基于测点数据的直接数控仿形加工算法研究
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摘要
随着航空航天、汽车、造船及模具等工业的发展，自由曲面零件在现代工业中得到越来越广泛的应用，制造行业迫切要求更深入研究有效的数控仿形加工技术，因此基于测点数据对自由曲面仿形加工成为当前研究的重点之一。本文在综述国内外数控仿型加工技术的发展过程以及研究现状的基础上，阐述了研究基于测点数据的直接数控仿形加工算法的重要性。在传统的数控铣床上开发了基于测点数据的直接数控仿形加工系统，同时对基于测点数据的直接数控仿形加工算法等问题进行了深入研究。
本文研究内容包括以下几个方面：
1．对非接触测量得到的大量曲面测点数据进行预处理。首先进行毛刺处理方法研究、针对不同测点数据类型的几种滤波处理方法研究以及光顺处理。其次研究了大规模测点数据压缩技术。通过实例对以上的预处理算法进行了验证。
2．针对经过预处理后的测点数据，研究了基于测点数据的粗加工刀具路径生成方法，包括基于多面体模型的粗加工算法和基于Z-Map模型的粗加工算法。经过理论分析和通过自由曲面的实际加工验证了这两种算法的有效性，并比较了这两种算法在不同情况下的使用效果。
3．研究了基于测点数据的精加工刀具路径的生成方法，包括基于多面体模型的精加工算法、基于反求截面的精加工算法以及基于虚空间的精加工算法。通过理论分析、实验加工对三种算法的有效性进行了论证，并比较了这些算法在不同情况下的使用效果。
4．在已有数控仿形加工系统的基础上，根据OMAC思想，开发并完善文件管理模块、基于测点数据仿形加工模块以及模拟加工模块。通过对几个典型实例的加工验证了系统的可行性。
最后，总结本论文研究工作的主要结论，并对后续研究作了展望。
With the development of industries such as aeroplane, auto-car, shipbuilding and mould, free-form surface parts are used more widely in modern industry. The NC profile machining technique is urgently to be developed by industrial users, so current researches emphasize on free-form surface machining based on measuring point data gotten by all kind of equipment. Based on the survey of present research situation at home and abroad of NC profile machining technology, the significance of direct NC profile machining based on measuring point data is presented in this dissertation. Direct NC profile machining system is developed on the NC milling machine. Meanwhile the relevant problems on the technology of profile manufacturing are profoundly studied.
The main work in the dissertation is arranged as follows:
1. Several pretreatment methods in measurement points data by non-contact measurement method are introduced. First, in order to eliminate burr, filter noise and smooth measurement points, some methods are introduced. Second, a new compressing technology is presented. Finally, the algorithms are validated by experiment.
2. Two rough tool-path generation approaches based on measuring point data, which include the rough machining algorithm based on polyhedron model and the rough machining algorithm based on Z-Map model, are recommended. The advantages and disadvantages of each algorithms are analysed by theory. At last, the machining effect and efficiency by using different algorithms are compared.
3. Three fine tool-path generation approaches based on measuring point data, which include the fine machining algorithm based on polyhedron model, the fine machining algorithm based on inverse tool model and the fine machining algorithm based on supposed space model, are presented, the advantages and disadvantages of each algorithms are analysed by theory. At last, the machining effect and efficiency by using different algorithms are compared.
4. Based on OMAC, file managing module, profile machining module and simulation module are increased to original NC profile machining system. At last, the new NC system is validated by machining free-form surface.
Finally, main results and conclusions of this dissertation have been summarized; the prospects and study emphases of the future research work have been discussed and forecast.
本文研究内容包括以下几个方面：
1．对非接触测量得到的大量曲面测点数据进行预处理。首先进行毛刺处理方法研究、针对不同测点数据类型的几种滤波处理方法研究以及光顺处理。其次研究了大规模测点数据压缩技术。通过实例对以上的预处理算法进行了验证。
2．针对经过预处理后的测点数据，研究了基于测点数据的粗加工刀具路径生成方法，包括基于多面体模型的粗加工算法和基于Z-Map模型的粗加工算法。经过理论分析和通过自由曲面的实际加工验证了这两种算法的有效性，并比较了这两种算法在不同情况下的使用效果。
3．研究了基于测点数据的精加工刀具路径的生成方法，包括基于多面体模型的精加工算法、基于反求截面的精加工算法以及基于虚空间的精加工算法。通过理论分析、实验加工对三种算法的有效性进行了论证，并比较了这些算法在不同情况下的使用效果。
4．在已有数控仿形加工系统的基础上，根据OMAC思想，开发并完善文件管理模块、基于测点数据仿形加工模块以及模拟加工模块。通过对几个典型实例的加工验证了系统的可行性。
最后，总结本论文研究工作的主要结论，并对后续研究作了展望。
With the development of industries such as aeroplane, auto-car, shipbuilding and mould, free-form surface parts are used more widely in modern industry. The NC profile machining technique is urgently to be developed by industrial users, so current researches emphasize on free-form surface machining based on measuring point data gotten by all kind of equipment. Based on the survey of present research situation at home and abroad of NC profile machining technology, the significance of direct NC profile machining based on measuring point data is presented in this dissertation. Direct NC profile machining system is developed on the NC milling machine. Meanwhile the relevant problems on the technology of profile manufacturing are profoundly studied.
The main work in the dissertation is arranged as follows:
1. Several pretreatment methods in measurement points data by non-contact measurement method are introduced. First, in order to eliminate burr, filter noise and smooth measurement points, some methods are introduced. Second, a new compressing technology is presented. Finally, the algorithms are validated by experiment.
2. Two rough tool-path generation approaches based on measuring point data, which include the rough machining algorithm based on polyhedron model and the rough machining algorithm based on Z-Map model, are recommended. The advantages and disadvantages of each algorithms are analysed by theory. At last, the machining effect and efficiency by using different algorithms are compared.
3. Three fine tool-path generation approaches based on measuring point data, which include the fine machining algorithm based on polyhedron model, the fine machining algorithm based on inverse tool model and the fine machining algorithm based on supposed space model, are presented, the advantages and disadvantages of each algorithms are analysed by theory. At last, the machining effect and efficiency by using different algorithms are compared.
4. Based on OMAC, file managing module, profile machining module and simulation module are increased to original NC profile machining system. At last, the new NC system is validated by machining free-form surface.
Finally, main results and conclusions of this dissertation have been summarized; the prospects and study emphases of the future research work have been discussed and forecast.
引文
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[3] 罗庆生，韩宝玲．制造业的发展方向和创新趋势．科技进步与对策．2000，17(5)．
[4] 戴晓华．基于开放式体系的仿型铣床数控系统研究．浙江大学硕士学位论文，2002．
[5] 戴晓华，王文等．开放式数控系统研究现状及发展趋势．组合机床与自动化加工技术，2000(11)．
[6] 王威．可重构虚拟数控系统研究及原型开发．杭州：浙江大学硕士学位论文，2001．
[7] 王正兵．开放式体系结构—数控系统发展潮流．制造技术及机床，2002(1)．
[8] 游有鹏，董伟杰等．开放式数控系统——新一代NC的主流．航空制造技术，1999(5)．
[9] 张明亮，解旭辉等．开放性数控技术的发展．机电工程，1999(4)．
[10] 廖德岗．开放式数控系统的研究及其发展现状．机械，1999(3)．
[11] 刘磊等．基于仿型测量数据的层切法数控加工．华中科技大学学报，1999(2)：10-12．
[12] S.C.Park, Tool-path planning for direction-parallel area milling. Computer-Aider Design, 2000(32).
[13] Bo H.Kim, Byoung, K.Choi. Machining efficiency comparison direction-parallel tool path with contour-parallel tool path, Computer-Aided Design, 2002(34).
[14] 曾明贤．仿形木工机床开发现状与市场前景．木工机床，1998(2)．
[15] 凌国平．我国仿形技术发展和使用的调查分析．镇江船舶学院学报，1990(1)．
[16] 刘光磊，吴立言，沈允文．一种曲面加工的双靠模法．新技术新工艺，2000(5)．
[17] 胡永鉴．新型电液仿形系统．制造技术与机床，1994．1．
[18] 赵葛冒，司徒忠等．仿形系统在CAM中的拓展与应用研究，制造业自动化，1999．12．
[19] 邓昌奇．PLC在数控仿形加工中心的应用．自动化与仪器仪表，2001(4)．
[20] 汪道明，朱志红等．曲面数控仿型系统的研究与实现．机械与电子，2000(6)．
[21] 卢杰持．DIGIT-02C数控仿形系统．设计与研究，1991(6)．
[22] 王平江．曲面测量、建模及数控加工集成研究．武汉：华中理工大学博士学位论文，1996．
[23] 来新民．基于计算机视觉的自由曲面逆向工程关键技术研究．天津大学博士学位论文，1997．
[24] 李剑．基于激光测量的自由曲面数字制造基础技术研究．浙江大学博士学位论文，2002．
[25] K.Saito, T.Miyoshi. Non-contact 3D digitizing and machining system for free-form surface. Annals of CIRP, 1989(40).
[26] C. Bradley, G.W. Vickers. Automated rapid prototyping utilizing laser scanning and free-form machining. Annals of the CIRP, 1992(41).
[27] C.Jones, C Bradley, G.W.Vickers. Laser scanning and quasi-helical tool path definition of arbitrary curved surface models. Computers Industrial Engineering, 1994 26(2).
[28] Chien-nan Huang, Aaeid Motavalli. Reverse engineering of planar parts using machine vision. Computers Industrial Engineering, 1994.26(2).
[29] Alan C. Automatic generation of NC cutter path from massive data points. Computer-Aider Design, 1998(1).
[30] 陈钢，张利波，周济．POCKET加工算法研究．电子机械工程，1998(1)．
[31] S.C.Park, B.K.Choi. Boundary extraction algorithm for cutting area detection.. Computer-Aider Design, 2001 (33).
[32] M H. Voronoi diagrams and offset curves of curvilinear polygons. Computer-Aider Design, 1998(4).
[33] C.A.H.Lambregts. An efficient automatic tool path generator for 2D free-form pockets. Computer-Aider Design, 1996.
[34] C.Jones, C Bradley, G.W.Vickers. Laser scanning and quasi-helical tool path definition of arbitrary curved surface models. Computers Industrial Engineering, 1994.26(2).
[35] S.C.Park, B.K.Choi. Tool-path planning for direction-parallel area milling. Computer-Aider Design, 2000(32).
[36] J S Hwang. Interference-free tool-path generation in the NC machining of parametric compound surfaces Computer-Aider Design, 1992(7).
[37] C.A.H.Lambregts. An efficient automatic tool path generator for 2D free-form pockets. Computer-Aider Design, 1996.
[38] Eungki Lee, Contour offset approach to spiral toolpath generation with constant scallop height, Computer-Aider Design, 2003(35).
[39] S C.Park. Tool-path generation for Z-constant contour machining, Computer-Aider Design, 2003(35).
[40] 汪道明等．激光仿形的杂散点处理．华中数控应用专栏，2000．
[41] 鞠华．逆向工程中自由曲面的数据处理与误差补偿研究．浙江大学博士学位论文，2003
[42] 胡俊等，自由曲面激光仿形测量数据的光顺方法．机床与液压，2002(5)．
[43] 黄雪梅等．三维散乱数据三角形网格逼近的一种算法．计算机工程与设计，1998(2)．
[44] 张丽艳等．海量测量数据简化技术．计算机辅助设计与图形学学报，2001．
[45] 李学艺．离散数据复杂曲面的粗加工．计算机辅助设计与图形学学报，2003(3)．
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