CN114065432B - Manufacturing cost estimation method based on process flow - Google Patents
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Abstract
The invention discloses a manufacturing cost estimation method based on a process flow, which is characterized by firstly fusing manufacturing characteristic identification of manufacturability driving; then constructing a process template library, and carrying out process template matching, including manufacturing characteristic type matching; wall thickness, depth, corner radius, maximum/minimum width match; aperture matching; matching dimensional tolerance, form and position tolerance and roughness; reading process information from a system knowledge base according to the matched typical process template, and making a process decision of a typical structure; and finally constructing a manufacturing cost analysis model based on the process flow. The method of the invention starts from the manufacturing characteristics and the processing technological process of the part, and fully considers each stage in the part processing process, so that the final manufacturing cost estimation result is more accurate.
Description
Technical Field
The invention belongs to the technical field of machine manufacturing, and particularly relates to a manufacturing cost estimation method.
Background
Document 2016, Vol52, P341-353 discloses a method for estimating man-hours of parts based on manufacturing flow and manufacturing characteristics. The method researches the influence mechanism of the processing technology on the manufacturing characteristic man-hour and puts forward the concept of manufacturing characteristic combination; on the basis, development of a database with five working hours of production preparation, feeding and discharging, tool changing, rough machining and finish machining is realized; then, the concept of the manufacturing flow chart is put forward, and the man-hour estimation of similar parts is realized through the modification of the historical part manufacturing flow chart and the calling of data in the man-hour database. The method disclosed by the document realizes modification reuse of a manufacturing process of a base part by searching and reasoning a manufacturing characteristic example library, can estimate the working hours of the deformed parts, but has lower matching precision for parts with larger manufacturing characteristic difference, so that the working hour estimation result of the parts is not accurate enough; in addition, only four typical machining processes of turning, milling, grinding and drilling are considered in the literature, and non-mechanical machining processes such as stabilizing treatment, surface treatment, inspection processes, auxiliary processes and the like are not considered, so that the accuracy of part manufacturing cost estimation is reduced.
Disclosure of Invention
In order to overcome the defects of the prior art, the invention provides a manufacturing cost estimation method based on a process flow, which comprises the steps of firstly fusing manufacturing characteristic identification of manufacturability driving; then constructing a process template library, and carrying out process template matching, including manufacturing characteristic type matching; wall thickness, depth, corner radius, maximum/minimum width match; aperture matching; matching dimensional tolerance, form and position tolerance and roughness; reading process information from a system knowledge base according to the matched typical process template, and making a process decision of a typical structure; and finally constructing a manufacturing cost analysis model based on the process flow. The method of the invention starts from the manufacturing characteristics and the processing technological process of the part, and fully considers each stage in the part processing process, so that the final manufacturing cost estimation result is more accurate.
The technical scheme adopted by the invention for solving the technical problem comprises the following steps:
step 1: fusing manufacturability-driven manufacturing feature identification;
defining a set of continuous surfaces with manufacturing attributes satisfied by the parts under the same clamping;
step 1-1: calculating the feasible space of each processing surface in the three-dimensional CAD model in the cutter shaft direction by utilizing the axial process knowledge of the surface processing cutter;
step 1-2: pre-dividing the three-dimensional CAD model into a plurality of processing areas based on the attribute adjacency graph of the processing surface, and directly outputting the three-dimensional CAD model if the three-dimensional CAD model is the basic feature; if yes, continuing the step 1-3;
the basic features are defined as: in a machining region map G ═ (V, E), if all sides in the edge set E are non-convex, the machining region map represents a basic feature corresponding to the machining region in the part; the definition of the intersecting feature is: for the machining region graph G ═ V, E, if a convex edge or a convex cut edge exists in the edge set E, the machining region graph corresponding to the machining region in the part is an intersection feature;
step 1-3: respectively calculating a feasible tool axial set according to the types of different intersection characteristics, and extracting a base surface set of the machining area on the basis;
the definition of the basal plane is as follows: given a manufacturing feature F with a knife axis direction n k If there is a plane f in the fabricated feature i And n k Perpendicular, then called plane f i A base surface for making feature F;
step 1-4: for each processing area, taking a base plane as a seed plane, and obtaining each processing area subgraph by adopting a processing plane clustering algorithm of fusion manufacturing semantics;
the machined area subgraph is defined as follows: for graph G ═ V, E, where V denotes the face of the part and E denotes the edge, if:
1) for any two vertices V in V i And v j Presence of a connecting vertex v i And v j And each side in the path is a non-convex side;
2)
in the axial direction n of the tool k And satisfies the following conditions: n is k ·n i (p) is not less than 0, wherein n i (p) is a processed surface f i Normal vector at point p, processing surface f i And v i Correspondingly;
3) having at most one plane f j In the axial direction n of the tool k The included angle theta satisfies theta (n) j ,n k )<δ (δ is a given threshold), then the graph G is called a processing region subgraph;
step 1-5: taking the sub-images of the processing area as characteristic traces, optimizing and combining the sub-images of the processing area, and performing characteristic explanation to complete manufacturing characteristic identification;
step 2: rapidly generating a process flow based on a process template;
step 2-1: constructing a process template library;
analyzing the machining process based on the part structure, and extracting a process template and a rule corresponding to the machining scheme in the machining process, wherein the process template and the rule comprise machining process information represented by a typical process object and process decision knowledge represented by a rule mode; the process template refers to a process object and a related processing scheme thereof in the processing process, and comprises a characteristic template and a part process route template;
directly embedding typical process template rules into typical process objects and sub-objects thereof, and establishing typical process rules, typical process rules and a typical step rule base;
typical process rules constrain the value and process route of basic process information, typical process rules constrain process content and process step sequence arrangement, and typical process step rule constraint detailed design comprises the generation of process step content and processing elements and processing strategy selection;
adopting a processing method of generating rule constraint part characteristics to realize the association of manufacturing characteristics and a typical characteristic process template and construct a typical characteristic process template fused with rules; forming a process template library by the typical characteristic process template of the fusion rule; the typical feature process template refers to a processing scheme that can cover the processing of multiple manufacturing features;
step 2-2: matching process templates;
after obtaining a product, a part group, material attributes and typical attribute information to which the part manufacturing characteristics belong, obtaining a typical process template from a process template library based on rule matching according to the obtained information; the process template matching comprises manufacturing feature matching and process route matching, wherein the manufacturing feature matching comprises the following steps:
step 2-2-1: manufacturing feature type matching;
if the types of the two manufacturing features are different, the similarity of the two features is considered to be 0; if the feature types are the same, the similarity is 1;
let two characteristics to be compared be T 1 And T 2 Similarity of type is S T And (3) representing, performing feature type matching by using an equation (1):
step 2-2-2: wall thickness, depth, corner radius, maximum/minimum width match;
wall thickness, depth, corner radius, maximum/minimum width matching is performed using equation (2):
S G ＝0.2×S TH +0.2×S DE +0.2×S FI +0.2×S MAX +0.2×S MIN (2)
wherein S G Similarity representing wall thickness, depth, corner radius, maximum/minimum width value match, S TH Whether the wall thickness value in the manufacturing characteristic attribute of the new part falls in the wall thickness range of the characteristic information associated with the characteristic process template or not is shown, and if the wall thickness value falls in the wall thickness range, S TH Is 1, otherwise is 0; s DE Representing whether the depth value in the new part manufacturing feature attribute falls into the depth range of the feature information associated with the feature process template, and if so, S DE Is 1, otherwise is 0; s FI Indicating whether the corner radius value in the new part manufacturing characteristic attribute falls in the corner radius range of the characteristic information associated with the characteristic process template, and if the value is within the given range, S FI Is 1, otherwise is 0; s MAX Indicating whether the maximum width value in the new part manufacturing feature attribute falls within the maximum width range of the feature information associated with the feature process template, and if so, S MAX Is 1, otherwise is 0; s MIN Indicating whether the minimum width value in the new part manufacturing feature attribute falls within the minimum width range of the feature information associated with the feature process template, and if so, S MIN Is 1, otherwise is 0;
step 2-2-3: aperture matching;
for the hole characteristic type, the aperture range of the characteristic information associated with the characteristic process template is matched with the aperture value in the manufacturing characteristic attribute of the new part according to the aperture size, and S is used DI Indicating whether the minimum width value in the new part manufacturing feature attribute falls within the minimum width range of the feature information associated with the feature process template, and if so, S DI Is 1, otherwise is 0;
step 2-2-4: matching dimensional tolerance, form and position tolerance and roughness;
the similarity comparison of the dimensional tolerance, the form and position tolerance and the roughness depends on the grades of the dimensional tolerance, the form and position tolerance and the roughness, and the formula (3) shows that:
wherein S A And the similarity of dimensional tolerance, form and position tolerance and roughness matching is shown. S DIM Indicating whether the dimensional tolerance in the new part manufacturing feature attribute falls within the dimensional tolerance range of the feature information associated with the feature process template, and if so, S DIM Is 1, otherwise is 0; s FP Indicating whether the geometric tolerance in the manufacturing characteristic attribute of the new part falls in the geometric tolerance range of the characteristic information associated with the characteristic process template, and if so, S FP Is 1, otherwise is 0; s RO Representing whether the roughness in the new part manufacturing characteristic attribute falls in the roughness range of the characteristic information associated with the characteristic process template, and if so, S RO Is 1, otherwise is 0;
step 2-2-5: the similarity of the feature information associated with the feature process template for the new part manufacturing feature is defined as a weighted sum of wall thickness, depth, corner radius, maximum/minimum width, bore diameter, dimensional tolerance, form and position tolerance, roughness similarity, expressed as δ, calculated by equation (4):
taking the characteristic template with the maximum similarity as a characteristic process template of the characteristic to be manufactured;
step 2-2-6: if delta is greater than 0.5, the features are considered to be matched, all the new part manufacturing features and the associated features are circularly traversed, and the number m of matched associated feature pairs and the feature similarity weighted sum delta of each pair are output;
step 2-2-7: the new part manufacturing features have a plurality of associated feature matching pairs in a typical process template, using S TM Representing the similarity between the new part and the macroscopic process template as shown in formula (5):
step 2-2-8: finally, calculating S of the new part manufacturing characteristics and the associated characteristics in all typical process templates TM Value of S TM Carrying out process route matching on the typical process template with the highest value to serve as a process route template matched with the new part;
step 2-3: reading process information from a system knowledge base according to the matched typical process template, and making a process decision of a typical structure; copying the process content in the process template into new process information; for the processing procedure, screening machine tool information and entering a process step decision;
in the step decision, screening matched structural features, creating a processing element object aiming at the features, constructing a typical structure model which can cover the whole processing process, and finishing automatic decision of process level, procedure level and step level of the typical structure model; the process information of the automatic decision is subjected to navigation revision, and the process, the process step and the tooling information are edited to realize the automatic generation of the process flow of the typical structure of the part;
and step 3: constructing a manufacturing cost analysis model based on the process flow;
developing a manufacturing cost knowledge base of a typical structure of the part by analyzing the influence characteristics of different process elements on the manufacturing cost; analyzing the incidence relation between the processing technology and the manufacturing cost, and constructing a manufacturing cost knowledge base based on the technological process; the method is combined with a processing process flow to realize the estimation of the manufacturing cost of the part, and comprises the following steps:
step 3-1: analyzing and summarizing the incidence relation between the process elements and the working hours/costs in the part manufacturing process, wherein the incidence relation comprises machining parameters and working hours, machining geometry and working hours, manufacturing resources and costs, and carrying out quantitative representation so as to construct a cost knowledge base;
step 3-2: analyzing the influence rule of the manufacturing characteristics on the processing technology, and constructing an association function f between the manufacturing characteristics and the processing technology in a typical process rule and process template embedding mode 1 On the basis, the quantitative association of the process elements and the cost in the comprehensive cost knowledge base represents f 2 Establishing a manufacturing cost analysis mathematical model; the technical indexes of the cost comprise machine tool cost, cutter cost, machine tool conversion cost, cutter replacement cost, clamping cost and machining cost;
step 3-3: according to the process information contained in the process flow, the constructed manufacturing cost model is adopted to estimate the manufacturing cost of each procedure in the process flow one by one, and the whole process flow is further integrated to estimate the manufacturing cost of the whole part, so that an estimation route with unified processing technology-manufacturing cost is formed.
Preferably, the non-convex edge comprises a convex cut edge, a concave edge, an concave cut edge and a semantic edge.
The invention has the following beneficial effects:
1) the method of the invention starts from the manufacturing characteristics and the processing technological process of the part, and fully considers each stage in the part processing process, so that the final manufacturing cost estimation result is more accurate.
2) According to the method, the manufacturing cost analysis model based on the process flow is constructed by revealing the potential incidence relation among the manufacturing characteristics, the processing technology and the manufacturing cost, and an advanced and applicable model representation and theoretical method is provided for intelligent management and control of the manufacturing cost.
3) The method has higher efficiency under the condition of ensuring the accuracy of the estimation result of the manufacturing cost. Meanwhile, the method has high openness and modifiability, and can be developed and perfected in use, so that the usability and the estimation accuracy of the method under various conditions are ensured.
Drawings
FIG. 1 is a flow chart of the method of the present invention.
FIG. 2 is a general flow chart of the method for identifying three-dimensional CAD model manufacturing features in the method of the present invention.
FIG. 3 is an exemplary illustration of an exemplary manufacturing signature of the present invention.
FIG. 4 is a schematic diagram of a rapid generation overall scheme of a process flow based on a process template in the method of the present invention.
FIG. 5 is an exemplary illustration of an exemplary process flow of the present invention.
FIG. 6 is a schematic illustration of a manufacturing cost analysis scheme in the method of the present invention.
FIG. 7 is an exemplary graph of an example manufacturing cost estimate of the present invention.
Detailed Description
The invention is further illustrated with reference to the following figures and examples.
The invention provides a manufacturing cost estimation method based on a process flow. The method is based on manufacturing feature identification driven by manufacturability, and realizes the MBD model-oriented process flow rapid generation technology; and revealing a potential correlation relationship between the processing technology and the manufacturing cost, establishing a manufacturing cost analysis knowledge base, constructing a manufacturing cost analysis model based on the process flow, and realizing the estimation of the manufacturing cost of the typical part.
As shown in fig. 1, a manufacturing cost estimation method based on a process flow includes the following steps:
step 1: fusing manufacturability-driven manufacturing feature identification;
the manufacturing feature is a machined surface formed by continuously machining with a tool in one process. Unlike design features, it is not a closed geometric body, but a combined object of faces and faces, which is a collection of faces with crafting semantics. The manufacturing feature is a tie for realizing CAD/CAPP/CAM integration and is a basic unit of manufacturing processing.
To better characterize the nature of the manufacturing features, the project defines the manufacturing features as a set of continuous surfaces of a part that meet specific manufacturing attributes (e.g., tool axial, precision constraints, rational machining methods, etc.) under the same fixture. Theoretically, there is one feasible tool axis for the machining of each type of manufacturing feature, satisfying tool accessibility, and the surfaces of the same feature satisfy the same accuracy constraints (geometry accuracy, surface mutual position accuracy, surface roughness, etc.), i.e., each type of manufacturing feature satisfies the manufacturability requirements described above. Therefore, the manufacturing feature recognition of the three-dimensional CAD model is realized by detecting whether a group of adjacent surfaces in the three-dimensional CAD model meet manufacturability constraints, namely, the feasible space of the cutter shaft direction of the machining surface is calculated by analyzing the accessibility of the machining surface and taking the feasible cutter shaft direction knowledge of common machining surface types as guidance, and manufacturing semantics such as size, tolerance, surface roughness and the like are further fused for constraint according to the feasible space, so that a group of continuous surfaces which have the same cutter shaft direction and the same precision grade and meet certain geometric topological constraints are clustered into a manufacturing feature.
The steps of manufacturing feature recognition in the method are as follows:
step 1-1: calculating the feasible space of each processing surface in the three-dimensional CAD model in the cutter shaft direction by utilizing the axial process knowledge of the surface processing cutter;
step 1-2: pre-dividing the three-dimensional CAD model into a plurality of processing areas (basic features or intersecting features) based on the processing surface attribute adjacency graph, and directly outputting the basic features if the basic features exist; if yes, continuing the step 1-3;
step 1-3: respectively calculating a feasible tool axial set according to the types of different intersection characteristics, and extracting a base surface set of the machining area on the basis;
the definition of the basal plane is as follows: given a manufacturing feature F with a knife axis direction n k If there is a plane f in the fabricated feature i And n k Perpendicular, then called plane f i A base surface for making feature F;
step 1-4: for each processing area, the base surface is used as a seed surface, and a processing surface clustering algorithm with fusion manufacturing semantics is adopted to obtain sub-images of each processing area;
the machined region subgraph is defined as follows: for graph G ═ (V, E), if:
1) for any two vertices V in V i And v j Presence of a connecting vertex v i And v j And each side in the path is a non-convex side;
2)
in the axial direction n of the tool k Satisfies the following conditions: n is k ·n i (p) is not less than 0, wherein n i (p) is a processed surface f i Normal vector at point p, processing surface f i And v i Corresponding;
3) having at most one plane f j In the axial direction n of the tool k The included angle theta satisfies theta (n) j ,n k )<δ (δ is a given threshold), then the graph G is called a processing region subgraph;
step 1-5: taking the sub-images of the processing area as characteristic traces, optimizing and combining the sub-images of the processing area, and performing characteristic explanation to complete manufacturing characteristic identification;
and 2, step: rapidly generating a process flow based on a process template; on the basis of manufacturing a carrier with characteristics, defining a process template with a typical structure, and researching a process flow rapid generation method based on matching of manufacturing requirements and the process template, wherein the method comprises the following specific steps:
step 2-1: constructing a process template library;
analyzing the machining process based on the part structure, and extracting corresponding typical process template rules, wherein the typical process template rules comprise machining process information represented by typical process objects and process decision knowledge represented by rule modes;
directly embedding typical process template rules into typical process objects and sub-objects thereof, and establishing typical process rules, typical process rules and a typical step rule base;
typical process rules constrain the value and process route of basic process information, typical process rules constrain process content and process step sequence arrangement, and typical process step rule constraint detailed design comprises the generation of process step content and processing elements and processing strategy selection;
adopting a processing method of generating rule constraint part characteristics to realize the association of manufacturing characteristics and a typical characteristic process template and construct a typical characteristic process template fused with rules; forming a process template library by the typical characteristic process template of the fusion rule; the typical feature process template refers to a processing scheme that can cover the processing of multiple manufacturing features;
step 2-2: matching process templates;
after obtaining the product, part group, material attribute and typical attribute information of the part manufacturing characteristics, obtaining a typical process template from a process template library based on rule matching according to the obtained information; the process template matching comprises manufacturing feature matching and process route matching, wherein the manufacturing feature matching comprises the following steps:
step 2-2-1: manufacturing feature type matching; the manufacturing features in the process data mainly include basic manufacturing features such as holes, cavities, grooves, end faces, etc.;
in the manufacturing feature matching process, only the manufacturing results of manufacturing features of consistent feature type have re-use value. If the types of the two manufacturing features are different, the similarity of the two features is considered to be 0; if the feature types are the same, the similarity is 1;
let two characteristics to be compared be T 1 And T 2 Similarity of type is S T And (3) representing, performing feature type matching by using an equation (1):
step 2-2-2: wall thickness, depth, corner radius, maximum/minimum width match; manufacturing features of the same feature type, differing wall thicknesses, depths, corner radii, maximum/minimum widths may result in disparate reuse values. For example, the two cavities are similar in shape, but the wall thickness, the depth and the corner radius of the two cavities are greatly different, so that the machining method is greatly different, the corresponding parameter setting is also greatly different, and the process reusability value is low.
Wall thickness, depth, corner radius, maximum/minimum width matching is performed using equation (2):
S G ＝0.2×S TH +0.2×S DE +0.2×S FI +0.2×S MAX +0.2×S MIN (2)
wherein S G Similarity representing wall thickness, depth, corner radius, maximum/minimum width value match, S TH Indicating whether wall thickness values in the new part manufacturing characterization attribute fall within the characterizationIn the wall thickness range of the characteristic information related to the process template, if the wall thickness range falls into the characteristic information, S TH Is 1, otherwise is 0; s DE Representing whether the depth value in the new part manufacturing feature attribute falls into the depth range of the feature information associated with the feature process template, and if so, S DE Is 1, otherwise is 0; s FI Indicating whether the corner radius value in the new part manufacturing characteristic attribute falls in the corner radius range of the characteristic information associated with the characteristic process template, and if the value is within the given range, S FI Is 1, otherwise is 0; s MAX Indicating whether the maximum width value in the new part manufacturing feature attribute falls within the maximum width range of the feature information associated with the feature process template, and if so, S MAX Is 1, otherwise is 0; s MIN Indicating whether the minimum width value in the new part manufacturing feature attribute falls within the minimum width range of the feature information associated with the feature process template, and if so, S MIN Is 1, otherwise is 0;
step 2-2-3: aperture matching;
for the hole characteristic type, the aperture range of the characteristic information associated with the characteristic process template is matched with the aperture value in the manufacturing characteristic attribute of the new part according to the aperture size, and S is used DI Indicating whether the minimum width value in the new part manufacturing feature attribute falls within the minimum width range of the feature information associated with the feature process template, and if so, S DI Is 1, otherwise is 0;
step 2-2-4: matching dimensional tolerance, form and position tolerance and roughness;
in the process design process, the selection of dimensional tolerance, form and position tolerance and roughness processing method is closely related. For two manufacturing features with identical geometries, if the difference in dimensional accuracy is large, the corresponding machining processes may be very different. The similarity comparison of the dimensional tolerance, the form and position tolerance and the roughness depends on the grades of the dimensional tolerance, the form and position tolerance and the roughness, and the formula (3) shows that:
wherein S A And the similarity of dimensional tolerance, form and position tolerance and roughness matching is shown. S DIM Indicating whether the dimensional tolerance in the new part manufacturing feature attribute falls within the dimensional tolerance range of the feature information associated with the feature process template, and if so, S DIM Is 1, otherwise is 0; s FP Indicating whether the geometric tolerance in the manufacturing characteristic attribute of the new part falls in the geometric tolerance range of the characteristic information associated with the characteristic process template, and if so, S FP Is 1, otherwise is 0; s RO Representing whether the roughness in the new part manufacturing characteristic attribute falls in the roughness range of the characteristic information associated with the characteristic process template, and if so, S RO Is 1, otherwise is 0;
step 2-2-5: the similarity of the feature information associated with the feature process template for the new part manufacturing feature is defined as a weighted sum of wall thickness, depth, corner radius, maximum/minimum width, bore diameter, dimensional tolerance, form and position tolerance, roughness similarity, expressed as δ, calculated by equation (4):
taking the characteristic template with the maximum similarity as a characteristic process template of the characteristic to be manufactured;
step 2-2-6: the process template matching is to match the characteristic information in the typical process template with the characteristic information of the part to be manufactured and deduce the typical process template to which the part to be manufactured belongs. Firstly, performing feature matching, judging whether the features are matched according to the feature matching method, if delta is greater than 0.5, determining that the features are matched, circularly traversing all new part manufacturing features and associated features, and outputting the number m of matched associated feature pairs and the feature similarity weighted sum delta of each pair;
step 2-2-7: the new part manufacturing features have a plurality of associated feature matching pairs in a typical process template, using S TM Representing the similarity between the new part and the macroscopic process template as shown in formula (5):
step 2-2-8: finally, calculating S of the new part manufacturing characteristics and the associated characteristics in all typical process templates TM Value of S TM The typical process template with the highest value is used as a macro process template matched with the new part;
step 2-3: reading process information from a system knowledge base according to the matched typical process template, and making process decision of a typical structure; for general processes, copying the process contents in the process template into new process information; for the processing procedure, screening machine tool information and entering a process step decision;
in the step decision, screening matched structural features, creating a processing element object aiming at the features, constructing a typical structure model which can cover the whole processing process, and finishing automatic decision of process level, procedure level and step level of the typical structure model; the process information of the automatic decision is subjected to navigation revision, and the process, the process step and the tooling information are edited to realize the automatic generation of the process flow of the typical structure of the part;
and step 3: constructing a manufacturing cost analysis model based on the process flow;
developing a manufacturing cost knowledge base of a typical structure of the part by analyzing the influence characteristics of different process elements on the manufacturing cost; analyzing the incidence relation between the processing technology and the manufacturing cost, and constructing a manufacturing cost knowledge base based on the process flow; the method is combined with a processing process flow to realize the estimation of the manufacturing cost of the part, and comprises the following steps:
step 3-1: analyzing and summarizing the incidence relation between the process elements and the working hours/costs in the part manufacturing process, wherein the incidence relation comprises machining parameters and working hours, machining geometry and working hours, manufacturing resources and costs, and carrying out quantitative representation so as to construct a cost knowledge base;
step 3-2: analyzing the influence rule of the manufacturing characteristics on the processing technology, and constructing an association function f between the manufacturing characteristics and the processing technology in a typical process rule and process template embedding mode 1 On the basis, the process in the cost knowledge base is integratedQuantitative association of elements with cost representation f 2 Establishing a manufacturing cost analysis mathematical model; the technical indexes of the cost comprise machine tool cost, cutter cost, machine tool conversion cost, cutter replacement cost, clamping cost and machining cost;
step 3-3: and according to the process information contained in the process flow, the constructed manufacturing cost model is adopted to estimate the manufacturing cost of each procedure in the process flow one by one, and the whole process flow is further integrated to estimate the manufacturing cost of the whole part, so that an estimation route with unified processing process-manufacturing cost is formed.
The specific embodiment is as follows:
the manufacturing cost estimation method based on the process flow comprises the following specific steps:
1. referring to fig. 2 and 3, the manufacturing feature recognition is performed on the three-dimensional CAD model of the part, and the basic flow is as follows:
and step one, under the guidance of the axial process knowledge of the common surface machining tool, calculating the feasible space of each machining surface in the three-dimensional CAD model in the cutter axis direction.
And secondly, pre-dividing the three-dimensional CAD model into a plurality of processing areas (basic features or intersecting features) based on the processing surface attribute adjacency graph, and directly outputting the basic features if the basic features exist.
And thirdly, respectively calculating a feasible tool axial set according to the types of the different intersection features, and extracting a base surface set of the machining area on the basis. The definition of the basal plane is as follows: given a manufacturing feature F with a knife axis direction n k If there is a plane f in the fabricated feature i And n k Perpendicular, then called plane f i To create the base of feature F.
And step four, for each processing area, taking the base surface as a seed surface, and obtaining each processing area subgraph by adopting a processing surface clustering algorithm with fusion manufacturing semantics. The machined region subgraph is defined as follows: for graph G ═ V, E), if satisfied
1) For any two vertices V in V i And v j Presence of a connecting vertex v i And v j And the way ofEach edge in the diameter is a non-convex edge (including convex edge, concave edge, semantic edge and the like);
2)
in the axial direction n of the tool k And satisfies the following conditions: n is k ·n i (p) is not less than 0, wherein n i (p) is a processed surface f i Normal vector at point p, processing surface f i And v i Corresponding;
3) having at most one plane f j In the axial direction n of the tool k The included angle theta satisfies theta (n) j ,n k )<δ (δ is a given threshold), the graph G is called a machining region sub-graph.
And fifthly, taking the machined area subgraphs as the characteristic traces, optimizing and combining the machined area subgraphs, and performing characteristic explanation to complete the manufacturing characteristic identification.
2. Referring to fig. 4 and 5, a process template of a typical structure is defined on the basis of a manufacturing feature as a carrier, and a process flow is rapidly generated on the basis of matching of a manufacturing requirement with the process template, and the method comprises the following steps:
the method comprises the steps of firstly, analyzing a machining process based on a typical structure of a part, extracting corresponding typical process template rules, and mainly comprising machining process information represented by a typical process object and process decision knowledge represented by a rule mode. And directly embedding the rules into the typical process object and the sub-objects thereof, and establishing typical process rules, typical procedure rules and typical step rules. Typical process rules restrict the value and the process route of basic process information, typical process rules restrict the process content and the process step sequence arrangement, and typical process step rules restrict the detailed design of the process step content and the generation of processing elements, the selection of processing strategies and the like. And (3) adopting a processing method of generating rule constraint part characteristics to realize the association of the typical structure and the typical process template and construct the typical process template with the fusion rule.
And secondly, after obtaining information such as products, part groups, material attributes, typical attributes and the like of the typical structure of the part, obtaining typical process templates from a process template library based on rule matching according to the obtained information, if a plurality of templates are matched, screening by a user, and if the process templates are not matched, modifying screening conditions by the user and re-matching.
And step three, reading process information from a system knowledge base according to the matched typical process template, and making process decision of a typical structure. For general procedures, procedure contents in the process template are copied into new process information, and for machining procedures, machine tool information is screened and step decision is made. In the step decision, matched structural features are screened, a processing element object aiming at the features is created, a typical structure model covering the whole processing process is constructed, and the process level, procedure level and step level automatic decision of the typical structure is completed. And performing navigation revision on the automatically-decided process information, editing information such as procedures, work steps, tools and the like, and realizing automatic generation of the part process flow.
3. Referring to fig. 6, a manufacturing cost knowledge base of a typical structure of a part is developed by analyzing the characteristics of the impact of different process elements on manufacturing costs. And synthesizing the association relations between the machining precision and the machining process and between the machining process and the manufacturing cost, and revealing the potential association relation between the machining precision and the manufacturing cost, thereby constructing a manufacturing cost knowledge base taking the manufacturing characteristics as the core. And the manufacturing cost estimation driven by the machining precision is realized by combining the machining process flow. The manufacturing cost analysis model is constructed by the following steps:
analyzing and summarizing the incidence relation between the process elements and the working hours/costs in the part manufacturing process, including the machining parameters and the working hours, the machining geometry and the working hours, the manufacturing resources and the costs and the like, and carrying out quantitative representation, thereby supporting the construction of a cost knowledge base.
Analyzing the influence rule of the manufacturing characteristics on the machining process from the machining precision, and constructing an association function f between the machining precision and the machining process in a typical process rule and process template embedding mode 1 On the basis, the quantitative association of the process elements and the cost in the comprehensive cost knowledge base represents f 2 And establishing a manufacturing cost analysis mathematical model. Wherein, the technical indexes of the cost mainly comprise the cost of the machine tool and the cutterThe tool cost, the machine tool conversion cost, the cutter replacement cost, the clamping cost, the machining cost and the like.
And thirdly, according to the process information contained in the process flow, adopting the constructed manufacturing cost model to estimate the manufacturing cost of each procedure in the process flow one by one, and further integrating the whole process flow to estimate the manufacturing cost of the whole part.
Claims (2)
1. A manufacturing cost estimation method based on a process flow is characterized by comprising the following steps:
step 1: fusing manufacturability-driven manufacturing feature identification;
defining a set of continuous surfaces with manufacturing attributes satisfied by the parts under the same clamping;
step 1-1: calculating the feasible space of each processing surface in the three-dimensional CAD model in the cutter shaft direction by utilizing the axial process knowledge of the surface processing cutter;
step 1-2: pre-dividing the three-dimensional CAD model into a plurality of processing areas based on the attribute adjacency graph of the processing surface, and directly outputting the three-dimensional CAD model if the three-dimensional CAD model is the basic feature; if yes, continuing the step 1-3;
the basic features are defined as: in a machining region map G ═ (V, E), if all sides in the edge set E are non-convex, the machining region map represents a basic feature corresponding to the machining region in the part; the definition of the intersection features is: for the machining region graph G ═ V, E, if a convex edge or a convex cut edge exists in the edge set E, the machining region graph corresponding to the machining region in the part is an intersection feature;
step 1-3: respectively calculating a feasible tool axial set according to the types of different intersection characteristics, and extracting a base surface set of the machining area on the basis;
the definition of the basal plane is as follows: given a manufacturing feature F with a knife axis direction n k If there is a plane f in the fabricated feature i And n k Perpendicular, then called plane f i A base surface to fabricate feature F;
step 1-4: for each processing area, the base surface is used as a seed surface, and a processing surface clustering algorithm with fusion manufacturing semantics is adopted to obtain sub-images of each processing area;
the machined region subgraph is defined as follows: for graph G ═ V, E, where V denotes the face of the part and E denotes the edge, if:
1) for any two vertices V in V i And v j Presence of a connecting vertex v i And v j And each side in the path is a non-convex side;
2)
in the axial direction n of the tool k And satisfies the following conditions: n is k ·n i (p) is not less than 0, wherein n i (p) is a processed surface f i Normal vector at point p, processing plane f i And v i Corresponding;
3) having at most one plane f j In the axial direction n of the tool k The included angle theta satisfies theta (n) j ,n k )<δ (δ is a given threshold), then the graph G is called a processing region subgraph;
step 1-5: taking the sub-images of the processing area as characteristic traces, optimizing and combining the sub-images of the processing area, and performing characteristic explanation to complete manufacturing characteristic identification;
step 2: rapidly generating a process flow based on a process template;
step 2-1: constructing a process template library;
analyzing the machining process based on the part structure, and extracting a process template and a rule corresponding to the machining scheme in the machining process, wherein the process template and the rule comprise machining process information represented by a typical process object and process decision knowledge represented by a rule mode; the process template refers to a process object and a related processing scheme thereof in the processing process, and comprises a characteristic template and a part process route template;
directly embedding typical process template rules into typical process objects and sub-objects thereof, and establishing typical process rules, typical process rules and a typical step rule base;
typical process rules constrain the value and process route of basic process information, typical process rules constrain process content and process step sequence arrangement, and typical process step rule constraint detailed design comprises the generation of process step content and processing elements and processing strategy selection;
adopting a processing method of generating rule constraint part characteristics to realize the association of manufacturing characteristics and a typical characteristic process template and construct a typical characteristic process template fused with rules; forming a process template library by the typical characteristic process template of the fusion rule; the typical feature process template refers to a processing scheme that can cover the processing of multiple manufacturing features;
step 2-2: matching process templates;
after obtaining a product, a part group, material attributes and typical attribute information to which the part manufacturing characteristics belong, obtaining a typical process template from a process template library based on rule matching according to the obtained information; the process template matching comprises manufacturing feature matching and process route matching, wherein the manufacturing feature matching comprises the following steps:
step 2-2-1: manufacturing feature type matching;
if the types of the two manufacturing features are different, the similarity of the two features is considered to be 0; if the feature types are the same, the similarity is 1;
let two characteristics to be compared be T 1 And T 2 Similarity of type is S T And (3) representing, performing feature type matching by using an equation (1):
step 2-2-2: wall thickness, depth, corner radius, maximum/minimum width match;
wall thickness, depth, corner radius, maximum/minimum width matching is performed using equation (2):
S G ＝0.2×S TH +0.2×S DE +0.2×S FI +0.2×S MAX +0.2×S MIN (2)
wherein S G Similarity representing wall thickness, depth, corner radius, maximum/minimum width value match, S TH Whether the wall thickness value in the manufacturing characteristic attribute of the new part falls in the wall thickness range of the characteristic information associated with the characteristic process template or not is shown, and if the wall thickness value falls in the wall thickness range, S TH Is 1, otherwise is 0; s DE Representing whether the depth value in the new part manufacturing feature attribute falls into the depth range of the feature information associated with the feature process template, and if so, S DE Is 1, otherwise is 0; s FI Indicating whether the corner radius value in the new part manufacturing characteristic attribute falls in the corner radius range of the characteristic information associated with the characteristic process template, and if the value is within the given range, S FI Is 1, otherwise is 0; s MAX Indicating whether the maximum width value in the new part manufacturing feature attribute falls within the maximum width range of the feature information associated with the feature process template, and if so, S MAX Is 1, otherwise is 0; s MIN Indicating whether the minimum width value in the new part manufacturing feature attribute falls within the minimum width range of the feature information associated with the feature process template, and if so, S MIN Is 1, otherwise is 0;
step 2-2-3: aperture matching;
for the hole characteristic type, the aperture range of the characteristic information associated with the characteristic process template is matched with the aperture value in the manufacturing characteristic attribute of the new part according to the aperture size, and S is used DI Indicating whether the minimum width value in the new part manufacturing feature attribute falls within the minimum width range of the feature information associated with the feature process template, and if so, S DI Is 1, otherwise is 0;
step 2-2-4: matching dimensional tolerance, form and position tolerance and roughness;
the similarity comparison of the dimensional tolerance, the form and position tolerance and the roughness depends on the grades of the dimensional tolerance, the form and position tolerance and the roughness, and the formula (3) shows that:
wherein S A Similarity representing dimensional tolerance, form and position tolerance and roughness matching; s DIM Indicating whether dimensional tolerances fall within the manufacturing attributes of the new partIn the dimension tolerance range of the feature information associated with the feature process template, if the dimension tolerance range falls into the S DIM Is 1, otherwise is 0; s FP Indicating whether the geometric tolerance in the manufacturing characteristic attribute of the new part falls in the geometric tolerance range of the characteristic information associated with the characteristic process template, and if so, S FP Is 1, otherwise is 0; s RO Representing whether the roughness in the new part manufacturing characteristic attribute falls in the roughness range of the characteristic information associated with the characteristic process template, and if so, S RO Is 1, otherwise is 0;
step 2-2-5: the similarity of the feature information associated with the feature process template for the new part manufacturing feature is defined as a weighted sum of wall thickness, depth, corner radius, maximum/minimum width, bore diameter, dimensional tolerance, form and position tolerance, roughness similarity, expressed as δ, calculated by equation (4):
taking the characteristic template with the maximum similarity as a characteristic process template of the characteristic to be manufactured;
step 2-2-6: if delta is greater than 0.5, the features are considered to be matched, all the new part manufacturing features and the associated features are circularly traversed, and the number m of matched associated feature pairs and the feature similarity weighted sum delta of each pair are output;
step 2-2-7: the new part manufacturing features have a plurality of associated feature matching pairs in a typical process template, using S TM Representing the similarity between the new part and the macroscopic process template, as shown in formula (5):
step 2-2-8: finally, calculating S of the new part manufacturing characteristics and the associated characteristics in all typical process templates TM Value of S TM Carrying out process route matching on the typical process template with the highest value to serve as a process route template matched with the new part;
step 2-3: reading process information from a system knowledge base according to the matched typical process template, and making a process decision of a typical structure; copying the process content in the process template into new process information; for the processing procedure, screening machine tool information and entering a process step decision;
in the step decision, screening matched structural features, creating a processing element object aiming at the features, constructing a typical structure model which can cover the whole processing process, and finishing automatic decision of process level, procedure level and step level of the typical structure model; the process information of the automatic decision is subjected to navigation revision, and the process, the process step and the tooling information are edited to realize the automatic generation of the process flow of the typical structure of the part;
and step 3: constructing a manufacturing cost analysis model based on the process flow;
developing a manufacturing cost knowledge base of a typical structure of the part by analyzing the influence characteristics of different process elements on the manufacturing cost; analyzing the incidence relation between the processing technology and the manufacturing cost, and constructing a manufacturing cost knowledge base based on the process flow; the method is combined with a processing process flow to realize the estimation of the manufacturing cost of the part, and comprises the following steps:
step 3-1: analyzing and summarizing the incidence relation between the process elements and the working hours/costs in the part manufacturing process, wherein the incidence relation comprises machining parameters and working hours, machining geometry and working hours, manufacturing resources and costs, and carrying out quantitative representation so as to construct a cost knowledge base;
step 3-2: analyzing the influence rule of the manufacturing characteristics on the processing technology, and constructing an association function f between the manufacturing characteristics and the processing technology in a typical process rule and process template embedding mode 1 On the basis, the quantitative association of the process elements and the cost in the comprehensive cost knowledge base represents f 2 Establishing a manufacturing cost analysis mathematical model; the technical indexes of the cost comprise machine tool cost, cutter cost, machine tool conversion cost, cutter replacement cost, clamping cost and machining cost;
step 3-3: according to the process information contained in the process flow, the constructed manufacturing cost model is adopted to estimate the manufacturing cost of each procedure in the process flow one by one, and the whole process flow is further integrated to estimate the manufacturing cost of the whole part, so that an estimation route with unified processing technology-manufacturing cost is formed.
2. The method of remotely upgrading a rack interface unit via a 1553B interface of claim 1, wherein the non-convex edges comprise convex cut edges, concave cut edges, and semantic edges.
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