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

摘要： 零件表面微观几何形貌表达以及机械作用力的仿真计算,是影响精密加工仿真结果预测准确度的关键。传统仿真中常采用理想光滑表面模型替代零件真实的几何形貌,往往导致仿真结果与实际加工效果产生巨大偏差。以滚磨光整加工为背景,借鉴数字孪生理念,提出采用高保真模型模拟预测机械加工作用效果。该模型是一个多维度、多尺度的数据集合,在保留零件表面微观几何尺寸信息的同时,还兼容加工要求、材料和表面质量等信息。研究了面向数字孪生滚磨光整加工的高保真模型几何建模方法,提出了数字孪生滚磨光整加工系统框架,分析了该框架下的高保真模型迭代运行机制。最后,通过对比一尺寸为20 mm×20 mm×3 mm铝合金试件的滚磨光整加工实验和仿真实验结果,验证了所提方法的有效性。

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