349 lines
15 KiB
C#
349 lines
15 KiB
C#
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 ConcaveCurvesForce
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{
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private const double PI = Math.PI;
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private const double AngularIncrement = 0.006; // h1
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private const double AxialIncrement = 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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// 计算中间变量
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int N = toolParams.NumberOfTeeth; // 刀齿数
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double r = toolParams.ToolRadius; // 刀具半径
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double beta = 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 a_e = position.RadialDepth; // 径向切削深度
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double a_p = position.AxialDepth; // 径向切削深度
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double R = position.CurvatureRadius; // 目标曲率半径
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double nrot = position.SpindleSpeed; // 主轴转速
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double fd = position.FeedRate; // 进给速度
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double thetaPit = 2.0 * PI / N; // 齿间角
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double beta_rad = beta * PI / 180.0; // 螺旋角转换为弧度
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double Rr = r - R_bull; // 径向偏移量(mm)
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double kb = Math.Tan(beta * PI / 180.0) / r; // 刀具常数
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double trot = 60.0 / nrot; // 主轴旋转周期
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double c = fd / (nrot * N); // 每齿进给量
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double e = R - r;
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double H = 2.0 * PI * e;
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double nrev = fd / H;
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double trev = 60.0 / nrev;
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double krev = trev / trot * N;
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double dphi = 2.0 * PI / krev;
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// 计算切入角
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double thetaSt = Math.Asin(-((-Math.Pow(a_e, 2)
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+ 2.0 * R * a_e
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+ 2.0 * Math.Pow(r, 2)
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- 2.0 * R * r)
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/ (2.0 * R - 2.0 * r)) / r) + 0.5 * PI;
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double thetaEx = PI; // 切出角
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// 计算切厚最大角
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double thetaMax = CalculateThetaMax(R, r, a_e, dphi) + 0.5 * PI;
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// 计算相对坐标和距离
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double xRel = position.Cx - position.X;
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double yRel = position.Cy - position.Y;
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double distance = Math.Sqrt(xRel * xRel + yRel * yRel);
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// 计算角向和轴向积分数目
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int K = (int)(2.0 * PI / AngularIncrement);
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int L = (int)(a_p / AxialIncrement);
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// 初始化结果数组
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double[] fx = new double[K];
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double[] fy = new double[K];
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double[] fz = new double[K];
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double[] fxGlobal = new double[K];
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double[] fyGlobal = new double[K];
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double[] fzGlobal = new double[K];
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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]; // z处的刀具半径
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double[] kappa_z = new double[L]; // z处的轴向浸入角(rad)
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double[] psi_z = new double[L]; // z处的径向滞后角(rad)
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double[] db_z = new double[L]; // z处的微元切削宽度(mm)
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double[] ds_z = new double[L]; // z处的微元刃口长度(mm)
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double[] tool_helixangel_z = new double[L];// z处的螺旋角(rad)
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int m = 0;
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int n = 0;
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int totalSteps = L * N * K;
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double[] h = new double[totalSteps];
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double[] r1 = new double[N * K];
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// 主计算循环
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for (int i = 0; i < K; i++)
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{
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double r2 = i * AngularIncrement; // 螺旋槽底部切削刃的接触角
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for (int k = 0; k < N; k++)
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{
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r1[n] = r2 + k * thetaPit; // 第k个齿当前角度的位置
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double phi_j = r1[n];
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for (int j = 0; j < L; j++)
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{
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double z = (j + 1) * AxialIncrement;// 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] = r;
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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(beta_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] = beta_rad;
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psi_z[j] = z * Math.Tan(beta_rad) / r;
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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] = AxialIncrement / sin_kap;
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// 计算微元刃口长度ds(z)
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ds_z[j] = AxialIncrement / (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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if (phi_j_z >= thetaSt && phi_j_z <= thetaEx)
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{
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double chipThickness;
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double phi = phi_j_z - 0.5 * PI;
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if (phi_j_z <= thetaMax)
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{
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// lp计算公式
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double lp = Math.Sqrt(
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2.0 * R * r
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- 2.0 * R * a_e
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+ Math.Pow(R, 2) * Math.Pow(Math.Sin(phi), 2)
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+ Math.Pow(r, 2) * Math.Pow(Math.Sin(phi), 2)
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+ Math.Pow(a_e, 2) - Math.Pow(r, 2)
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- 2.0 * R * r * Math.Pow(Math.Sin(phi), 2))
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- R * Math.Sin(phi) + r * Math.Sin(phi);
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chipThickness = r - lp;
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}
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else
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{
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// lQ计算公式
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double lQ = CalculateLQ(R, r, a_e, dphi, phi);
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chipThickness = r - lQ;
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}
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h[m] = chipThickness;
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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++;
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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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double fxFromY1 = fy[i] * (xRel / distance);
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double fyFromY1 = fy[i] * (yRel / distance);
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double fxFromX1 = fx[i] * (yRel / distance);
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double fyFromX1 = fx[i] * (-xRel / distance);
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fxGlobal[i] = fxFromX1 + fxFromY1;
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fyGlobal[i] = fyFromX1 + fyFromY1;
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fzGlobal[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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double fxFromY1 = fy[i] * (xRel / distance);
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double fyFromY1 = fy[i] * (yRel / distance);
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double fxFromX1 = fx[i] * (-yRel / distance);
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double fyFromX1 = fx[i] * (xRel / distance);
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fxGlobal[i] = fxFromX1 + fxFromY1;
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fyGlobal[i] = fyFromX1 + fyFromY1;
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fzGlobal[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, fxGlobal, fyGlobal, fzGlobal, K);
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}
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private double CalculateThetaMax(double R, double r, double a_e, double dphi)
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{
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double numerator =
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2.0 * R * a_e
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+ 2.0 * R * r
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+ 2.0 * Math.Pow(R, 2) * Math.Cos(2.0 * dphi)
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+ Math.Pow(a_e, 2) * Math.Cos(2.0 * dphi)
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+ Math.Sin(2.0 * dphi) * Math.Sqrt(
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a_e * (a_e - 2.0 * r)
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* (2.0 * R - a_e)
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* (a_e - 2.0 * R + 2.0 * r))
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- 2.0 * Math.Pow(R, 2) - Math.Pow(a_e, 2)
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- 2.0 * R * a_e * Math.Cos(2.0 * dphi)
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- 2.0 * R * r * Math.Cos(2.0 * dphi);
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double denominator = 4.0 * Math.Sin(dphi) * (R - r);
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return Math.Acos(numerator / denominator) / r;
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}
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private double CalculateLQ(double R, double r, double a_e, double dphi, double phi)
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{
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double term1 = Math.Pow(R, 2) * Math.Cos(dphi - 2.0 * phi);
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double term2 = 2.0 * R * r;
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double term3 = Math.Pow(r, 2) * Math.Cos(dphi - 2.0 * phi);
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double term4 = Math.Pow(R, 2) * Math.Cos(2.0 * phi) / 2.0;
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double term5 = Math.Pow(r, 2) * Math.Cos(2.0 * phi) / 2.0;
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double term6 = Math.Pow(R, 2) * Math.Cos(2.0 * dphi - 2.0 * phi) / 2.0;
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double term7 = Math.Pow(r, 2) * Math.Cos(2.0 * dphi - 2.0 * phi) / 2.0;
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double term8 = Math.Pow(R, 2);
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double term9 = Math.Pow(R, 2) * Math.Cos(dphi);
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double term10 = Math.Pow(r, 2) * Math.Cos(dphi);
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double term11 = 2.0 * R * r * Math.Cos(dphi - 2.0 * phi);
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double term12 = R * r * Math.Cos(2.0 * phi);
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double term13 = R * r * Math.Cos(2.0 * dphi - 2.0 * phi);
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double term14 = 2.0 * R * r * Math.Cos(dphi);
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double sqrtContent = term1 + term2 + term3 - term4 - term5 - term6 - term7
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- term8 + term9 + term10 - term11 + term12 + term13 - term14;
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double lQ = Math.Sqrt(sqrtContent)
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- R * Math.Sin(phi)
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+ r * Math.Sin(phi)
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- R * Math.Sin(dphi - phi)
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+ r * Math.Sin(dphi - phi);
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return lQ;
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}
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private void SetResults(ToolPosition position, double[] fxGlobal, double[] fyGlobal, double[] fzGlobal, 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 += fxGlobal[i];
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sumFy += fyGlobal[i];
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sumFz += fzGlobal[i];
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}
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position.AverageFx = sumFx / K;
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position.AverageFy = sumFy / K;
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position.AverageFz = sumFz / K;
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// 计算最大值
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double maxAbsFx = 0, maxAbsFy = 0, maxAbsFz = 0;
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int idxFx = 0, idxFy = 0, idxFz = 0;
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for (int i = 0; i < K; i++)
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{
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if (Math.Abs(fxGlobal[i]) > maxAbsFx)
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{
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maxAbsFx = Math.Abs(fxGlobal[i]);
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idxFx = i;
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}
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if (Math.Abs(fyGlobal[i]) > maxAbsFy)
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{
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maxAbsFy = Math.Abs(fyGlobal[i]);
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idxFy = i;
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}
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if (Math.Abs(fzGlobal[i]) > maxAbsFz)
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{
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maxAbsFz = Math.Abs(fzGlobal[i]);
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idxFz = i;
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}
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}
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position.MaxFx = fxGlobal[idxFx];
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position.MaxFy = fyGlobal[idxFy];
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position.MaxFz = fzGlobal[idxFz];
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}
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}
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}
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