CN112163361A - Method for realizing dynamic refinement of simulation local grid in thin-wall casing machining process - Google Patents
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Abstract
The invention discloses a method for realizing dynamic refinement of a simulation local grid in a thin-wall casing machining process, which comprises the following steps of firstly, compiling a simulation pretreatment automatic setting script program by utilizing Python language according to the actual machining working condition of a part; secondly, performing three-dimensional modeling on the workpiece, designing a tool path according to actual working conditions, exporting a tool path file, dispersing the tool path into a plurality of tool positions, and determining a machining area and an area needing refining; then, extracting coarse grid information of a region needing to be refined, calculating to obtain grid information after local refinement, replacing the coarse grid information of the original input file, and completing carrying of a calculation result of the previous step before calculation of the next step; and finally, submitting a new input file for calculation. If the calculation is finished, stopping refining; and if the calculation is not finished, continuously traversing the result file of the previous step, and finishing the local grid refining work of the next step until the calculation is finished. The method can accurately and efficiently predict the physical quantity distribution condition of the large-scale thin-wall part in the machining process.
Description
Technical Field
The invention relates to a method for realizing the dynamic refinement of a simulation local grid in the machining process of a thin-wall casing, in particular to a finite element simulation method combining a 'living and dead' unit technology and a grid dynamic refinement technology.
Background
The aircraft engine is the heart of the aircraft, and the casing is a key component of the aircraft engine. In order to obtain excellent service performance, the requirement on the machining process of the casing is very high. At present, the characteristics of the processing of large thin-wall casing parts mainly comprise the following aspects: the high-strength light-weight steel plate has the advantages of strong integrity, light weight, high strength requirement, large material removal amount, easy deformation in processing, low processing efficiency and the like, and belongs to a typical part difficult to process.
Aiming at the characteristics and problems of the thin-wall casing part machining, the related research is developed by adopting a finite element simulation technology to become a hot topic, and finite element software can simulate the cutting machining process of the part by utilizing a method for displaying dynamics and implicit statics, and calculate the cutting force, the cutting temperature, the stress strain distribution, the deformation of the part and the like in the machining process. At present, in finite element simulation analysis, local grid refinement is often carried out on a weight bearing area, and grid coarsening is carried out on other unimportant areas, so that the calculation efficiency is improved to a certain extent; or the problem that the calculation is difficult to converge caused by grid distortion is solved by adopting the self-adaptive grid re-division technology. For example, Alain Rassineux [1 ]]A great deal of research is carried out on the mesh adaptive technology in the two-dimensional metal cutting and fracture simulation, and the research result is rich in the aspect of the two-dimensional triangular mesh adaptive technologyRich; martin
[2]The local two-dimensional quadrilateral grid dynamic refining technology is successfully applied in the two-dimensional metal cutting simulation; biyunfao et al of Zhejiang university [3]Aiming at the aviation integral thin-wall structural part, simulation prediction is carried out on the machining deformation of the part by adopting a 'living and dead' unit technology; fangtao Yang [4 ]]The three-dimensional grid self-adaptive technology in crack propagation simulation is deeply researched, and a certain research result is obtained; wuhao of Qinghua university [5 ]]The finite element posterior error theory is deeply researched, a Marc program is used as a calculation tool, and the self-adaptive finite element is used for researching the stress value of the dam finite element; zhao national group of Shandong university [ 6)]Research on mesh adaptive generation techniques has been long pursued and home-made adaptive meshing software has been developed. In summary, through research of scholars at home and abroad, the two-dimensional triangular mesh self-adaptive partitioning technology is mature at present, corresponding mesh partitioning software is developed correspondingly, but the development of the mesh partitioning software can only finish single partitioning of the mesh of an initial part in pretreatment, the integration of the mesh partitioning software and finite element simulation software is deficient, and in the research of the three-dimensional mesh dynamic self-adaptive technology, the local mesh refinement during equal-material plastic deformation and crack propagation is mainly focused, so that the research and the application of the combination of the 'life-death' unit technology and the mesh self-adaptation in large-material removal simulation have obvious defects.
Aiming at large-size and complex integral structural parts, the number of grids is often large, so that the calculation cost is extremely high, and the efficiency of finite element simulation is greatly influenced; the problem of low calculation efficiency can be solved by adopting a mass scaling technology, but the problem of poor accuracy of a calculation result cannot be avoided; in addition, when implicit static analysis is used, the selection of the 'living and dead' unit and the loading of the cutting force are both excessively dependent on manual selection, and the workload is large. In summary, the problems of overlarge simulation model size, complex structure, low calculation efficiency and high cost exist in the current simulation. Therefore, it is necessary to establish an efficient and low-cost calculation method to improve the difficult situation of the simulation of the machining process of the large thin-wall parts.
Disclosure of Invention
In order to solve the problems of difficult simulation and slow simulation in the machining process of large-sized thin-wall parts, the invention aims to provide a method for realizing the dynamic refinement of the simulated local meshes in the machining process of a thin-wall casing. Therefore, the total number of the part grid division can be reduced to a great extent, the calculation amount is reduced, and the automatic setting of the simulation pretreatment can be realized, so that the aim of improving the simulation calculation efficiency is fulfilled on the premise of ensuring the calculation accuracy, and effective guarantee and technical support can be provided for the improvement of the actual production and the part processing quality.
In order to achieve the purpose, the invention provides the following scheme:
a method for realizing the dynamic refinement of the simulation local grid in the thin-wall casing processing process comprises the following steps:
the invention discloses a method for realizing dynamic refinement of a simulation local grid in a thin-wall casing machining process, which comprises the following steps of firstly, compiling a simulation pretreatment automatic setting script program by utilizing Python language according to the actual machining working condition of a part, wherein the simulation pretreatment automatic setting script program comprises the following steps: modeling, material parameters, contact conditions, boundary conditions, life and death unit setting and initial grid division; secondly, establishing a workpiece model by using three-dimensional modeling software, designing a tool path according to actual working conditions, exporting a tool path file (. cls format), dispersing the tool path into a plurality of tool positions, and determining a machining area and an area needing to be refined; then, extracting coarse grid information of a region needing to be refined, calculating to obtain grid information after local refinement, correspondingly replacing the coarse grid information of an original input file (in format), and completing the carrying of a calculation result of a previous step before the calculation of a next step, namely the transmission of a new physical field and an old physical field; finally, a new input file (. inp format) is submitted for calculation. If the calculation is finished, stopping refining; and if the calculation is not finished, continuously traversing the result file (odb format) of the previous step, and finishing the local grid refining work of the next step until the calculation is finished. The method can accurately and efficiently predict the physical quantity distribution condition of the large-sized thin-wall part in the machining process, and solves the problems of difficult simulation and slow simulation of the large-sized thin-wall part.
The method comprises the following specific steps:
(1) compiling a simulation analysis preprocessing script program by utilizing Python language to realize automatic setting of material parameters, contact conditions, boundary conditions, selection of 'living and dead' units, loading and initial grid division of the finite element analysis model;
(2) establishing a three-dimensional finite element analysis model of the part in the machining process according to the actual working condition;
(3) the method comprises the following steps of (1) calling tool path information of a part, wherein a discrete tool path is a plurality of tool positions, and modeling a tool scanning body;
(4) determining a processing area according to the tool track and the tool shape, namely determining an area needing to be subjected to local grid dynamic refining processing;
(5) and (3) compiling a script program by utilizing Python, extracting coarse grid information needing to be refined in the initial grid in the step (2), and calculating to obtain grid information (cell number and node number) after local refinement, wherein the grid information calculating method is as follows.
Take an example where a coarse grid is refined into 27 fine grids, as shown in fig. 7. A. B, C are the number of rows (x), columns (y) and rows (z) of the original coarse grid cells of the workpiece, and the total number of the cells is A multiplied by B multiplied by C; a. b, c are the number of rows (x), columns (y), rows (z) of the cells of the refined area, and the total number of the cells is a multiplied by b multiplied by c:
unit numbering rules:
the number of the refined unit is close to the maximum value of the original coarse grid unit number, the number of the original coarse grid unit is A multiplied by B multiplied by C, namely the unit number initial value of the refined grid is A multiplied by B multiplied by C +1, and the specific numbering sequence is as follows:
1) according to the small units 1-27 in fig. 7, from small to large. And completing the numbering of all the small units of the coarse grid.
2) And sequentially thinning and numbering the next column of units in the same row. And sequentially completing the numbering of all the units in each row.
The thinning sequence is schematically shown in fig. 8, and is performed in the order of numbers 1-6.
Node numbering rules:
since there are common nodes between different units, the numbering rules of the nodes are different compared to the units. The node number of the original coarse grid is (A +1) × (B +1) × (C +1), that is, the initial value of the cell number of the refined grid is (A +1) × (B +1) × (C +1) + 1.
The specific numbering sequence is as follows:
1) the eight nodes 22, 23, 26, 27, 38, 39, 42, 43 inside the coarse mesh (see fig. 7) of the refined region are numbered.
2) Nodes (6,7,10,11,54,55,58,59) within the xy-plane of all the coarse meshes of the refined region are numbered.
3) Nodes (21,25,37,41,24,28,40,44) within all coarse mesh xz-planes of the refined region are numbered.
4) Nodes (18,19,34,35,30,31,46,47) within yz-planes of all the coarse meshes of the refined region are numbered.
5) The nodes (5,9,8,12,53,57,56,60) on all x-direction edges of the coarse grid of the refined region are numbered.
6) The nodes (2,3,14,15,50,51,62,63) on all y-direction edges of the coarse grid of the refined region are numbered.
7) Nodes (17,33,29,45,20,36,32,48) on all the z-direction edges of the coarse mesh region of the refined region are numbered.
Wherein, the refining sequence of the coarse grid in each step is carried out according to the sequence numbered from 1 to 6 in the coarse grid refining sequence diagram.
Then, correspondingly replacing the coarse grid information in the original input file (in format), defining a new 'life and death' unit, and completing loading again;
(6) a script program is compiled by utilizing Python, so that the physical field transmission between the new grid and the old grid is realized, and a brand new inp file is formed;
(7) submitting a new input file (in format) for calculation;
(8) and (4) judging whether the calculation is finished, if not, continuing traversing the result file (odb format), and repeating the operations in the steps (4) to (7) until the calculation is finished. In the period, Python programming is utilized to judge whether the calculation is finished or not and realize the automatic connection of each step of analysis, so that complete and full-automatic analysis and calculation are formed, and a large amount of repetitive manual setting work is avoided.
Compared with the prior art, the invention has the advantages that:
compared with the traditional simulation, the method for realizing the dynamic refinement of the simulated local grid in the thin-wall casing machining process can simplify the high-load material removal simulation process into a form of combining a 'dead' unit with the dynamic refinement of the local grid, and compared with the global refinement, the calculation efficiency after the dynamic refinement of the local grid is adopted can be improved by more than 2 times.
Moreover, the simulation pretreatment setting, the dynamic refinement of the local grid, the carrying before and after the refinement of each grid and the relay calculation between new tasks after the refinement are programmed by utilizing Python language, so that the full automation of the simulation of the machining process is completely realized.
Drawings
FIG. 1 is a flow chart of a method for local dynamic refinement of a simulation grid in a thin-wall casing machining process according to the present invention;
FIG. 2 is an initial grid-division diagram before the local grid-refinement of the receiver of the present invention and a grid-division diagram after the global refinement;
FIG. 3 is a detailed view of a local grid simulating an analysis step in a thin-walled casing manufacturing process according to the present invention;
FIG. 4 is a cloud of results of a thin-walled casing processing process of the present invention after a local grid dynamic refinement in a certain analysis step is simulated;
FIG. 5 is a diagram of the present invention for a thin-walled casing manufacturing process for simulating dynamic refinement of local grids and carrying a physical field map of the previous step;
FIG. 6 is a diagram of a simulated final machining distortion of a thin-walled casing machining process according to the present invention;
FIG. 7 is a schematic diagram of a single grid refinement;
fig. 8 is a schematic diagram of a coarse mesh refinement sequence.
Detailed Description
In order that the present disclosure may be more readily understood, a more complete description of the present disclosure is now provided in connection with the accompanying drawings. The following description is exemplary only, and is not limiting. All other embodiments obtained by a person skilled in the art without making any inventive step should be within the scope of protection of the present application.
The invention provides a method for realizing simulation local grid dynamic refinement in a thin-wall case machining process, which is based on ABAQUS finite element analysis software and combines a 'living and dead' unit technology and a local grid dynamic refinement technology to finish the material removal process of a large-scale thin-wall case part and provides an efficient and accurate numerical simulation method for the prediction of deformation and residual stress in the part machining process. Fig. 1 shows a flowchart of the procedure of the present invention. The material removing process is to dynamically realize the layer-by-layer removal of materials by writing a Python script program to dynamically refine local grids and combining the automatic setting of a 'live-dead' unit.
(1) On the basis of determining the actual working condition of the part, a simulation pretreatment automatic setting program is compiled by utilizing a Python language, and the method comprises the following steps of: three-dimensional modeling, material parameter setting, contact condition setting, boundary condition setting, living and dead unit setting and initial grid division;
(2) carrying out three-dimensional modeling on the workpiece;
(3) designing a tool path, exporting a tool path file (cls format), discretizing the tool path into a plurality of tool location points, and determining a machining area and an area needing grid refinement;
(4) extracting coarse grid information needing to be refined in the initial grid in the step (1) according to the cutter information and the cutter position information, calculating to obtain grid information (unit number and node number) after local refinement, replacing the grid information in an original input file (inp format), and defining a new 'live and dead' unit;
(5) the transmission of the new and old physical fields needs to complete the connection of the calculation result of the previous step before the calculation of the next step. From this, a completely new input file (. inp format) is formed;
(6) submitting a new input file (in format) for calculation;
(7) and (4) after the previous step of calculation is finished, continuously traversing the result file (odb format), and repeating the steps (3) to (6) to finish the next step of grid refinement until the calculation is finished.
Example 1
The part selected in the embodiment is a typical conical casing, the inner diameter of the large end of the conical casing is 330mm, the outer diameter of the conical casing is 350mm, the inner diameter of the small end of the conical casing is 270mm, the outer diameter of the conical casing is 290mm, the wall thickness of the conical casing is 10mm, and the machining allowance is 8 mm.
Referring to fig. 1, a method for implementing dynamic refinement of a simulated local grid in a thin-wall casing machining process includes the following steps:
the method comprises the following steps of determining the actual machining working condition of the thin-wall casing, wherein the method comprises the following steps: the size and shape of the part, the cutting mode, the feed path, the clamping mode, the size of the cutting force, the material parameters, the boundary conditions and the like;
step two, establishing a three-dimensional finite element simulation analysis model of the thin-wall case machining process according with the actual working condition, and automatically setting and programming the simulation pretreatment based on a script program language Python of finite element software ABAQUS, wherein the method comprises the following steps: material parameters, contact conditions, boundary conditions, "living and dead" unit selection, loading and initial grid division, as shown in fig. 2, are an initial grid map before local grid refinement and a grid map after global refinement of the casing part of the invention;
a cls file is used for discretizing the tool path and modeling a tool scanning body, so that a machining area, namely an area needing local grid refining treatment in the subsequent process, is determined by combining the tool path and the tool geometry, and a local grid dynamic refining diagram corresponding to one analysis step is shown in FIG. 3;
fourthly, compiling a script program by utilizing Python, extracting initial coarse grid information in the second step, calculating the grid cell number and the node number of the part according to an area needing to be refined, replacing corresponding coarse grid information in an input file (in format), loading the refined grid again and setting a 'life and death' unit, and as shown in figure 4, obtaining a calculation result after the dynamic refinement and the 'life and death' unit are set based on the local grid;
after grid refinement, the physical field of the previous step of calculation needs to be carried, and a method of a predefined field can be adopted in combination with a script program written by Python to realize the physical field transmission between the new grid and the old grid, so that a brand-new input file (in format) for subsequent calculation is formed, and as shown in FIG. 5, a result cloud picture of the physical field of the previous step carried after the next step of refinement is carried out;
step six, submitting the brand new input file (in format) formed in the step five for submission calculation;
and step seven, setting a judgment statement and judging whether the calculation is finished. And if not, continuously traversing the calculation result file (odb format) of the previous step, extracting grid information to perform detailed calculation and physical field transmission between the new grid and the old grid, and then repeating the operation of the fourth step to the sixth step until the calculation is finished. The final Python script program can integrate all the operations from step one to step seven, thereby effectively avoiding too frequent and complicated manual operations. Fig. 6 is a diagram of a deformation prediction result of the final simulation of the casing.
The above is a specific embodiment of the present invention, and in order to highlight the advantages of the present invention, the local grid dynamic refinement technique of the present invention is purposely compared with the conventional global grid refinement simulation in terms of simulation efficiency. As shown in fig. 2, the local mesh dynamic refinement method of the present invention can control the number of meshes per computational analysis step to be 89484, where the size of the coarse mesh is length × width × height: 3.5mm × 4mm × 0.5mm, the fine mesh size is length × width × height: 1.2mm × 1.4mm × 0.15 mm; the number of the grids after global refinement is 691200, and the grid size is length × width × height: 1.2 mm. times.1.4 mm. times.0.15 mm. In the aspect of computational efficiency, the time required for completing the computation is about 240 hours by using the globally refined model, but by adopting the method disclosed by the invention, under the same condition, the total number of grids is reduced by about 7.7 times, the time required for completing the computation is about 96 hours, and the computational efficiency is relatively improved by 2.5 times. Therefore, the method for realizing the dynamic refinement of the simulation local grid in the thin-wall casing machining process can greatly improve the efficiency of simulation calculation and greatly save the calculation cost.
The foregoing is only a primary feature, operation principle and advantage of the present invention, and it will be apparent to those skilled in the art that the present invention is not limited by the foregoing embodiments, and that the present invention can be flexibly modified and changed for different embodiments without departing from the basic principle thereof, and all such modifications and changes are within the scope of the present invention as defined by the spirit and scope of the present invention.
Claims (6)
1. A dynamic refinement method for a simulation local grid in a thin-wall casing machining process is characterized by comprising the following steps:
(1) on the basis of determining the actual working condition of the part, a simulation pretreatment automatic setting program is compiled by utilizing a Python language, and the method comprises the following steps of: three-dimensional modeling, material parameter setting, contact condition setting, boundary condition setting, living and dead unit setting and initial grid division;
(2) carrying out three-dimensional modeling on the workpiece;
(3) designing a tool path track according to the actual working condition, deriving a tool path file, discretizing the tool path into a plurality of tool location points, and determining a machining area and an area needing grid refinement;
(4) extracting coarse grid information needing to be refined in the initial grid in the step (1) according to the cutter information and the cutter position information, calculating to obtain grid information after local refinement, replacing the grid information in the original input file, and defining a new 'life and death' unit;
(5) the transmission of the new and old physical fields needs to complete the connection of the calculation result of the previous step before the calculation of the next step,
thus, a brand new input file is formed;
(6) submitting a new input file for calculation;
(7) and (5) after the previous step of calculation is finished, continuously traversing the result file, and repeating the steps (3) to (6) to finish the next step of grid refinement until the calculation is finished.
2. The method for dynamically refining the simulated local grid of the thin-wall case processing process according to claim 1, wherein in the step (3), three-dimensional hexahedral coarse grid refinement is performed according to the grid cell number and node number principle of ABAQUS, and the grid can be locally and dynamically refined according to the tool path.
3. The method for dynamically refining the simulation local grid in the thin-wall casing processing procedure according to claim 1, wherein the processing procedure, namely the material removal procedure, is to dynamically realize the layer-by-layer removal of the material by writing a Python script program to dynamically refine the local grid and combining with the automatic setting of a 'living and dead' unit.
4. The method for dynamically refining the simulation local grid in the thin-wall casing processing procedure according to claim 1, wherein in the step (4), the information of the coarse grid to be refined in the initial grid is extracted by discretizing an actual tool path into a plurality of tool positions and determining the tool positions after modeling according to a tool scanning volume.
5. The method for dynamically refining the simulation local grid in the thin-wall casing machining process according to claim 1, wherein the step (4) of calculating the grid information after local refinement comprises: the unit number and the node number are established according to the three-dimensional hexahedron grid and the unit and node number rule of the ABAQUS, and the unit and node numbers are calculated according to the mode of calculating the central unit and the rear edge unit.
6. The method for dynamically refining the simulation local grid in the thin-wall casing processing process according to claim 2, wherein the principles of the unit number and the node number are as follows:
A. b, C are rows of raw coarse grid cells of the workpiece respectively (x) A row of (y) A row (a)z) The total number of the units is A multiplied by B multiplied by C;a、b、 cfor refining the rows of the area cells (x) A row of (y) A row (a)z) The total number of units isa×b×c：
Unit numbering rules:
the number of the refined unit is close to the maximum value of the number of the original coarse grid unit, the number of the original coarse grid unit is A multiplied by B multiplied by C, namely the initial value of the number of the unit of the refined grid is A multiplied by B multiplied by C +1, and the number is increased from small to large;
numbering all small units of a coarse grid in sequence;
sequentially numbering all units in each row;
node numbering rules:
because different units have common nodes, the numbering rules of the nodes are different compared with the units;
the node number of the original coarse grid is (A +1)×(B+1)×(C +1), namely the initial value of the cell number of the grid after the thinning is (A +1)×(B+1)×(C+1)+1；
The specific numbering sequence is as follows:
1) numbering all internal nodes of the coarse grids in the refined region;
2) numbering nodes in the xy plane of all coarse grids in the refined region;
3) numbering nodes inside all coarse grid xz planes in the refined region;
4) numbering nodes inside yz planes of all coarse grids in the refined region;
5) numbering nodes on the x-direction edges of all coarse grids in the refined region;
6) numbering nodes on y-direction edges of all coarse grids in the refined region;
7) and numbering nodes on all edges of the coarse grid domain in the z direction in the refined region.
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