CN104217063B - Emulation design method for steel rail rolling pass - Google Patents

Abstract

The invention discloses a simulation design method for rail rolling passes, and belongs to the technical field of design and manufacture of rail rolling equipment. The invention provides a simulation design method for rail rolling passes which is convenient to operate and has high degree of automation, which can not only improve the accuracy of simulation analysis, but also avoid errors. By developing a set of simulation design software including a CAD pass design module, a CAE pass optimization module and a CAM pass processing code generation module, and calling the corresponding database data through the modules, first complete each rolling track of the rail The rolling pass design of the first pass, and then complete the division of the finite element mesh of different specifications and sizes and the establishment and modification of the relevant boundary condition model, and finally generate the CAM code of the rolling pass of each rolling pass corresponding to the roll. Since the design and optimization of the rail rolling pass and the generation of the CAM processing code are all completed by software, the operation is simplified, the efficiency is improved, and the production cost is reduced.

Description

Simulation Design Method for Rail Rolling Pass

technical field

The invention relates to a simulation design method, in particular to a simulation design method for rail rolling passes, and belongs to the technical field of design and manufacture of rail rolling equipment.

Background technique

The design of the current rail rolling pass is carried out in the following steps:

Step 1: Manually design the pass pattern, that is, use CAD software to directly give the CAD drawing of the rail rolling pass pattern manually. The pass pattern is the disassembled mold, and the rectangular billet is rolled into rails through different pass patterns. The current design method is to manually draw a sketch of the pass after determining the pass system, and then mark the design dimensions on the sketch. Calculation of key design parameters such as rate. Labor-intensive and time-consuming.

The second step: pass design optimization, commonly known as CAE simulation optimization. The accuracy and quality of the pass design completed by the existing design method cannot be known before production, and it is necessary to invest 500,000 to 1 million yuan in trial rolling to know what needs to be modified, and 2-4 trial rolling modifications are required To be finalized. In order to reduce the cost of trial production and increase the speed of pass shaping, with the continuous development of simulation technology, a more advanced method of simulation called CAE has been introduced to replace trial rolling, which greatly reduces the number of trial rolling and cost. However, the application of this kind of simulation analysis software is very difficult, and it takes 3-6 months for general technicians to basically master it, and it takes more than 1 year to be proficient in analysis. At the same time, the application steps of the simulation analysis software are complicated, and the modeling, network division, and boundary condition loading take a long time. The simulation analysis steps of different pass types are the same, which makes the analysis work seem boring and labor-intensive.

The third step: roll processing, referred to as CAM. After the pass design and shaping are completed, it needs to be configured on the roll for application, and the roll matching diagram needs to be designed. At present, after the roll matching diagram is sent to the workshop, the technical staff will manually complete the programming of the CNC lathe machining code. Not only is the labor intensity high, but the main problem is that there are many errors caused by manual writing and input. Roll processing errors often occur, and re-turning or even roll scrapping results in losses ranging from 100,000 to 1 million yuan.

Contents of the invention

The technical problem to be solved by the present invention is to provide a simulation design method for rail rolling passes that is easy to operate and has a high degree of automation, which can not only improve the accuracy of simulation analysis, but also avoid errors as much as possible.

The technical scheme adopted for solving the above-mentioned technical problems is: a kind of simulation design method for rail rolling pass, comprising the following steps,

a) Design software development, development of simulation design software including CAD pass design module, CAE pass optimization module and CAM pass processing code generation module;

b) Rolling pass design, use the CAD pass design module of the simulation design software developed in step a, call the corresponding parameters of the existing pass system parameterized database at the bottom layer, and automatically generate all the rolling passes of each rolling pass of the rail The pass design diagram and the rolling pass diagram of the corresponding rolls, complete the rolling pass design of each rolling pass of the rail, and save the rolling passes of the corresponding rolls of each rolling pass and the keys of the corresponding rolled parts the coordinates of the point;

c) rolling pass optimization, using the CAE pass optimization module of the simulation design software developed in step a, according to the rolling passes of the corresponding rolls and the corresponding rolling parts of each rolling pass saved in step b The coordinates of the key points, call the existing ANSYS pre-processing at the bottom layer, realize the background sub-network without manual operation, complete the grid division of the rolling process model of each rolling pass, and generate the corresponding rolling pass and corresponding rolling Based on the finite element simulation model of parts, the division of finite element meshes of different specifications and sizes of passes and the establishment and modification of related boundary condition models are completed;

d) CAM code generation, using the CAM pass processing code generation module of the simulation design software developed in step a, according to the rolling passes of the corresponding rolls and the corresponding rolling parts of each rolling pass saved in step b The coordinates of key points, and the boundary condition models of different specifications and sizes of passes established and modified in step c, automatically generate the corresponding roll configuration diagram by calling the underlying application function of AutoCAD software, and combine the needs of the on-site CNC machining machine tool system The file format generates mechanical processing codes that can be recognized by mechanical processing equipment, and completes the CAM code design of the rolling pass of each rolling pass corresponding to the roll, thus completing the simulation design of a rail rolling pass.

Further, in step b, while automatically generating all the rolling pass design diagrams of each rolling pass of the rail and the rolling pass diagrams of the corresponding rolls through the CAD pass design module, at least automatically generating the corresponding The center line, auxiliary line and label of the graphics; and according to the generated rolling pass diagrams, calculate the area of the corresponding rolling pass as required.

Furthermore, when optimizing the rolling pass in step c, it is also possible to directly read the relevant files of AutoCAD through appropriate modification on the basis of the existing AutoCAD pass file, and call ANSYS pre-processing through the bottom layer to realize no need for Manually operated backstage grid division, and quickly complete the grid division of the rolling process model for each rolling pass.

Further, the CAD pass design module of the simulation design software in step a is developed based on the AutoCAD secondary development program tool VBA, combined with ActiveX, and its operating environment is Windows platform.

The beneficial effects of the present invention are: by developing a set of simulation design software comprising a CAD pass design module, a CAE pass optimization module and a CAM pass processing code generation module, and calling corresponding database data through the modules respectively, First complete the rolling pass design of each rolling pass of the rail, and then complete the division of finite element meshes of different specifications and sizes of pass and the establishment and modification of related boundary condition models, and finally generate the corresponding rolls of each rolling pass CAM code design of rolling pass. Since the design and optimization of the rail rolling pass and the generation of the CAM processing code are all completed by software, this not only reduces the labor intensity of manual operators, simplifies the operation process, but also improves the degree of automation. At the same time, the entire The optimization process is completed by software, and the data used are the previously summarized inventory data, as well as the data calculated and simulated based on the inventory data, so that not only can effectively improve the accuracy of simulation analysis, but also Try to avoid mistakes, especially when generating machining codes that can be recognized by machining equipment.

Description of drawings

Fig. 1 a～Fig. 1 d is that the present invention is used in the simulation design method of rail rolling pass and adopts described CAD pass design module, utilizes the experience data of existing stock to automatically generate each rolling pass of rail Main rolling pass design drawing;

Fig. 2a～Fig. 2f are the finite elements of the passes of different specifications and sizes that are involved in the simulation design method for rail rolling passes of the present invention using the CAE pass optimization module and using the data in the previous step to complete The simulation diagram of grid division and the establishment and modification of relevant boundary condition models;

3a to 3c are screenshots of main rolls generated by the CAM pass processing code generation module and cross-sections of generated NC codes involved in the invention of the simulation design method for rail rolling passes.

detailed description

As shown in Figures 1a to 1d, 2a to 2f, and 3a to 3c, the present invention provides a convenient operation and high degree of automation, which can not only improve the accuracy of simulation analysis, but also avoid mistakes as much as possible. Simulation design method of rail rolling pass. The described simulation design method comprises the following steps,

a) Design software development, development of simulation design software including CAD pass design module, CAE pass optimization module and CAM pass processing code generation module;

b) Rolling pass design, use the CAD pass design module of the simulation design software developed in step a, call the corresponding parameters of the existing pass system parameterized database at the bottom layer, and automatically generate all the rolling passes of each rolling pass of the rail The pass design diagram and the rolling pass diagram of the corresponding rolls, complete the rolling pass design of each rolling pass of the rail, and save the rolling passes of the corresponding rolls of each rolling pass and the keys of the corresponding rolled parts Coordinates of points, adopting the CAD pass design module can also analyze the key design parameters such as the area of each pass, extension coefficient, reduction rate, and form a report;

c) rolling pass optimization, using the CAE pass optimization module of the simulation design software developed in step a, according to the rolling passes of the corresponding rolls and the corresponding rolling parts of each rolling pass saved in step b The coordinates of the key points, call the existing ANSYS pre-processing at the bottom layer, realize the background sub-network without manual operation, complete the grid division of the rolling process model of each rolling pass, and generate the corresponding rolling pass and corresponding rolling The finite element simulation model of the parts, on this basis, the division of the finite element meshes of different specifications and sizes of the pass and the establishment and modification of the relevant boundary condition models are completed. The CAE pass optimization module can also be used for modeling, network Division, boundary condition loading, etc., thereby greatly reducing labor intensity, and at the same time eliminating errors in artificial modeling, network division, and boundary condition loading, greatly improving the accuracy of simulation analysis;

d) CAM code generation, using the CAM pass processing code generation module of the simulation design software developed in step a, according to the rolling passes of the corresponding rolls and the corresponding rolling parts of each rolling pass saved in step b The coordinates of key points, and the boundary condition models of different specifications and sizes of passes established and modified in step c, automatically generate the corresponding roll configuration diagram by calling the underlying application function of AutoCAD software, and combine the needs of the on-site CNC machining machine tool system The file format generates mechanical processing codes that can be recognized by mechanical processing equipment, and completes the CAM code design of the rolling pass of each rolling pass corresponding to the roll, thus completing the simulation design of a rail rolling pass. Adopt above-mentioned simulation design software that includes CAD pass design module, CAE pass optimization module and CAM pass processing code generation module by developing a set, and call corresponding database data through described module respectively, complete each rolling of rail first The rolling pass design of the rolling pass, and then complete the division of the finite element mesh of the pass of different specifications and sizes and the establishment and modification of the relevant boundary condition model, and finally generate the rolling pass of each rolling pass corresponding to the roll The method of CAM code design. In the described method, since the design and optimization of the rail rolling pass and the generation of the CAM processing code are all completed by software, this not only reduces the labor intensity of manual operators, simplifies the operation process, and improves At the same time, the entire optimization process is completed by software, and the data used are the empirical data of the previous inventory summary and the data calculated on the basis of the inventory data, which can not only effectively improve the simulation analysis. It can also avoid errors as far as possible, especially errors that occur when generating machining codes that can be recognized by machining equipment.

In the above-described embodiment, according to the custom of the usual design drawings, while automatically generating all the rolling pass design drawings of each rolling pass of the rail and the rolling pass drawings of the corresponding rolls through the CAD pass design module, Also automatically generate at least the center line, auxiliary line and label of the corresponding graphics; and calculate the area of the corresponding rolling pass according to the generated rolling pass diagrams as required. At the same time, when optimizing the rolling pass in step c, it is also possible to directly read the relevant files of AutoCAD through appropriate modification on the basis of the existing AutoCAD pass file, and call ANSYS pre-processing at the bottom layer to realize no manual operation The backstage meshing of the grid, and quickly complete the meshing of the rolling process model for each rolling pass. In order to make the applicability of the simulation design method of the present invention strong, at the same time, the development difficulty of the simulation design method can be simplified, the CAD pass design module of the simulation design software in the step a is based on the AutoCAD secondary development program tool VBA, And combined with ActiveX development, its operating environment is Windows platform.

Embodiment one

On the basis of the secondary development module of AutoCAD, the whole process of realizing the background sub-network operation without manual operation by using the bottom layer to call ANSYS pre-processing is as follows,

(1) First, according to the position of each key point calculated by the secondary development module of AutoCAD, a file recognizable by ANSYS is generated, and its implementation code is:

Dim uproller As Variant

Open uproller For Output As1#

Print#1,"/PREP7"

Print#1,"/NERR,0,99999,,,0"

Print#1,"EDMP,RIGI,1,0,0"

Print#1,"MP,DENS,1,7"

Print#1,"K,";pt1(0);",";pt1(1);",";pt1(2)

Print#1,"K,";pt2(0);",";pt2(1);",";pt2(2)

...

Print#1,"LSTR,3,4"

Print#1,"LFILLT,1,2,"; convert(HR2); ",,"

Print#1,"LFILLT,2,3,"; convert(HR1); ",,"

Print#1,"K,";pt1(0);",";pt1(1)+d;",";pt1(2)

...

Print#1,"LESIZE,3,";kxcc;",,,,,,,1"

Print#1,"MSHAPE,0,2D"

Print#1,"MSHKEY,1"

Print#1,"AMESH,ALL"

Print#1,"K,";0;",";L4/2+bj/2;",";0

Print#1,"K,";100;",";L4/2+bj/2;",";0

Print#1,"TYPE,2"

Print#1,"EXTOPT,ESIZE,45,0,"

Print#1,"EXTOPT,ACLEAR,1"

...

Print#1,"NUMOFF,ELEM,2000000"

Print#1,"EDWRITE,ANSYS,'upRoller','k',"; path

Print#1,"FINISH"

Print#1,"/CLEAR,START"

close#1

(2) The bottom layer invokes ANSYS, processes the files recognizable by ANSYS, performs grid division on the roll, and generates a finite element model, and its implementation code is:

Dim uprollerline1As String

Dim uprollerline2As String

 ….

Open uprollerbat For Output As#90

...

Print#90,uprollerline1

Close#90

Dim lngPId As Long

Dim lngPHandle As Long

FirstWord＝Mid(path,1,1)

ChDrive First Word

ChDir path

lngPId=Shell(uprollerbat)

...

By invoking ANSYS pre-processing in the background, the construction of a 3D CAD model without manual processing is realized; for the parameterization of the mesh division of each pass roll, rolled piece, etc., the ANSYS pre-processing is invoked in the bottom layer, and no manual operation is required. The background sub-network of each pass quickly completes the grid division of the rolling process model of each pass; finally, through the GUI interface of each pass, the input and modification of various geometric parameters and grid sizes, the underlying call of ANSYS pre-processing, and the network are realized. Grid division and model output, thus completing the division of finite element grids of different specifications and sizes and the establishment and modification of related boundary conditions.

Embodiment two

Taking a certain H-shaped steel BD1 roll matching as an example, the whole process of realizing the CAM module is introduced.

(1) First, according to the secondary development module of AutoCAD, calculate the position of each key point of the BD1 roll, and generate the CAD graphics of the BD1 roll.

(2) According to the position of each key point of the BD1 roll, combined with the format of the on-site CNC machining machine tool system, a machining code that can be recognized by machining is generated, and its realization code is:

Open text For Output As1#

Print#1,"1.DIAMOF"

Print#1,"2.M3S"; zs

Print#1,"3.G54T";num1;"D";num2

Print#1,"4.G0G90G95G41X560Z-50F"; sd

Print#1,"5.G1X"; CStr(ncL5/2-ncR1-10)

Print#1,"6.Z0"

Print#1,"7.G91X"; CStr(ncR1+10); "RND="; CStr(ncR1)

Print#1,"8.Z"; CStr(L)

Print#1,"9.X"; CStr((ncL1-ncL2)/2)

Print#1,"10.Z"; CStr(ncL9+20)

Print#1,""

Print#1,"11.G0G90G41X";CStr(ncL5/2+ncL1/2);"Z";CStr(2300-x4-40);"1 hole bed caudal side"

Print#1,"12.G1X"; CStr(ncL5/2+ncL1/2-(kx4L1-kx4L4+ncL2)/2)

Print#1,"13.G91Z40"

Print#1,"14.X";CStr((kx4L1-kx4L4-2*kx4L3)/2);"Z";CStr(kx4L2/2);"RND=";CStr(kx4r2)

Print#1,"15.X"; CStr(kx4L3); "Z"; CStr(kx4L5); "RND="; CStr(kx4r1)

Print#1,"16.Z"; CStr(ncL8+20)

Print#1,""

Print#1,"17.G0G90G41X";CStr(ncL5/2+ncL1/2);"Z";CStr(2300-x3-40);"2-hole bed caudal side"

Print#1,"18.G1X"; CStr(ncL5/2+ncL1/2-(kx3L1-kx3L4+ncL2)/2)

Print#1,"19.G91Z40"

...

Print#1,"36.X"; CStr((ncL2-ncL1)/2)

Print#1,"37.Z"; CStr(-L-10)

Print#1,"38.X50"

Print#1,""

Print#1,"39.G0G90G42X"; CStr(ncL5/2+ncL1/2+50); "Z"; CStr(2300+60); "4 holes"

Print#1,"40.G1X"; CStr(ncL5/2-ncR1-10)

Print#1,"41.Z2300"

Print#1,"42.G91X"; CStr(ncR1+10); "RND="; CStr(ncR1)

Print#1,"43.Z"; CStr(-ncL3)

Print#1,"44.X"; CStr(-(ncL2-ncL1)/2)

Print#1,"45.Z"; CStr(-ncL4); "RND="; CStr(kx1r6)

Print#1,"46.X";CStr(-kx1L6);"Z";CStr(-kx1L11);"RND=";CStr(kx1r5)

Print#1,"47.X";CStr(-Abs(nc1pt5(1)-nc1pt6(1)));"Z";CStr(kx1L11-kx1L10);"RND=";CStr(kx1r4)

...

Print#1,"66.Z"; CStr(-kx2L5); "RND="; CStr(kx2r4)

Print#1,"67.X";CStr(Abs(nc2pt5(1)-nc2pt6(1)));"Z";CStr(kx2L11-kx2L10);"RND=";CStr(kx2r5)

Print#1,"68.X";CStr(kx2L6);"Z";CStr(-kx2L11);"RND=";CStr(kx2r6)

Print#1,"69.Z"; CStr(-ncL7-50)

Print#1,"70.X50"

Print#1,"71.M5"

Print#1,"72.M2"

close#1

The developed pass design and finite element numerical simulation integrated software system is based on the established pass parameter database, through the pass parameterized CAD secondary development module to determine the position of the key points of each roll, generate CAD graphics for each roll, combined with the branch process According to the file format and control method required by the CNC machine tool, the personnel have the experience of matching rolls, realize the automatic output of the NC code of the CNC machining program, and complete the CAM of the roll.

The pass design and finite element numerical simulation integrated software system developed by the present invention is the simulation design software described in the present invention. According to the established pass parameter database, the key points of each roll are determined through the pass parameterized CAD secondary development module. Point position, generate CAD graphics for each roll, combined with the experience of roll matching by the technicians of the manufacturing plant, according to the file format and control mode required by the CNC machine tool, realize the automatic output of the NC code of the CNC machining program, and complete the CAM of the roll.

In order to facilitate the understanding of the meanings of the symbols in Fig. 1, Fig. 2 and Fig. 3, the present invention provides the following three program tables for illustration.

Table 1 Billet rolling schedule of a certain type of rail

Table 2 Universal rolling schedule of a certain type of rail

Table 3 Section description of numerical simulation of full rolling of a certain type of rail

Claims (3)

1. a kind of emulation design method for steel rail rolling pass, it is characterised in that：Comprise the following steps,

A) design software is developed, and kit contains CAD hole type designs module, CAE optimization for hole module and CAM pass machining codes The design of Simulation software of generation module；

B) rolling groove is designed, and using the CAD hole type design modules of the step a design of Simulation softwares developed, is called by bottom The relevant parameter in existing pass schedule parametric data storehouse, automatically generates whole rolling groove design drawings of each rolling pass of rail With the rolling groove figure of corresponding roll, the rolling groove design of each rolling pass of rail is completed, and preserves each rolling pass correspondence The coordinate of the rolling groove of roll and each key point of correspondence rolled parts；

C) rolling groove optimizes, using the CAE optimization for hole modules of the step a design of Simulation softwares developed, according to step b The coordinate of the rolling groove of each rolling pass correspondence roll of middle preservation and each key point of correspondence rolled parts, is called by bottom Existing ANSYS pre-treatments, realize that the operation of rolling model meshes that each rolling pass is completed without manually-operated backstage subnetting are drawn Point, and the limit element artificial module of corresponding rolling groove and corresponding rolled parts is generated, different size chi is completed on this basis The division of the finite element grid of very little pass and the foundation and modification of relevant border condition model；

D) CAM code buildings, utilize the CAM pass machining code generation modules of the step a design of Simulation softwares developed, root According to the rolling groove and the coordinate of each key point of correspondence rolled parts of each rolling pass correspondence roll preserved in step b, and The boundary condition model for the variant specification pass that step c is set up and modification is completed, by the bottom for calling AutoCAD softwares Layer application function automatically generates corresponding roller matching figure, and the file format that the live numerical control machine bed system of combination needs, The recognizable machining code of machining equipment is generated, the CAM generations of the rolling groove of each rolling pass correspondence roll are completed Code design, so just completes the design of Simulation work of a steel rail rolling pass,

, can also be on the basis of existing AutoCAD passes file, by appropriate when carrying out step c rolling groove optimization Modification, directly reads AutoCAD associated documents, and ANSYS pre-treatments are called by bottom, realizes without manually-operated backstage Subnetting, and it is rapidly completed the operation of rolling model meshes division of each rolling pass.

2. the emulation design method according to claim 1 for steel rail rolling pass, it is characterised in that：In step b, lead to Cross the whole rolling groove design drawings and corresponding roll of described each rolling pass of CAD hole type design Module Generation rail While rolling groove figure, center line, boost line and the mark of correspondence figure are also at least automatically generated；And respectively rolling according to generation Drilling type figure, calculates the area of corresponding rolling groove as needed.

3. the emulation design method according to claim 1 or 2 for steel rail rolling pass, it is characterised in that：In step a The CAD hole type design modules of design of Simulation software be to be based on AutoCAD secondary development program instrument VBA, and combine ActiveX Exploitation, its running environment is windows platform.