面向快速成型的设备控制、工艺优化及成型仿真研究
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摘要
设备控制是快速成型制造能够顺利实施的基础；工艺优化是提高成型质量，确保快速成型制造正确、高效进行的关键；而成型仿真则是验证快速成型工艺的一种有效手段，也是虚拟制造的关键技术之一。目前，国内外的相关研究还不是十分完善。为此，本文采用理论与实践相结合的方式，对这三个方面进行了较为深入的研究，主要内容及结果如下：
（1）提出了面向快速成型设备的可重构控制软件体系结构，利用组件技术建立了可重构机制，并依据快速成型设备控制软件相似功能的抽象描述进行了可重构模块的划分。定义了设备控制软件中的关键数据对象，利用COM组件设计了可重构模块，并开发了便于用户进行多任务、多参量设备控制的图形用户界面。通过重构开发，将设备控制软件成功应用于两种不同工艺的快速成型设备。
（2）提出了面向快速成型设备的可扩展路径规划软件体系结构，利用插件技术建立了可扩展机制，并依据路径规划软件的数据处理流程进行了可扩展模块的划分。定义了路径规划软件中的关键数据对象，利用插件设计了可重构模块，并开发了便于用户进行多任务、多参量路径规划的宿主程序。研究了用于提高路径生成效率的并行算法，并通过对比实验验证了算法的有效性。
（3）研究了面向快速成型工艺的计算机辅助生产效率优化。通过分析快速成型生产过程的时间消耗，建立了3维零件在3维成型空间中的2.5维排料优化规则。在此基础上，研究了计算机辅助2.5维排料，提出利用3维零件模型在成型方向的投影将2.5维排料转化为2维排料的简化方法，并研究了一种利用切片数据来生成投影的算法。通过对比实验，验证了效率优化是有效的。
（4）研究了面向快速成型工艺的几何仿真。提出了面向快速成型工艺的通用材料填充模型：离散成型空间模型。根据成型矢量在不同快速成型工艺中的作用，基于该模型分别研究了“添加材料式”快速成型工艺和“去除材料式”快速成型工艺的动态几何仿真。为减少动态仿真时显卡需要处理的数据量，研究了显示数据的动态缩减算法，并以几种常见模型为例验证了算法的有效性。
（5）研究了面向快速成型设备的浮雕图像处理方法。利用可视化工具库研究了二维浮雕图像的三维化处理和三维浮雕模型的切片轮廓提取方法，并基于可扩展路径规划软件体系结构研究了面向快速成型设备的浮雕数控代码生成方法。针对快速成型工艺的优势，以及浮雕仅需要确保外观质量的特点，提出了空心浮雕的概念，并研究了直接从图像生成空心浮雕数控代码的算法。基于选区激光熔化工艺制造出了金属材料的空心浮雕。
（6）研究了面向选区激光熔化工艺的计算机辅助成型质量优化。提出了针对成型方向和能量输入的两步优化法。建立了成型方向的优化模型，并通过遗传算法求解模型实现了成型方向的计算机辅助优化。建立了用于能量输入调节的倾斜角静态查找表，实现了能量输入的计算机辅助优化。通过对比实验，验证了成型质量优化是有效的。
Equipment control is basal for successful implementation of the Rapid Prototyping (RP)manufacturing. Process optimization is crucial to the correct and efficient working of RP.Process simulation is an effective means of process validation and one of key technologies forVirtual Manufacturing. At present, the researches on these aspects are incomplete. So, thispaper focuses on these aspects and studies some key technologies. The main contents andresults are as follows:
(1) A reconfigurable architecture of control software for RP equipment is introduced.Reconfigurable mechanism is established based on component technology. Reconfigurablemodules are divided according to the similar functions of control software. The key dataobjects of control software are defined. The reconfigurable modules are designed as COM(Component Object Model) component. A GUI (Graphic User Interface) for equipmentcontrol with multi-tasks and multi-parameters, is designed. By reconfigurable developing, thecontrol software is successfully applied to two different RP equipments.
(2) An extendable architecture of tool path planning software for RP equipment isintroduced. Extendable mechanism is established based on plug-in technology. Extendablemodules are divided according to the data processing of tool path planning software. The keydata objects of tool path planning software are defined. The extendable modules are designedas plug-ins. A host program for tool path planning with multi-tasks and multi-parameters, isdeveloped. Parallel algorithm for path generation is studied and verified by experiment.
(3) Computer-aided production efficiency optimization method for RP process is studied.After analysing the time consumption of RP production process,2.5-D nesting rules areestablished, aimed at arranging the3-D parts on the2-D platform more efficiently. Then,computer-aided2.5-D nesting is studied and a simplified method is presented. The methodcan transform the2.5-D nesting to2-D nesting by projection. At last, an experiment is givento verify the proposed optimization method.
(4) Geometric simulation for RP process is studied. A common model, namely DiscretedBuilding Space Model, for showing the addition of material in RP process is presented.According to the corresponding roles of building vector in different RP processes, dynamicgeometry simulations of “adding” RP process and “cutting” RP process are studied based onthe model. In order to reduce the graphics processing data, dynamic reduction algorithm fordisplay data is studied. At last, several common models are used to verify the proposedalgorithm.
(5) Bas-relief image processing methods for RP equipment is studied. The Visual Toolkit(VTK) is used for generating the3-D model from2-D bas-relief image and extracting thecontours from3-D bas-relief model. Then, the NC code generation for bas-relief is studiedbased on the extendable architecture of tool path planning software. Due to the advantages ofRP process and the characteristic of bas-relief, hollow bas-relief is presented to reduce thematerial used in RP process. The method for directly generating NC code for hollow bas-reliefis studied. At last, a hollow bas-relief is fabricated by Selective Laser Melting (SLM) process.
(6). Computer-aided fabrication quality optimization method for SLM process is studied.A two-step method is proposed for optimizing building orientation and energy input. Anoptimization model for building orientation is established and a solving method based ongenetic algorithms is given. In order to optimize energy input, a static lookup table isestablished. At last, an experiment is carried out to verify the proposed optimization method.
（1）提出了面向快速成型设备的可重构控制软件体系结构，利用组件技术建立了可重构机制，并依据快速成型设备控制软件相似功能的抽象描述进行了可重构模块的划分。定义了设备控制软件中的关键数据对象，利用COM组件设计了可重构模块，并开发了便于用户进行多任务、多参量设备控制的图形用户界面。通过重构开发，将设备控制软件成功应用于两种不同工艺的快速成型设备。
（2）提出了面向快速成型设备的可扩展路径规划软件体系结构，利用插件技术建立了可扩展机制，并依据路径规划软件的数据处理流程进行了可扩展模块的划分。定义了路径规划软件中的关键数据对象，利用插件设计了可重构模块，并开发了便于用户进行多任务、多参量路径规划的宿主程序。研究了用于提高路径生成效率的并行算法，并通过对比实验验证了算法的有效性。
（3）研究了面向快速成型工艺的计算机辅助生产效率优化。通过分析快速成型生产过程的时间消耗，建立了3维零件在3维成型空间中的2.5维排料优化规则。在此基础上，研究了计算机辅助2.5维排料，提出利用3维零件模型在成型方向的投影将2.5维排料转化为2维排料的简化方法，并研究了一种利用切片数据来生成投影的算法。通过对比实验，验证了效率优化是有效的。
（4）研究了面向快速成型工艺的几何仿真。提出了面向快速成型工艺的通用材料填充模型：离散成型空间模型。根据成型矢量在不同快速成型工艺中的作用，基于该模型分别研究了“添加材料式”快速成型工艺和“去除材料式”快速成型工艺的动态几何仿真。为减少动态仿真时显卡需要处理的数据量，研究了显示数据的动态缩减算法，并以几种常见模型为例验证了算法的有效性。
（5）研究了面向快速成型设备的浮雕图像处理方法。利用可视化工具库研究了二维浮雕图像的三维化处理和三维浮雕模型的切片轮廓提取方法，并基于可扩展路径规划软件体系结构研究了面向快速成型设备的浮雕数控代码生成方法。针对快速成型工艺的优势，以及浮雕仅需要确保外观质量的特点，提出了空心浮雕的概念，并研究了直接从图像生成空心浮雕数控代码的算法。基于选区激光熔化工艺制造出了金属材料的空心浮雕。
（6）研究了面向选区激光熔化工艺的计算机辅助成型质量优化。提出了针对成型方向和能量输入的两步优化法。建立了成型方向的优化模型，并通过遗传算法求解模型实现了成型方向的计算机辅助优化。建立了用于能量输入调节的倾斜角静态查找表，实现了能量输入的计算机辅助优化。通过对比实验，验证了成型质量优化是有效的。
Equipment control is basal for successful implementation of the Rapid Prototyping (RP)manufacturing. Process optimization is crucial to the correct and efficient working of RP.Process simulation is an effective means of process validation and one of key technologies forVirtual Manufacturing. At present, the researches on these aspects are incomplete. So, thispaper focuses on these aspects and studies some key technologies. The main contents andresults are as follows:
(1) A reconfigurable architecture of control software for RP equipment is introduced.Reconfigurable mechanism is established based on component technology. Reconfigurablemodules are divided according to the similar functions of control software. The key dataobjects of control software are defined. The reconfigurable modules are designed as COM(Component Object Model) component. A GUI (Graphic User Interface) for equipmentcontrol with multi-tasks and multi-parameters, is designed. By reconfigurable developing, thecontrol software is successfully applied to two different RP equipments.
(2) An extendable architecture of tool path planning software for RP equipment isintroduced. Extendable mechanism is established based on plug-in technology. Extendablemodules are divided according to the data processing of tool path planning software. The keydata objects of tool path planning software are defined. The extendable modules are designedas plug-ins. A host program for tool path planning with multi-tasks and multi-parameters, isdeveloped. Parallel algorithm for path generation is studied and verified by experiment.
(3) Computer-aided production efficiency optimization method for RP process is studied.After analysing the time consumption of RP production process,2.5-D nesting rules areestablished, aimed at arranging the3-D parts on the2-D platform more efficiently. Then,computer-aided2.5-D nesting is studied and a simplified method is presented. The methodcan transform the2.5-D nesting to2-D nesting by projection. At last, an experiment is givento verify the proposed optimization method.
(4) Geometric simulation for RP process is studied. A common model, namely DiscretedBuilding Space Model, for showing the addition of material in RP process is presented.According to the corresponding roles of building vector in different RP processes, dynamicgeometry simulations of “adding” RP process and “cutting” RP process are studied based onthe model. In order to reduce the graphics processing data, dynamic reduction algorithm fordisplay data is studied. At last, several common models are used to verify the proposedalgorithm.
(5) Bas-relief image processing methods for RP equipment is studied. The Visual Toolkit(VTK) is used for generating the3-D model from2-D bas-relief image and extracting thecontours from3-D bas-relief model. Then, the NC code generation for bas-relief is studiedbased on the extendable architecture of tool path planning software. Due to the advantages ofRP process and the characteristic of bas-relief, hollow bas-relief is presented to reduce thematerial used in RP process. The method for directly generating NC code for hollow bas-reliefis studied. At last, a hollow bas-relief is fabricated by Selective Laser Melting (SLM) process.
(6). Computer-aided fabrication quality optimization method for SLM process is studied.A two-step method is proposed for optimizing building orientation and energy input. Anoptimization model for building orientation is established and a solving method based ongenetic algorithms is given. In order to optimize energy input, a static lookup table isestablished. At last, an experiment is carried out to verify the proposed optimization method.
引文
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