面向曲面零件性能的测量点云自适应生成刀具路径技术研究

The curved surface parts whose performance is the main manufacturing request is rather difficult to machine. An important approach to machine the parts is to use the closed-loop manufacturing mode of digital design-processing-measuring integration. When this kind of curved surface parts is machined under the closed-loop manufacturing mode, the reconfiguration of curved surface based on point cloud data exists errors, tool path does not unify and the dynamic property of the machine tool affects the machining quality, so research on the performance of surface parts oriented tool path adaptive generation technology based on point cloud data is one of the key technologies to realize the effective machining with high qualities. It should be guided by that the point cloud data directly generates the tool path and based on the deep analysis of the coupling relationship between geometric constraints and the performance constraints, to determine the targeted point cloud data satisfying the performance and study performance of surface parts oriented topology-shape design and the selection methodology of the tool path based on point cloud data. Additionally, it will also be studied that the tool position planning and the firing path generation method, the tool path interference inspection and the tool orientation planning based on the dynamic characteristics of the machining tool, so as to develop the tool path planning simulation system and finally explore a new performance of surface parts oriented tool path adaptive generation methodology for this kind of curved surface parts based on the point cloud data. The study achievements will provide important theoretical foundation and technological support for the closed-loop manufacturing technology of digital design-processing-measuring integration for the curved surface parts whose performance is the main manufacturing request and meanwhile enrich the machining and manufacturing theory of the complex curved surface parts.

以性能为主要制造要求的曲面零件加工难度大，数字化设计-加工-测量一体化闭环制造模式是实现其加工的重要手段。鉴于该类零件闭环制造模式下基于点云重构曲面存在误差和刀具加工轨迹具有非统一性以及机床动态特性影响曲面零件加工质量，研究面向曲面零件性能的测量点云自适应生成刀具路径技术是实现该类零件高质高效加工的关键技术之一。以点云直接生成刀具加工轨迹为主导，深入分析零件几何约束与性能约束耦合关系、确定满足性能要求目标点云基础上，面向零件性能及基于点云研究刀具轨迹拓扑形状设计及选择方法、刀位规划与光顺路径生成方法、刀具轨迹干涉检查方法、满足机床动态特性的刀轴矢量规划技术，开发刀具轨迹规划仿真系统，最终形成面向曲面零件性能的测量点云自适应生成刀具加工轨迹新方法、新技术。研究成果为以性能为主要制造要求的曲面零件数字化设计-加工-测量一体化闭环制造方法提供重要理论基础和技术支撑，丰富复杂曲面零件加工制造理论。

以性能为主要制造要求的曲面零件加工难度大，数字化设计-加工-测量一体化闭环制造模式是实现其加工的重要手段。鉴于该类零件闭环制造模式下基于点云重构曲面存在误差和刀具加工轨迹具有非统一性以及机床动态特性影响曲面零件加工质量，项目开展面向曲面零件性能的测量点云自适应生成刀具路径关键技术研究。针对高性能要求曲面零件结构特点和性能要求，基于采用三维扫描设备对高性能要求曲面零件毛坯或半成品扫描获取的测量点云数据，研究出复杂曲面截面特征点云数据基于离散曲率的弦高和角度相结合的强噪声剔除和局部特征保留的递推辨识滤波数据平滑、基于点距邻域特征的自适应修补、基于特征分段优化的数据精简等点云数据快速处理算法，以此为基础，分析了高性能要求曲面零件几何约束与性能约束耦合关系，提出了以修正量几何分布为有向距离约束矩阵的目标点云确定方法，为研究基于测量点云的高性能要求曲面零件刀具加工轨迹自适应生成技术奠定基础。与典型曲面零件数控加工相结合，分析不同加工轨迹拓扑形状下曲面加工动态切削力变化规律的基础上，提出了物理量约束下基于曲面目标点云数据的非均匀自适应刀具加工轨迹生成方法；研究出五轴数控机床旋转进给轴运动参数计算方法及刀矢变化与机床运动学特性之间的关联关系，以刀具和被加工曲面间具有良好切触状态及满足机床运动学特性为约束，发明了复杂曲面五轴数控加工刀矢的运动学控制方法及运动学约束的复杂曲面五轴数控加工刀矢光顺方法；通过建立刀矢在工件局部坐标系下及工件全局坐标系下表示方法间的映射关系及刀矢变化与数控机床旋转进给轴转角间的映射关系，提出了一种曲面五轴数控加工旋转进给轴无干涉转动域的求解方法；开发了高性能要求曲面零件刀具加工轨迹规划仿真系统，规划出高性能要求曲面无干涉刀具加工轨迹，并进行了试验验证。研究成果形成面向曲面零件性能的测量点云自适应生成刀具加工轨迹新方法、新技术，为高性能要求曲面零件数字化设计-加工-测量一体化闭环制造方法提供理论基础和技术支撑，丰富曲面零件加工制造理论。通过项目实施，发表学术论文19篇(SCI检索9篇、EI检索17篇)，申请发明专利5项(授权2项)，2篇学术论文分别获辽宁省自然科学学术成果(论著类)三等奖、大连市自然科学优秀学术论文二等奖。