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double[] Px = new double[M];
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double[] Qx = new double[M];
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double[] R1 = new double[N * K_angle];
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int m = 0;
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int n_idx = 0;
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// 主计算循环
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// 三重循环计算切削力（角向→刀齿→轴向）
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for (int i = 0; i < K_angle; i++)
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{
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double phi_i = i * h1; // 第i个角向位置的基础径向浸入角(rad)
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for (int k = 0; k < N; k++)
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{
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// 第k个刀齿的基础径向浸入角
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R1[n_idx] = phi_i + k * Theta_pit;
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double phi_j = R1[n_idx];
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for (int j = 0; j < L_axial; j++)
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{
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double z = (j + 1) * da; // 当前轴向高度(mm)
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// 计算z处的刀具半径r(z)（分区计算）
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if (z >= 0 && z < R_bull) // 环形圆弧区(MN区)
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{
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r_z[j] = Rr + Math.Sqrt(R_bull * R_bull - Math.Pow(R_bull - z, 2));
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}
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else // 圆柱区(NS区)
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{
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r_z[j] = D / 2.0;
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}
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// 计算轴向浸入角、螺旋角、径向滞后角（分区）
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if (z >= 0 && z < R_bull) // 环形圆弧区
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{
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kappa_z[j] = Math.Acos((R_bull - z) / R_bull);
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tool_helixangel_z[j] = Math.Atan((r_z[j] - Rr) * Math.Tan(i0_rad) / R_bull);
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psi_z[j] = z / R_bull * Math.Tan(tool_helixangel_z[j]);
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}
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else // 圆柱区
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{
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kappa_z[j] = PI / 2.0;
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tool_helixangel_z[j] = i0_rad;
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psi_z[j] = 2 * z * Math.Tan(i0_rad) / D;
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}
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// 计算微元切削宽度db(z)，避免除零
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double sin_kap = Math.Sin(kappa_z[j]);
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if (sin_kap < 1e-6)
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sin_kap = 1e-6;
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db_z[j] = da / sin_kap;
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// 计算微元刃口长度ds(z)
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ds_z[j] = da / (Math.Cos(tool_helixangel_z[j]) * sin_kap);
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// 修正径向浸入角，角度归一化
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double phi_j_z = phi_j - psi_z[j];
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while (phi_j_z > 2 * PI)
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phi_j_z -= 2 * PI;
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while (phi_j_z < 0)
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phi_j_z += 2 * PI;
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// 计算Px、Qx、Ox
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Px[m] = (D / 2.0 - Ae) / Math.Tan(phi_j_z - PI / 2.0);
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double Ox = D / 2.0 * Math.Cos(Theta_st - PI / 2.0) - stj;
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Qx[m] = (D / 2.0 - stj * Math.Cos(phi_j_z - PI / 2.0)) * Math.Cos(phi_j_z - PI / 2.0);
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// 判断切削啮合区，计算未变形切屑厚度h
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if (phi_j_z >= Theta_st && phi_j_z <= Theta_ex)
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{
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if (Px[m] >= Ox)
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{
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h[m] = D / 2.0 - (D / 2.0 - Ae) / Math.Sin(phi_j_z - PI / 2.0);
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}
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else
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{
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h[m] = stj * Math.Sin(phi_j_z) * Math.Sin(kappa_z[j]);
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}
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// 计算微分切削力
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double dft = coefficients.ktc * h[m] * db_z[j] + coefficients.kte * ds_z[j];
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double dfr = coefficients.krc * h[m] * db_z[j] + coefficients.kre * ds_z[j];
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double dfu = coefficients.kuc * h[m] * db_z[j] + coefficients.kue * ds_z[j];
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if (direction == 1)
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{
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// 坐标变换矩阵
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// 坐标系转换矩阵T
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double[,] T = {
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{ -Math.Cos(phi_j_z), -Math.Sin(kappa_z[j]) * Math.Sin(phi_j_z), -Math.Cos(kappa_z[j]) * Math.Sin(phi_j_z) },
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{ Math.Sin(phi_j_z), -Math.Sin(kappa_z[j]) * Math.Cos(phi_j_z), -Math.Cos(kappa_z[j]) * Math.Cos(phi_j_z) },
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{ 0, Math.Cos(kappa_z[j]), -Math.Sin(kappa_z[j]) }
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};
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// 矩阵乘法计算转换后的微元力
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double fxComponent = T[0, 0] * dft + T[0, 1] * dfr + T[0, 2] * dfu;
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double fyComponent = T[1, 0] * dft + T[1, 1] * dfr + T[1, 2] * dfu;
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double fzComponent = T[2, 0] * dft + T[2, 1] * dfr + T[2, 2] * dfu;
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Fx[i] += fxComponent;
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Fy[i] += fyComponent;
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Fz[i] += fzComponent;
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}
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else if (direction == 2)
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{
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// 坐标变换矩阵
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double[,] T = {
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{ -Math.Cos(phi_j_z), -Math.Sin(kappa_z[j]) * Math.Sin(phi_j_z), -Math.Cos(kappa_z[j]) * Math.Sin(phi_j_z) },
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{ Math.Sin(phi_j_z), -Math.Sin(kappa_z[j]) * Math.Cos(phi_j_z), -Math.Cos(kappa_z[j]) * Math.Cos(phi_j_z) },
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{ 0, -Math.Cos(kappa_z[j]), Math.Sin(kappa_z[j]) }
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};
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double fxComponent = T[0, 0] * dft + T[0, 1] * dfr + T[0, 2] * dfu;
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double fyComponent = T[1, 0] * dft + T[1, 1] * dfr + T[1, 2] * dfu;
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double fzComponent = T[2, 0] * dft + T[2, 1] * dfr + T[2, 2] * dfu;
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Fx[i] += fxComponent;
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Fy[i] += fyComponent;
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Fz[i] += fzComponent;
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}
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m++;
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}
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}
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n_idx++;
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}
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if (direction == 1)
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{
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// 坐标转换到工件坐标系
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Fx_global[i] = Fy[i];
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Fy_global[i] = -Fx[i];
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Fz_global[i] = Fz[i];
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}
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else if (direction == 2)
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{
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// 坐标转换到工件坐标系
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Fx_global[i] = Fy[i];
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Fy_global[i] = Fx[i];
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Fz_global[i] = -Fz[i];
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}
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}
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// 计算并设置结果
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SetResults(position, Fx_global, Fy_global, Fz_global, K_angle);
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}
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private void SetResults(ToolPosition position, double[] Fx_global, double[] Fy_global, double[] Fz_global, int K)
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{
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// 计算平均值
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double sumFx = 0, sumFy = 0, sumFz = 0;
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for (int i = 0; i < K; i++)
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{
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sumFx += Fx_global[i];
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sumFy += Fy_global[i];
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sumFz += Fz_global[i];
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}
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double aFx = sumFx / K;
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double aFy = sumFy / K;
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double aFz = sumFz / K;
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// 设置结果到position对象
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position.AverageFx = aFx;
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position.AverageFy = aFy;
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position.AverageFz = aFz;
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// 计算最大值
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double maxFx = 0, maxFy = 0, maxFz = 0;
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for (int i = 0; i < K; i++)
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{
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if (Math.Abs(Fx_global[i]) > Math.Abs(maxFx)) maxFx = Fx_global[i];
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if (Math.Abs(Fy_global[i]) > Math.Abs(maxFy)) maxFy = Fy_global[i];
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if (Math.Abs(Fz_global[i]) > Math.Abs(maxFz)) maxFz = Fz_global[i];
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}
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position.MaxFx = maxFx;
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position.MaxFy = maxFy;
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position.MaxFz = maxFz;
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}
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}
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}
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