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<h1 id="轉角的nc優化後進給率比經驗上可行的進給率還低">轉角的NC優化後進給率比經驗上可行的進給率還低</h1>
<h2 id="現象說明">現象說明</h2>
<p>在進行NC進給率優化時，轉角處常會出現大幅度的進給率降低，有時甚至比經驗上可行的進給率還要低。這個現象讓使用者感到困惑：明明實際加工時轉角處不需要降那麼多，為什麼優化結果會這樣？</p>
<h2 id="控制器的轉角降速行為">控制器的轉角降速行為</h2>
<p>在轉角處，控制器在高速情況下會<strong>自動漸慢</strong>。這是控制器的內建行為，同時也是硬體限制，目的是確保機台能夠安全且準確地完成方向改變。控制器也提供參數可以調變這類加減速行為。</p>
<h3 id="緩衝距離與速度的關係">緩衝距離與速度的關係</h3>
<p>速度越快，需要的緩衝距離越長。下圖展示了數個直線路徑的加工條件：</p>
<p><img src="img/StraightLine-path.png" alt="直線路徑加工條件"></p>
<p>圖中標示了不同區段的主軸轉速(S)與進給率(F)設定：</p>
<ul>
<li>through1/through2：S500，F200/F100</li>
<li>low1/low2/low3：S1200，F200/F400/F600</li>
<li>high1/high2/high3：S7200，F1200/F2400/F3600</li>
</ul>
<h2 id="力量模擬誤差分析">力量模擬誤差分析</h2>
<p>下圖為套用並比對測力計資料後的力量模擬誤差圖，由藍到紅為誤差比率由小到大：</p>
<p><img src="img/corner-force-overview.png" alt="轉角力量誤差總覽"></p>
<h3 id="誤差特徵">誤差特徵</h3>
<p>從上圖可以觀察到以下特徵：</p>
<ol>
<li><strong>越靠近抬刀（朝Z向轉角）的誤差越大</strong></li>
<li><strong>進給率越高，高誤差的區間越長</strong></li>
</ol>
<h3 id="誤差來源">誤差來源</h3>
<p>誤差主要源自於<strong>控制器降速</strong>。從圖中下方的<code>F3600</code>轉角處單轉波形圖可以看到：</p>
<table>
<thead>
<tr>
<th>資料來源</th>
<th>說明</th>
</tr>
</thead>
<tbody>
<tr>
<td>左圖（模擬理想力）</td>
<td>系統依據設定進給率計算的理想切削力</td>
</tr>
<tr>
<td>右圖（測力計資料）</td>
<td>實際量測的切削力，約為理想力的三分之一</td>
</tr>
</tbody>
</table>
<p>實驗材料為S45C，該處<strong>實際進給應比理想進給的三分之一更低</strong>。</p>
<h2 id="為什麼優化值比經驗值還低">為什麼優化值比經驗值還低？</h2>
<p>系統做NC進給率優化時，轉角處常會有大幅度的進給率降低。除了轉角通常會造成切削力特大的理由外，比經驗上可行的進給率還低的原因是：</p>
<blockquote>
<p><strong>控制器已有自行調降進給率，系統的優化值只是把它顯示出來。</strong></p>
</blockquote>
<p>換句話說，優化結果反映的是控制器實際執行的進給率，而非NC程式中標示的進給率。這個「過低」的優化值其實是真實的機台行為。</p>
<h2 id="結論">結論</h2>
<p>當您發現轉角處的優化進給率異常偏低時，這通常不是系統的錯誤，而是：</p>
<ol>
<li>控制器為了安全轉向，已經自動降低了實際進給率</li>
<li>系統的優化功能如實反映了這個降速行為</li>
<li>如果按照經驗值設定，實際加工時控制器也會自行降速到類似的數值</li>
</ol>
<p>理解這個現象後，可以更合理地評估優化結果，並在必要時調整轉角策略或機台參數。</p>
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<h1 id="關於仿真過程cpu的使用率">關於仿真過程CPU的使用率</h1>
<h2 id="仿真的運算線程">仿真的運算線程</h2>
<p>時序資料的計算是單線程（同一時間只使用一個CPU核心），其他資料則可以平行計算。</p>
<h3 id="幾何移除">幾何移除</h3>
<p>幾何移除是單線程，因為按照次序切削才能得到正確的CWE（刀具工件接觸面）。幾何移除後的工件幾何表面是淡粉色，通常代表該處的物理量尚未計算完成。</p>
<h3 id="物理計算">物理計算</h3>
<p>切削力的計算在取得CWE之後，因其不受計算次序影響，一般模式下為多線程計算。力矩等物理量也會在這個步驟多線程計算。</p>
<p>溫度的計算必須是時序，所以又會收斂至單線程。</p>
<p>整個加工仿真的計算過程就這樣分分合合，一個步被計算完成後會在該步著上指定指標的顏色。</p>
<h2 id="cpu的使用率">CPU的使用率</h2>
<h3 id="幾何解析度大時">幾何解析度大時</h3>
<p>幾何解析度大的時候，幾何移除較物理計算快，所以仿真過程會看到一大片的淡粉色跟在刀具後面跑。未計算完成的步數有數量限制，幾何移除在該數量內才會運行。所以在物理計算跟不上幾何移除的速度時，粉色步數會維持固定數量。</p>
<p>這種情況主要是CPU的多核運算（物理計算），比較容易看到CPU多核使用率偏高。</p>
<p><img src="geom-quick.png" alt="幾何解析度大時"></p>
<h3 id="幾何解析度小時">幾何解析度小時</h3>
<p>幾何解析度小的時候，幾何移除較物理計算慢，所以幾乎看不到淡粉色。</p>
<p>這種情況主要是CPU的單核運算（幾何計算）。</p>
<p><img src="geom-slow.png" alt="幾何解析度小時"></p>
<h3 id="平衡狀態">平衡狀態</h3>
<p>如果幾何解析度剛好使得幾何計算與物理計算不互相拖累，那淡粉色區域會出現並在某個長度內變化。此時物理計算不會拖累幾何計算，通常幾何計算才是運算速度的瓶頸。</p>
<h3 id="cpu未跑滿的情況">CPU未跑滿的情況</h3>
<p>CPU沒有跑滿，原因可能包含:</p>
<ul>
<li>作業系統為了確保GUI能即時反應，預留空間不讓跑。如Windows桌面軟體(如WPF)會把非GUI的執行緒優先權降一個等級。</li>
<li>軟硬件吞吐量對該程序已達極限。
偵測的CPU使用量未達100%但是其他機能如Cache、匯流速度已滿，系統環境的智慧功能如CPU預測指令失誤(Branch Misprediction)也不會包含在偵測的CPU使用量中。</li>
</ul>
<p>這部分目前沒有解法。</p>
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<h1 id="銑削物理座標系">銑削物理座標系</h1>
<p>銑削力、銑削力矩、形變等物理性質，可以用不同座標系表示。感測器原始資料對應的座標系也不一樣。</p>
<p>用HiNC檢視物理仿真資料時，常會看到座標系的標示字，本章說明三個座標系。</p>
<p><img src="img/Machining-3-Coordinate.png" alt="Machining-3-Coordinate"></p>
<h2 id="工件座標系">工件座標系</h2>
<p>工件座標系(Workpiece Coordinate)，簡寫<code>[W]</code>。</p>
<p>通常是程式原點座標系。</p>
<p>工件座標系與動力計座標系一致。</p>
<h2 id="刀具行進座標系">刀具行進座標系</h2>
<p>刀具行進座標系(Tool Running Coordinate)，簡寫<code>[TR]</code>。</p>
<p>以刀具行進方向除去刀具法向移動後作為 +X ，刀具法向量作為 +Z ，以右手定則定義 +Y 。以順銑而言，+Y 方向遠離壁面。</p>
<p>刀具行進座標系適合理解加工狀態。</p>
<h2 id="主軸旋轉座標系">主軸旋轉座標系</h2>
<p>主軸旋轉座標系(Spindle Rotation Coordinate)，簡寫<code>[SR]</code>。</p>
<p>刀具行進座標系對 Z 軸旋轉主軸運動角度 <span class="math">\(\theta\)</span> 後為主軸旋轉座標系。</p>
<p>主軸旋轉座標系與智慧刀把座標系一致，因智慧刀把感測器會隨主軸一併旋轉。</p>
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