发动机缸孔表面宏微几何形貌的集成检测与三维全息表征

In order to evaluate multi-process machining quality of automobile engine cylinder bore, and solve the theoretical and technical problems that it’s difficult to achieve a multi-scale three-dimensional holographic evaluation in a unified coordinate system caused by the isolated measurement methods for macroscopic and microscopic surface topography geometry, this project proposes a new efficient multi-spectral confocal measurement method for multi-scale macro and micro topography of cylinder bore based on spectral confocal physical theory. It studies the theoretical model of the measurement system considering the system parameters of optical distortion and error compensation, constructing the foundation for the integrated experimental measurement system. It studies the extraction and reconstruction method for morphology field parameters and characteristic parameters of macroscopic geometric shape and microscopic surface topography based on multi-scale feature measurement planning and wavelet spectrum theory and the international standards of three-dimensional surface morphology assessment, constructing the data foundation of multi-scale macro and micro holographic geometric topography. It establishes a unified integrated three-dimensional holographic evaluation system for geometry error and surface morphology based on unified coordinate system by the geometry deviation analysis of the theoretical model and the rebuild model and the multiview expression of surface morphology and feature parameters, providing a software tool for evaluation of the macro and micro geometric surface morphology. Based on theoretical and technical research, experimental system is built to evaluate the quality of the cylinder bore multi-process machining process to verify the theoretical and technological achievements of this project.

以汽车发动机缸孔多工序加工质量评价为背景，针对其宏观几何形状和微观表面形貌分离测量方法导致的难以实现统一坐标系下的多尺度三维全息评价引发的理论技术问题，结合光谱共焦物理学原理，提出缸孔多尺度宏微形貌的多点光谱共焦高效测量新方法，研究测量系统理论模型，耦合光学器件畸变的系统参数、误差补偿技术，为集成实验测量系统的构建奠定基础；基于多尺度特征测量规划和小波频谱理论，依据表面形貌三维评定国际标准，研究几何宏观形状和表面微观形貌场域参数与特征参数的提取和重建方法，为多尺度宏微几何形貌的全息表征奠定数据基础；通过理论模型和重建模型的几何形状偏差分析、表面形貌的场域和特征参数的多视图表达，建立基于统一坐标系的几何形状误差和表面形貌特征的一体化三维全息表征体系，为加工表面的宏微几何形貌评价提供软件工具。在理论和技术研究基础上，构建实验系统，结合缸孔多工序加工工艺的质量评定验证项目的理论与技术成果。

以发动机缸孔加工质量评价为背景，针对其形貌的技术问题，结合结合光谱共焦物理学原理，针对现有距离检测方法对环境鲁棒性差、测量效率低下等缺陷，以及国外光谱共焦检测技术快速发展而我国该技术发展明显落后的现状，提出一种基于光谱共焦测量原理的高精度位移检测系统。研究了光谱共焦测量系统的测量系统方案，在方案的基础上进行各个元器件设计，完成了测量系统硬件搭建，提出了一种波峰提取方法，对光谱数据进行了拟合分析，对测量过程中可能产生的误差进行分析，并针对各种误差提出校正方法和补偿模型，最终得到光谱共焦测量系统，该系统的测量范围为1.5mm，测量精度可达3微米，具有一定的现实意义和较好的实用价值。