复杂曲面局部协调设计技术

综合利用CAGD中的曲线曲面理论和方法,通过构造合理的局部区域来裁剪N边汇交曲面,并利用汇交曲面的原始信息解决局部NURBS曲面的协调设计．该方法在新生成曲面与裁剪汇交曲面之间保证处处G^1连续,同时光滑地逼近于局部区域的特征走向．这种基于特征敏感的带复杂边界条件约束的协调曲面重构方法,作为曲面高级编辑工具已应用于计算机辅助反求工程CAD软件RE—SOFTV6．0中．实际应用表明,局部协调设计技术能够较好地解决复杂曲面造型和反求工程建模中模型的整体连续性和保形性．     

未知曲面数控加工干涉区域求取算法研究

质量和效率是自由曲面零件数控加工所追求的一对相互矛盾的目标，曲面的分片加工可以较好地解决这这一问题，而自由曲面零件分片加工方法中一个关键问题是如何求取自由曲面的干涉区域，提出了在对自由曲面密集采样测量的基础上，利用未知曲面测点信息，通过参数曲面局部逼近和干涉区域测点问几何关系遍历求取干涉区域的算法，该方法避开了烦琐的自由曲面重建处理，仿真和实验研究的结果验证了算法的有效性。     

自适应三角片离散法实现三轴数控加工仿真

自动地根据加工面的起伏情况，采用不同分辨率的三角片逼近曲面，从而大幅度地减少三角片总数，在保证仿真实时性的同时仍然保持很高的图像质量；而且可以进行平移、旋转和缩放等操作．当要评估加工误差，检查过切、欠切和干涉时，可以自动地切换到全分辨率模型，保证了这些检查的准确性和正确性．     

反求工程中的混合切片技术

提出一种基于平面与“点云”、平面与NURBS曲面求交计算的混合切片方法．该方法可以保证切片曲线在点云和曲面的连接处达到G^1连续，在此基础上的重构曲面既能保证与相邻曲面的连续性要求，又能满足对点云的逼近精度要求，对反求建模尤其是过渡特征的重建有着重要意义．文中详细探讨了平面与曲面求交和点云切片两个核心算法，并对基于模型特征的混合切片方案的选择原则以及不同方法进行了论述和比较．最后用实例证明该方法在反求建模中是切实可行的．     

基于Z-map模型的自由曲面无干涉刀具轨迹生成算法研究

刀具轨迹生成是自由曲面零件数控加工中重要的研究内容.本文分析了自由曲面数控加工中常用的刀具轨迹生成策略和方法,设计和实现了一种基于Z-map结构的自由曲面无干涉刀具轨迹生成算法.本算法采用进化算法进行刀具干涉检测,不仅解决了生成刀具轨迹时因走刀步长不合理而产生的过切问题,而且也确保了生成的刀具轨迹为无干涉刀具轨迹.     

基于层次B样条的网格模型变形技术

针对常用的网格模型提出了一个基于层次B样条控制的三维网格空间变形框架．首先由用户交互地选取编辑区域，由程序完成编辑区域的参数化和均匀重采样；然后用层次B样条光顺拟合这些均匀采样点，所得的R样条曲面作为网格模型的基曲面，计算待编辑区域中网格顶点相对该B样条基曲面的局部坐标，该局部坐标平移、旋转不变，可视为模型的内蕴几何特征，并作为变形操作中的不变量．用户通过编辑层次B样条基曲面或者直接编辑三维网格模型，可实现多分辨率变形．实验结果表明：该方法操作直观方便，无论对整体还是局部变形，都能取得可控、可靠的变形效果，且采刚B样条曲面的控制手段易于与已有的造型系统合成．     

基于高斯映射下自由曲面的形状分析及边界计算

测定单一类型（凸或马鞍）区域和计算其边界是进行自由曲面的形状分析与控制研究的基本内容之一．目前这方面的研究局限于一些特殊曲面，如可展曲面，对自由曲面则无来境的理论和方法．本文提出了一些对复杂自由曲面进行形状分析的几何结论．通过计算高斯抛物线，划分了曲面的单类型区域．设计了算法判断单类型区域、分离单类型区域，并计算其边界，对自由曲面整体的形状有了较好的把握．最后蛤出了算法对两个例子的计算结果．     

基于函数迭代系统的3-D分形插值算法

提出了一种新的分形插值算法，通过矩形剖分上的采样数据点构建分形插值曲面。该算法保证分形插值时的边界连续性，而且对于初始数据集没有任何对称性限制。所构建的分形插值曲面整体上保持原始数据的主要特征，局部上具备自相似的特点。实验结果表明算法的有效性和低时间复杂度，有利于分形插值的实际应用。     

复杂曲面五轴加工局部干涉处理技术研究

针对复杂曲面环形刀五轴数控加工中的局部干涉问题,提出了一种基于曲 率匹配及网格点的干涉处理技术。首先,利用曲率匹配原则选出合理的刀具半径,以保证在 切触点处沿任何方向上刀具与被加工曲面之间不会发生干涉,然后在各个切触点处通过比较 刀具曲面最小主曲率与加工曲面最大主曲率确定出刀具的初始倾角。为了判断切触点邻近区 域是否存在干涉问题,采用了网格点来快速自动生成检测区域及初始检测点。文中对有效检 测点的筛选以及干涉的判断和处理技术分别进行了详细论述。最后,以非均匀有理B 样条 曲面为加工实例,对上述算法进行了测试和验证。     

博士信箱

长沙读者 安红兵 问：在CIMATRON软件中，模拟切屑能否转动？ 答：在CIMATRON V10.6以后的版本就可以。方法是在SIMULATOR界面内，将毛坯渲染为实体，然后按下ROTATE SOLID按钮，右键控制旋转。温州读者 张鄞问：我不小心将CIMATRON的中文字体文件删掉了，可以用其他字体文件替换吗？另外，有一个从前视图看上去是C型的曲面，需用T型刀加工，我只能编端铣刀。因为刀具路径的计算是以刀具的底部为准，所以实际用T型刀加工C型曲面的上半部时产生了过切。我想打开曲面的自身检测干涉功能，哪知凹进去的曲面没有被加工。可…     

改进的八叉树模型在3D刀轨显示系统中的应用

在传统的八叉树模型的基础上增加了扩展八叉树结点,同时引入了混合式的八叉树教据结构,并将它们应用到数控加工的三维刀轨显示系统中;叙述了实体从B-rep表示法转换为相应的改进型八叉树模型的方法,并在这种改进的八叉树模型的基础上完成对零件加工过程的实时性仿真;最后通过运行实际的数控加工程序证明该算法的可行性和有效性.     

Inspection of the machined surfaces using manufacturing data

Accuracy of complex machined parts is usually estimated using coordinate measurement machines. The inspection results can be used to control or monitor a production system. Traditional inspection process of a machined surface commonly compares the resulting manufactured surface with the CAD-model or the nominal designed surface. Although, the result of this CAD-based inspection can be used to accept or reject the machined part, it does not provide the correct information required to study the machining errors and their behaviour. This paper presents a methodology to inspect a machined surface directly based on its actual CAM geometric model. The presented CAM-based inspection methodology can be used to model and understand the real machining errors, which can be utilized for process control, design for manufacturing or closed-loop machining.     

Automated surface subdivision and tool path generation for -axis CNC machining of sculptured parts

As an innovative and cost-effective method for carrying out multiple-axis CNC machining, -axis CNC machining technique adds an automatic indexing/rotary table with two additional discrete rotations to a regular 3-axis CNC machine, to improve its ability and efficiency for machining complex sculptured parts. In this work, a new tool path generation method to automatically subdivide a complex sculptured surface into a number of easy-to-machine surface patches; identify the favorable machining set-up/orientation for each patch; and generate effective 3-axis CNC tool paths for each patch is introduced. The method and its advantages are illustrated using an example of sculptured surface machining. The work contributes to automated multiple-axis CNC tool path generation for sculptured part machining and forms a foundation for further research.     

机械加工MBD毛坯模型的特征识别设计方法

为了解决基于模型的定义(MBD)环境下机械加工毛坯辅助设计问题,采用特征识别技术辅助创建三维毛坯模型.首先分析了机械加工工艺设计环节MBD毛坯模型的组成要素与模型要求,并建立零件模型的属性面邻接图;根据零件模型上加工特征的特点划分简单特征、体积特征和表面特征;通过属性面邻接子图的模式从特征集合中识别出简单特征与体积特征,并利用补特征法与半空间法抑制这2种特征;最后,根据工艺员输入的表面加工余量创建抑制表面特征的实体.在整个毛坯设计推理过程中研究了三维制造标注的维护方法,最终达到辅助工艺员快速设计MBD毛坯模型的目的.     

三维工序模型切削载荷动态变化的工艺优化策略

综合零件的加工特征及约束条件并引入布尔差运算,可以分解出零件典型面组并 生成对应的工艺路线谱系,达到零件加工工艺快速优化设计的目的。通过分析三维工序模型典 型面组加工时的动态特性,采用B 样条曲线插值参数化的方法构建刀具-工件接触区域动态边界 的统一数学模型,预测切削载荷动态变化状况,并进行切削参数优化达到有效控制切削载荷的 目的。最后以某零件的车削加工为例进行分析,验证该工艺优化策略的可行性。     

Three dimensional modeling and finite element simulation of a generic end mill

The geometry of cutting flutes and the surfaces of end mills is one of the crucial parameters affecting the quality of the machining in the case of end milling. These are usually represented by two-dimensional models. This paper describes in detail the methodology to model the geometry of a flat end mill in terms of three-dimensional parameters. The geometric definition of the end mill is developed in terms of surface patches; flutes as helicoidal surfaces, the shank as a surface of revolution and the blending surfaces as bicubic Bezier and biparametric sweep surfaces. The proposed model defines the end mill in terms of three-dimensional rotational angles rather than the conventional two dimensional angles. To validate the methodology, the flat end milling cutter is directly rendered in OpenGL environment in terms of three-dimensional parameters. Further, an interface is developed that directly pulls the proposed three-dimensional model defined with the help of parametric equations into a commercial CAD modeling environment. This facilitates a wide range of downstream technological applications. The modeled tool is used for finite element simulations to study the cutting flutes under static and transient dynamic load conditions. The results of stress distribution (von mises stress), translational displacement and deformation are presented for static and transient dynamic analysis for the end mill cutter flute and its body. The method described in this paper offers a simple and intuitive way of generating high-quality end mill models for use in machining process simulations. It can be easily extended to generate other tools without relying on analytical or numerical formulations.     

A machining potential field approach to tool path generation for multi-axis sculptured surface machining

This paper presents a machining potential field (MPF) method to generate tool paths for multi-axis sculptured surface machining. A machining potential field is constructed by considering both the part geometry and the cutter geometry to represent the machining-oriented information on the part surface for machining planning. The largest feasible machining strip width and the optimal cutting direction at a surface point can be found on the constructed machining potential field. The tool paths can be generated by following the optimal cutting direction. Compared to the traditional iso-parametric and iso-planar path generation methods, the generated MPF multi-axis tool paths can achieve better surface finish with shorter machining time. Feasible cutter sizes and cutter orientations can also be determined by using the MPF method. The developed techniques can be used to automate the multi-axis tool path generation and to improve the machining efficiency of sculptured surface machining.     

Geometric parameter optimization in multi-axis machining

This paper presents a systematic method for the determination of optimal geometric machining parameters in multi-axis machining. Machining accuracy is considered to be determined by a set of geometric parameters: the design parameters of the cutter, the positioning of the cutter, the orientation of the cutter etc. First, we formulate the general nonlinear constrained optimization model of the machining process. The optimal machining result is expected to produce the least deviation between the designed surface and the actual surface. This objective is accomplished by minimizing the deviation between the designed surface and the actual surface during machining. The details of how to characterize and calculate the deviation is then discussed for both ruled surface milling and general free-form surface milling. The swept surface is developed based on robotic manipulation and is used to model the actual surface. A signed distance function is constructed to perform the comparison which returns the signed distance from each sampled point to the designed surface. The direct search algorithm (Nelder-Mead simplex algorithm and pattern search algorithm in this paper) is used to solve our optimization problems due to possible discontinuity of the objective function and large nonlinearity of the problem. Three numerical examples and necessary comparisons are given to demonstrate the effectiveness of our method. The first example shows the generation of the swept volume of a filled-end cutter. The second example employs the swept surface generation method to solve a parameter optimization problem. Sensitivity analysis is performed for the parameters critical to machining accuracy. The third example optimizes the cutter orientation relative to the part surface to minimize the kinematics error caused by kinematics transformation and interpolation of multi-axis machines.     

Method for automating digital fixture-setups that are optimal for machining castings to minimize scrap

The motivation for this paper is to describe a method for lowering the cost of finishing large castings that have machined surfaces for attaching other components. Considerable time is required to set-up each cast part on a machine-tool, sometimes taking longer than the machining itself, and errors in set-up can result in scrapping expensive parts or attempts to salvage them by rework. Although the focus of the paper is to demonstrate a new technology and software for set-up prior to the machining of iron/aluminum/steel sand castings, the same technology also is applicable to large welded assemblies on which finished machining occurs. In this paper, we outline a method, currently being implemented, that can predictively, and off-line, identify the adjustments needed to position and orient each part in its fixture before machining operations begin so that, after machining, all finished features will lie in their tolerance zones. Computer models first simulate all the to-be-machined (TBM) surfaces and any contact points with the fixture by feature-fitting point clouds taken from selective scanning of the raw casting. The locations of these features are compared with their locations on the CAD model of the part. Then, by using the T-Map model for tolerances, all possible locations of the part in its machining fixture are identified so that all TBM faces lie in their tolerance-zones. An optimum location may then be chosen.     

Sensitivity analysis of material input data influence on machining induced residual stress prediction in Inconel 718

Inconel 718 is commonly used in structural critical components of aircraft engines due to its properties at high temperatures. In order manufacture the final part, these components have to be machined, so the final surface integrity obtained after machining becomes a key issue. Residual stresses, which are included in surface integrity, are an important issue. Although much of the research carried out on machining induced residual stresses has been empirical, finite element modelling appears to be a complementary solution to gain understanding of it. However, some of the major drawbacks still need to be solved before it can become a reliable tool for industry, such us the identification of input parameters and computational cost. This paper deals with the study of machining induced residual stresses. An orthogonal cutting 2D finite element model was used and a sensitivity analysis was conducted to determine the influence of model input data on the predicted residual stresses. The results obtained from the sensitivity analysis showed that material constitutive law was the most relevant input data when predicting residual stress fields. Importantly the material behaviour at a high heating rate in adition to high strain rate must be considered.