涡扇叶片在机测量自适应采样方法

涡扇叶片的加工和检测精度直接影响到涡扇的结构强度和气动性能。为提高叶片的在机测量精度和效率，提出一种基于弯矩理论的自适应曲面采样方法，以解决叶片曲面在前缘和后缘位置处曲率急剧变化以及轮廓面的全局采样问题。根据曲面的几何特征变化，自适应确定检测点的分布密度和数量。仿真和在机测量实验验证了该方法的有效性和可行性。通过与双向等参数法、改进的分区等参数法和Hammersley序列法的采样结果对比表明，基于弯矩理论的自适应采样方法实现了对采样点位置及数量的微细精准调整，采样误差小，重构表面精度高，满足在机测量对时间和精度的要求。     

基于二次测量的曲面反求自适应采样方法研究

针对叶片CAD模型未知的情况,提出一种基于二次测量的曲面反求变弧长自适应采样方法。通过三坐标测量机测量反映叶片曲面形状的关键几何要素,重构曲面初始模型;基于初始模型获得的叶片曲率信息,确定采样方向和进给方向;基于变弧长自适应采样方法,使用三坐标测量机对叶片采样;基于获得的采样点坐标信息,反求出CAD模型。通过模拟仿真试验,在采样点数目能够准确反映曲面曲率的情况下,相对于采用等弧长、等弦弧比、等弦弧差自适应采样方法,采用变弧长自适应采样方法的曲面拟合精度明显提高。     

复杂曲面微模具的加工仿真及实验研究

采用逆向工程方法获取微模具的点云数据,利用逆向工程软件对点云数据进行处理、曲面重构和误差分析,获得了具有较高曲面造型精度的模具模型.利用UG加工模块,对微模具的数控微细铣削加工过程进行仿真,确定合理的切削参数和数控程序.以微小型三轴数控铣床为加工平台,利用微径球头铣刀对微模具进行加工实验.最终,实现了特征尺寸在微米级、具有复杂曲面结构微模具的高质量加工.     

基于三坐标测量机自适应测量的自由曲面逆向

自由曲面的精确测量和重构是决定具有自由曲面特征的零部件复现精度的重要因素,传统逆向中测量与重构是相互独立又不能有效评估的。为提高自由曲面测量速度和重构精度,基于三坐标测量机(Coordinate measuring machine,CMM),提出自适应测量的曲面重构方法。测量过程中,通过不断拟合样件上已测点,预算待测点及其测量矢量,指导CMM自动采集曲面上数据。由点云拟合自由曲面模型后,检验拟合模型上点与样件上相应点的误差;若误差偏大,则在测量点云中加入检测点后重新拟合曲面,进一步检测重拟合实体模型直至满足精度要求,得到精准数据点和精致的自由曲面模型。辅以计算机图形可视化实例验证本法,测量精度及其重构精度可达μm级,具有自由曲面特征的零部件整个逆向周期呈数量级下降,算法鲁棒性强。     

基于自适应测量和实时重构的自由曲面特征产品的逆向研究

为提高自由曲面测量速度和重构精度,基于三坐标测量机CMM,提出自适应测量的曲面重构方法。测量过程中,通过不断拟合样件上已测点,预算待测点及其测量矢量,指导CMM自动采集曲面上数据。由点云拟合自由曲面模型后,检验拟合模型上点与样件上相应点的误差;若误差偏大,则在测量点云中加入检测点后重新拟合曲面,进一步检测重拟合实体模型直至满足精度要求,得到精准数据点和精致的自由曲面模型。辅以计算机图形可视化实例验证本法,测量精度及其重构精度可达μ级,具有自由曲面特征的零部件整个逆向周期呈数量级下降,算法鲁棒性强。     

基于形状特征的自由曲面建模技术

针对自由曲面重构建模中存在的问题,对曲面数字化及离散点参数优化技术进行了研究。基于自由曲面的形状特征,提出了一种曲面自适应数字化技术。建立了基于显式的最小二乘重构误差的参数优化模型,运用子空间共轭梯度内部反射牛顿优化技术实现了大规模数据点的参数优化。研究结果表明,自适应数字化技术大大提高了曲面的采样效率;参数优化模型合理且优化算法收敛迅速。     

基于坐标测量机的自由曲面检测采样策略

为了实现自由曲面快速精确的检测和评定,研究了检测过程涉及的采样策略。提出采用随机Hamersley采样、简单随机采样和列系统采样3种方法设置自由曲面上的测量点。采用拟粒子群算法优化变换参数,实现被测曲面与设计曲面之间的定位,采用曲面细分法搜索设计模型上与被测点距离最近点以计算自由曲面轮廓度误差。为了对基于坐标测量机(CMM)在不同采样策略下的检测结果进行比较,采用非均匀有理B样条生成零件设计模型,选择相同的加工工艺在不同的加工中心加工多个零件得到粗糙度不同的自由曲面。最后,使用CMM在所设计的采样策略下实测零件,用提出的方法计算零件的轮廓度误差,并与CMM内置软件的计算结果进行比较。实验结果显示:选择随机Hammersley采样法和中等采样点数的采样策略检测效果最佳,不仅测量精度高,而且耗时少、成本低。应用提出的方法计算自由曲面轮廓度误差时,其精度比由CMM内置软件计算结果高10%~22%,表明提出的方法适用于自由曲面零件轮廓度误差的快速精确检测与评定。     

基于CMM自由曲面自适应测量及实时重构技术研究

逆向工程研究的重点是提高测量的速度和重构的精度。对自由曲面的测量提出应用接触式三坐标测量机进行自适应测量的实时重构方法。该方法通过不断的对已测曲面点的拟合来预测待测点的坐标和测量矢量,从而可以指导三坐标测量机自动完成整个曲面的测量,并借助非均匀B-spline拟合自由曲面模型,在线评价重构模型误差,直至误差大小满足精度阀值。实例验证表明,该方法可以有效地提高自有曲面逆向重构精度,整个逆向周期大大减少,精度较好。因此,所提出的算法可有效地提高自由曲面工件逆向重构精度,缩短逆向周期。     

一种面向点云制造自由曲面的CMM自适应采样方法

通过分析点云制造过程,提出了一种面向点云制造自由曲面的CMM自适应采样方法。首先,提取点云边界并选择初始采样点,进而依据中间曲面与原始点云之间的偏差不断自适应地增加采样点,直至满足采样精度要求。并提出了相应的点云边界提取方法以及点云与自由曲面偏差的计算方法。最后,将所提方法与具有代表性的两种采样方法:基于高斯曲率的自适应采样和等参数采样进行了对比,并分别以三种方法得到的采样点在三坐标测量机上进行测量,通过测量结果及测量时间的对比验证了所提出的自适应采样方法能够在提高采样效率的同时保持较高的采样精度,且该方法不依赖于曲面的CAD模型,因此能够应用于点云制造自由曲面的测量及检测。     

自由曲面逆向工程系统的研究

在曲面数字化规划和曲面重构研究的基础上,开发了基于非接触测量的逆向工程系统。在曲面重构数字化方面,提出基于曲面曲率和被测点切线斜率的自适应采样规划。在曲面重构方面,提出基于曲面曲率的数据点自适应压缩方法,以实现对散乱点的ＮＵＲＢＳ曲面重构。试验表明所开发的逆向工程系统是可靠和有效的。     

A Novel Method of Efficient Machining Error Compensation Based on NURBS Surface Control Points Reconstruction

A novel method to improve the efficiency of error compensation in free-form surface machining based on the Non-Uniform Rational B-Splines (NURBS) surface control points reconstruction is proposed in this article. With the presented method, a relatively small number of inspection points are needed to be measured for error compensation. The machined surface is obtained by reconstructing the control points of the designed surface based on the on-machine measurement data. The machining error of the surface is obtained by calculating the difference between the machined surface and the designed one. Then a compensate surface is achieved using the mirror symmetry model and surface modification method to compensate the machining error. Experimental validation for the milling of a NURBS surface shows that the machining accuracy of the surface is improved by 62.57% through use of the proposed method.     

Investigation of diamond cutting tool lapping system based on on-machine image measurement

The profile tolerance of diamond cutting tool??s edge is one of the key factors in affecting machining accuracy. With the development of ultra-precision machining technology for optical free-form surfaces and optical microstructures, the demand for high-precision round nose diamond cutting tools is increasing. In this study, an on-machine image processing approach is applied to cutting edge geometry truing process, and profile data of cutting edge in sub-pixel precision is acquired using a series of image processing methods. According to the profile captured, the deviation from an ideal cutting edge is calculated and feedbacked to the controller. The lapping system is employed to lap the cutting edge pertinently using the deviation and the corresponding position captured, and the round edge of high accuracy is obtained efficiently. This method can avoid the error caused by the process of refixturing for offline measurement in the traditional lapping method of diamond cutting tool and reduce the influence of human factors. A truing experiment for cutting edge of the monocrystal diamond cutting tool is carried out at the developed lapping system based on on-machine image measurement, and round cutting edge of profile tolerance less than or equal to ±0.5???m is achieved.     

基于多波长协作的切削液残留表面激光位移测量误差补偿方法

在加工测量一体化过程中,工件表面切削液残留形成的油膜会严重影响光学在机测量的精度。 现有的误差补偿方法通 常需要获取油膜介质的先验信息,如成分、厚度等。 而这些信息受加工形质、切削液随机分布等因素的影响难以实时获取。 为 此,本文提出一种基于多波长协作的切削液残留表面激光位移测量误差补偿方法。 首先设计并搭建了基于激光三角位移测量 的多波长激光测量系统,可利用多波长激光测量同一被测点位移。 通过引入柯西色散规律,建立光学系统与激光波长的解析关 系,并基于此推导出多波长激光测量内在的差分特性,最终实现误差补偿。 本文依此方法进行了实验。 结果表明补偿后测量误 差绝对值小于 0. 01 mm,与未补偿的测量数据对比,误差降低了至少 92% 。     

[刀具及切削工艺]一种基于几何调控的辊轧叶片前后缘加工曲面自适应重建方法

针对航空发动机压气机辊轧叶片前后缘溢料端数控加工问题，提出了一种基于设计曲面几何调控的前后缘加工曲面自适应重建方法。根据自由变形理论以及曲面能量控制原理，建立了具有变形约束能力的自由曲面几何调控模型；利用该模型建立了基于遗传算法求解的辊轧叶片前后缘加工曲面自适应重建策略。该策略通过微量调整叶片设计曲面几何形状，使其在逼近叶身型面测量数据的同时尽可能维持初始几何形状，最终实现了辊轧叶片前后缘加工曲面的自适应重建。实例验证结果表明：利用该方法获得的辊轧叶片前后缘加工曲面可以在保证叶片形状精度的同时实现其与实际叶身的圆滑转接。     

纳米精度在位测量系统测头误差校正方法

针对超精密机床两轴联动接触式在位测量过程中测头误差影响测量精度的问题,提出了一种测头半径误差及形状误差校正方法。进行了在位测量实验,比较分析了测头误差未校正、测头半径误差校正及测头形状误差校正三种情况的测量结果,并分别与Taylor Hobson PGI840离线测量结果进行对比,以验证测头形状误差校正方法的有效性。测头形状误差校正后,面形精度PV值由420nm变为370nm,与离线测量PV值380nm的差值为10nm。结果表明,该在位测量系统测头误差校正方法有效,能够提高在位测量精度。     

Adaptive sampling point planning for free-form surface inspection under multi-geometric constraints

Free-form surfaces have been widely used in aerospace, automotive and other fields. Due to its complex geometry, free-form surface inspection is generally conducted by touch-trigger or measuring probe-based Coordinate Measurement Machines or On-machine Measurement. Sampling strategy plays a decisive role in improving both measurement accuracy and efficiency, which is determined by sample size and distribution of sample points. However, it is difficult to simultaneously take the surface curvature, sampling density and approximation error into account, considering the complexity of surface geometry. In this paper, triangle mesh simplification is innovatively adopted in sampling planning to achieve multi-geometric constraints. As triangle mesh has outstanding advantages in representing the surface features, strong stability and is easy to modify its structure, free-form surface is converted to a dense triangle mesh. Triangle mesh simplification is implemented by iteratively contracting triangle edges. An improved quadric error metric is established to decide contraction order and optimal target vertices under discrete curvature constraint. Sampling density is controlled by limiting the triangle edge length. Detailed adaptive sampling algorithm under multi-geometric constraints is then developed. Both simulation and experiment are conducted to validate feasibility and robustness of the proposed method. The results are compared with uniform sampling and existing adaptive sampling strategy to show that the proposed method can prominently reduce sampling error when sample size is small.     

基于形状特征的自由曲面采样算法的研究

测点采样是自由曲面零件检测的关键步骤.基于零件的两个形状特征因子:曲率因子、局部曲面片大小因子,提出一种面向不同类型曲面的采样算法,推导出曲率因子、局部曲面片大小因子的计算公式,进而优选合理的采样方案.该采样算法具有适应性广、无需繁琐的迭代过程等特点.用NURBS表达曲面,根据零件的梯度信息模拟制造误差并考虑测量误差,对采样过程进行了仿真分析,仿真结果验证了该采样策略的有效性.     

自由曲面测量若干关键问题的研究

结合国内外研究现状 ,对自由曲面测量中曲面CAD模型已知时测点的自适应分布、测量路径优化、自由曲面形状误差评定和 CAD模型未知时的测量规划和测点数据处理等几个关键问题的实现方法进行了分析研究 ,并对测点的自适应分布做了仿真研究 ,证明了其有效性     

Adaptive sampling method for inspection planning on CMM for free-form surfaces

Coordinate measurement machines (CMMs) have been widely used in inspecting mechanical parts with higher accuracy. Both the distribution and the number of the sampled points on measurand have an important effect on the efficiency and quality of the measurement of CMMs. In this paper, an adaptive sampling method is proposed for inspection planning on CMM for free-form surface. The points are iteratively sampled from a form error model, which is constructed by superimposing appropriate form errors on the nominal data. Moreover, a modified algorithm is introduced to determine the deviation of two point sets for the improvement of the inspecting accuracy, and the inspection uncertainty is also analyzed. A comparison is performed between the proposed method and the two well-known sampling methods, which are the equi-parametric method and the patch mean Gaussian curvature-based method, both simulated and experiment results show the effectiveness and robustness of this method.