关键词: 数字孪生, 滚磨光整加工, 表面模型, 加工仿真, 高保真模型

Abstract: The representation of surface geometric morphology models and mechanical simulation calculations at the micro-scale are key factors affecting the prediction of machining simulation results.In traditional simulation,ideal smooth surface models are often used to replace the actual geometric morphology of parts,which often leads to significant discrepancies between simulation results and actual machining effects.The barrel processing was taken as the background and the concept of digital twins was used for reference,a high fidelity digital twin model was proposed to simulate the processing process,which was a multi-dimensional and multi-scale data set that preserves the micro geometric dimension information of the part surface while also being compatible with processing requirements,materials,and surface quality information.The geometric modeling method of high fidelity digital twin models were studied,a framework for digital twin barrel processing system was proposed,and the iterative operation mechanism of high fidelity models under this framework was analyzed.Finally,the effectiveness of the proposed method was verified by comparing the results of a barrel processing experiment and a simulation experiment on an aluminum alloy sample part with a size of 20mm×20mm×3mm.

Key words: digital twin, barrel processing, surface model, machining simulation, high fidelity model