反求工程在复杂冲压零件及成形模具设计中的应用研究
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摘要
反求工程（Reverse Engineering, RE）是产品创新设计和快速开发的重要手段，是各种先进制造模式的关键使能技术。本文根据反求工程在曲面形状复杂产品设计的特点，并结合冲压模具设计中的要点，在研究一般反求工程关键技术和冲压模具设计特点的基础上，通过对复杂曲面数字化、曲面重构、CAD建模和坯料尺寸反求等关键技术的研究，较完整地建立了一套适合复杂曲面形状冲压模具反求工程的方法和手段，以此来适应产品快速开发的需要。
在深入分析了复杂曲面数字化的各种测量方法的应用特点及其适用范围的基础上，提出了适合复杂冲压零件曲面数字化的方法。为了提高曲面数字化的效率和精度，探讨了用CMM进行数字化时的测点路径规划问题；为增强数据点的合理性及完备性，需对原始测量数据进行预处理，分析了数据预处理的各种手段，重点探讨了基于曲面曲率的一种自适应数据压缩方法。
根据复杂曲面及其反求的特点，以重构适应性好、编辑快捷的连续的Bezier曲面为最终目标，研究了适合复杂曲面冲压模具反求工程的几何建模技术及相应的关键技术，即：离散点集的三角划分，网格优化、网格简化、基于型曲面重构及其曲面光顺处理技术。
详尽地探讨了冲压毛坯尺寸形状的反求技术——逐次逼近法、拼合法、滑移线法、几何映射法，以及基于有限元技术的板料成形毛料计算方法，并分析了各自在冲压坯料反求中特点的及其适用范围。对油箱底壳冲压成形进行了力学分析，考虑了凸凹模尺寸、模具型腔参数、润滑和模具材料等因素对成形的影响，以及对成形中可能出现的各种缺陷进行了预测。在此的基础上，确定了初步的模具参数和工艺方案。对于毛坯形状的反求，提出了在造型软件UG中展开获得初始的毛坯形状，然后在板料成形模拟仿真软件Dynaform进行模拟修正，获得最终的毛坯形状的基于有限元技术的试错修改法。为了满足快速设计的需要，解决毛坯初步确定时手工展开毛坯费时、费力的问题，开发了一套采用VC++6.0语言，集成于UG造型软件中的计算毛坯形状自动提取软件。此软件的应用，可以很大程度提高效率，并为以后解决工程实际中的类似问题提供实际设计经验。
Reverse Engineering (RE) is an important means of products innovation design and prompt development, and it is the key technology of various advanced manufacture mode as well. According to the design characteristics of some product and die design, based on research on key techniques of general RE and design characteristics of stamping die, the digitalization, surface reconstruction, modeling of CAD and RE of stamping parts are studied. The corresponding methods of RE of complex stamping die & mould which has complex surfaces are proposed to meet the demands of products prompt development.
Based on analyzing all kinds of the measure method of the digitalization of complex surface and their scope of application and characteristics, surface digital method of RE which adapts to RE of complex stamping die are discussed. Sample points programming are researched deeply. In order to enhance rationality and maturity of points, original points should be compressed. Method of self-adaptation data compression based on surface curvature is introduced in the paper.
According to the characteristics of RE and complex surface, the corresponding key technique and geometric modeling techniques of RE of complex die are studied in order to obtain Bezier surface which has good reconstruction adapability-Triangulation within Arbitrary domain, optimization of gridding, simplification of gridding, surface reconstruction based on continuum and surface fairing. What's more, some question of modeling are discussed and corresponding resolvent are brought forward.
Some method which is used to calculate the shape of sheet metal are introduced in detail, such as, Gradual-approach Method, Cohere Method, Geometrical-mapping Method, Slide-line Method, blank calculation Based on Finite Element Method. What's more, the application ranges are analyzed respectively. Bottom shells of gasoline tanks is analyzed mechanically. some factors in forming are taken into account, such as, dimension of moulds，clearance between moulds, lubrication and mould material. Some potential bugs are forecasted, which are likely to happen in forming. Then, original mould parameter and forming technique are made certain. The primary shape of blank is obtained by means of the modeling software UG.. The final shape of blank is obtained through amending by means of the the finite element simulation software Dynaform. In order to meet the rapid design and resolve the program that the handcraft
operation that it takes more time, the software, integrated into UG, is developed to pick up shape of calculation blank on VC++6.0. The software will be effective and offer instructive and valuable suggestions in practice.
在深入分析了复杂曲面数字化的各种测量方法的应用特点及其适用范围的基础上，提出了适合复杂冲压零件曲面数字化的方法。为了提高曲面数字化的效率和精度，探讨了用CMM进行数字化时的测点路径规划问题；为增强数据点的合理性及完备性，需对原始测量数据进行预处理，分析了数据预处理的各种手段，重点探讨了基于曲面曲率的一种自适应数据压缩方法。
根据复杂曲面及其反求的特点，以重构适应性好、编辑快捷的连续的Bezier曲面为最终目标，研究了适合复杂曲面冲压模具反求工程的几何建模技术及相应的关键技术，即：离散点集的三角划分，网格优化、网格简化、基于型曲面重构及其曲面光顺处理技术。
详尽地探讨了冲压毛坯尺寸形状的反求技术——逐次逼近法、拼合法、滑移线法、几何映射法，以及基于有限元技术的板料成形毛料计算方法，并分析了各自在冲压坯料反求中特点的及其适用范围。对油箱底壳冲压成形进行了力学分析，考虑了凸凹模尺寸、模具型腔参数、润滑和模具材料等因素对成形的影响，以及对成形中可能出现的各种缺陷进行了预测。在此的基础上，确定了初步的模具参数和工艺方案。对于毛坯形状的反求，提出了在造型软件UG中展开获得初始的毛坯形状，然后在板料成形模拟仿真软件Dynaform进行模拟修正，获得最终的毛坯形状的基于有限元技术的试错修改法。为了满足快速设计的需要，解决毛坯初步确定时手工展开毛坯费时、费力的问题，开发了一套采用VC++6.0语言，集成于UG造型软件中的计算毛坯形状自动提取软件。此软件的应用，可以很大程度提高效率，并为以后解决工程实际中的类似问题提供实际设计经验。
Reverse Engineering (RE) is an important means of products innovation design and prompt development, and it is the key technology of various advanced manufacture mode as well. According to the design characteristics of some product and die design, based on research on key techniques of general RE and design characteristics of stamping die, the digitalization, surface reconstruction, modeling of CAD and RE of stamping parts are studied. The corresponding methods of RE of complex stamping die & mould which has complex surfaces are proposed to meet the demands of products prompt development.
Based on analyzing all kinds of the measure method of the digitalization of complex surface and their scope of application and characteristics, surface digital method of RE which adapts to RE of complex stamping die are discussed. Sample points programming are researched deeply. In order to enhance rationality and maturity of points, original points should be compressed. Method of self-adaptation data compression based on surface curvature is introduced in the paper.
According to the characteristics of RE and complex surface, the corresponding key technique and geometric modeling techniques of RE of complex die are studied in order to obtain Bezier surface which has good reconstruction adapability-Triangulation within Arbitrary domain, optimization of gridding, simplification of gridding, surface reconstruction based on continuum and surface fairing. What's more, some question of modeling are discussed and corresponding resolvent are brought forward.
Some method which is used to calculate the shape of sheet metal are introduced in detail, such as, Gradual-approach Method, Cohere Method, Geometrical-mapping Method, Slide-line Method, blank calculation Based on Finite Element Method. What's more, the application ranges are analyzed respectively. Bottom shells of gasoline tanks is analyzed mechanically. some factors in forming are taken into account, such as, dimension of moulds，clearance between moulds, lubrication and mould material. Some potential bugs are forecasted, which are likely to happen in forming. Then, original mould parameter and forming technique are made certain. The primary shape of blank is obtained by means of the modeling software UG.. The final shape of blank is obtained through amending by means of the the finite element simulation software Dynaform. In order to meet the rapid design and resolve the program that the handcraft
operation that it takes more time, the software, integrated into UG, is developed to pick up shape of calculation blank on VC++6.0. The software will be effective and offer instructive and valuable suggestions in practice.
引文
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[4] 许智钦，闫明，张宝峰等 逆向工程技术三维激光扫描测量 2001 NO.5
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[6] 杨峻，倪嘉陵 现代测量方法在逆求工程中的应用。武汉汽车工业大学学报，1998，20（3）
[7] 邢渊，周雄辉，阮雪榆。集成反向工程系统研究。机械工程学报，1998，3（3）
[8] Nirant V P,Andrei G J.Unideed review of 3D model generation for reverse engineering. Computer Integrated Manufacturing Systems,1994,7(4)
[9] 张畅 张祥林 黄树槐 快速造型技术中的反求工程。机械工程学报，1998，NO.1
[10] GOM Corp.Mobile Coordinate Measurement Technique Using Photogrammetry.
http://ww.gom.com/Etritop.html,1998.
[11] 高立志 林志航 方勇 基于视觉、CAD和CMM的自由曲面反求工程 西安交通大学学
1998 NO.7
[12] 李建军，温建勇，肖祥芷 逆向工程及其相关技术 机械与电子 1999 No.3
[13] 应济 新型快速制造系统。机电工程。1998，NO.3
[14] 雷刚，邹昌平，黄剑鸣 快速反求工程研究进展。机械工艺师 2000，NO.10
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[17] Lai J Y, Lu C Y. Reverse engineering of composite sculpturer surface.
International Journal of Advanced Manufacturing Technology,1996,12(3).
[18] 何映林，钱应璋。散论点曲面量造型技术及其飞机曲面工装模具设计与制造中的研究。航空学报，1996，17（6）
[19] 何汉武，孙健，陈新度，黄小平。 塑料模具逆向工程框架与实现方法研究 1999 NO.8
[20] 黄小平，杜晓明，熊有伦 逆向工程中的建模技术 中国机械工程 2000 NO.5
[21] 李江雄，柯映林，程耀东 基于实物的复杂曲面产品中的CAD建模技术。中国机械工程，1999，NO.10
[22] 王平江，黄雪梅等。曲面激光密集测量三维数据的三角片逼近方法。工程图学学报，1998，NO.1
[23] 张宇等。反求工程技术原理及其关键技术。昆明理工大学学报，1999，NO.4
[24] 吴克勤， 王亮申 反求工程及技术。辽阳石油化工高等专科学校学报。1999，Vol.15 NO.4
[25] 栗全庆，王宏，张英杰，赵汝嘉。 实物反求工程的关键技术分析 机械设计 1999 NO.6
[26] C.Bradley, G.W.Vichers,“Automated rapid prototyping utilizing laser scanning and free-from maching"，Annals of CIRP 1992 VOL.41
[27] R.M.Bolle, B.C.Vemuri "On three dimensional surface reconstruction methods". IEEE Transaction on pattern analysis and machine intelligence. Vol.13, NO.1,1991
{28} D.Shepard "A two-dimensional interpolation function for irregularly spaced data" Proc.ACM Nat.Conf 1964
[29] C.Bradley, G.W.Vichers, "free-from surface reconstruction for machine vision rapid prototyping" Optical Engineering,Vol.76,1991
[30] R.L.Hardy, "Multi-quadric equation of topography and other irregular surface"
J.Geophysical research, Vol.76.1991
[31] Shigeru Muraki, Naolazu Yokoya Kazuhihiko Yamamomo "3D surface reconstruction from contour line image by a regularization method". SPIE Vol.1359 .1995
[32] P Gu, X Yan "Neruasl network approach to the reconstruction of freeform surface reverse engineering", Computer-aid Design ,Vol.27,NO.1,1995
[33]B.Saarkar, C-H Menq. "CAD surface data exchange using STEP". Computer Aided
Design, Vol.23, NO.9
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