复杂自由曲面数控规划及其数据管理技术研究
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摘要
在机械制造领域,随着市场需求的不断扩大及生产技术的快速发展,对具有复杂、特殊外形零件的数控加工需求日益增加。这些零件大多具有曲率不规则分布的自由曲面表面,由此增大了特征信息提取与分析的难度,并对数控加工规划与数据管理等相关技术提出了更高的要求。针对于此,本文在复杂曲面分片规划、刀具轨迹生成、铣削参数智能决策和嵌入式系统文件管理等方面开展了深入研究,取得了以下主要研究成果:
1.提出了一种对复杂参数曲面的边界提取及分片规划算法。在对复杂曲面进行特征识别及特征曲面域划分的基础上,基于减法聚类及模糊C均值聚类算法进行了曲面片细分技术研究,初步确定了代表某一具体曲面形状区域的曲面片数量及曲面片中心位置,并对聚类曲面片的中心位置进行了优化处理。进而通过引入Voronoi图对曲面边界构建技术进行了研究,并给出了分析示例。
2.提出了基于参数线法的曲面片域内刀具轨迹规划策略。基于二叉离散算法,通过引入刀具沿进给方向的误差补偿值获取行距,并利用一阶泰勒展开式引入误差补偿值来获得各插补周期末的参数增量值,进而求得各插补点坐标值及法向矢量。经过对插补点的平移、旋转变换,得到了准确的位置增量值。最后通过引入离散能量法对曲面片域间直凸多边形边界的光顺技术进行了研究。
3.对面向自由曲面数控加工的刀具轨迹智能决策及自动规划策略进行了研究。在对复杂曲面五轴数控铣削加工的无干涉刀具组合优选策略研究的基础上,提出了基于曲面片中心点的干涉处理策略。进而基于专家系统与神经网络的结合优势提出了一种建立自由曲面铣削参数智能决策系统的结构模型,可实现自由曲面数控铣削加工走刀参数与切削参数的智能决策。
4.针对复杂曲面的海量数据管理及高可靠性要求,对嵌入式数控系统的Flash文件系统管理技术进行了研究,提出了扇区磨损均衡策略以及基于存储内容的坏损管理策略,实现了对Flash存储空间的合理利用和有效管理。提出了一种基于文件信息双链表结构的数据管理策略,给出了空闲扇区的自动获取与回收机制,进而实现了对程序数据的有效维护。最后针对大型零件程序的存储与分布式加工问题,对嵌入式数控系统的串行通讯技术进行了研究。该文件系统已在课题组TDNC-L4数控系统的研发工作中取得了成功应用。
In the field of mechanical manufacturing, the constant enlargement of the market requirements and the rapid development of production technology lead to the increasment of demands for NC machining of complex shape part. The curvatures of free-form surfaces mostly present irregular distribution. As a result, it is difficult for feature information extraction and analysis. Moreover, it puts forward higher requirements for the related technology like NC machining planning, data management, and etc. Accordingly, this dissertation makes deep research on subdivision planning of complex surface, tool path generation, milling parameter intelligent strategy, and file management based on embedded system. Main research achievements are as follows:
(1) An algorithm of boundary extraction and subdivision planning of complex parametric surface is proposed. On the basis of the complex surface feature recognition and feature surface patches division, further research of subdivision surface patch is carried out based on subtractive clustering and fuzzy c-means clustering algorithm. Firstly, the number and the center position of surface patches which can characterize a certain specific shape of surface domain are determined. Secondly, optimization treatment for the center position of clustering surface patches is carried out. Thirdly, surface boundary is constructed by the introduction of Voronoi diagram. Finally, an analysis example is given to illustrate the application of the method.
(2) A strategy of tool path planning is proposed on the basis of parametric line method for surface patch machining. Binary tree subdivision algorithm is adopted. And then cutter path interval is calculated through the introduction of error compensation along feeding direction, and parameter increment value is obtained by introducing error compensation on the basis of studying the first order Taylor expansion. Based on this, the calculative precision of the interpolation point’s parameter value of the complex parametric curved surface can be increased. Then by translation, rotation transformation for the interpolation point accurate, the accurate position incremental value is available. Finally, fairing operations are done on the straight convex polygon boundary.
(3) A thorough research of intelligent decision and automatic planning of tool path of free-form surface NC machining is conducted. On the basis of studying the optimum strategy of interference-free tool combination for 5-axis NC milling of complex surface, an interference treatment strategy based on center points of surface patches is proposed. Furthermore, a structural model based on integrating artificial neural network and expert system is designed for establishing milling parameter intelligent decision system of free-form surface, which can realize intelligent decision of feeding and cutting parameters of free-form surface NC machining.
(4) According to the requirements of massive data management and high reliability, technology of Flash file management system applied in embedded CNC system is researched. A strategy of wear-leveling for Flash sectors and damage management based on storage contents is proposed. With this strategy, rational utilization and effective management of the Flash storage space can be achieved. In addition, a data management strategy based on doubly-linked list structure for file information is put forward, on the basis of which, program data are effectively maintained. Finally, aiming at program storage for large-scale parts and distributed processing, serial communication between CNC system and PC is realized. A CNC system prototype of TDNC-L4 is developed based on the foregoing research achievements.
1.提出了一种对复杂参数曲面的边界提取及分片规划算法。在对复杂曲面进行特征识别及特征曲面域划分的基础上,基于减法聚类及模糊C均值聚类算法进行了曲面片细分技术研究,初步确定了代表某一具体曲面形状区域的曲面片数量及曲面片中心位置,并对聚类曲面片的中心位置进行了优化处理。进而通过引入Voronoi图对曲面边界构建技术进行了研究,并给出了分析示例。
2.提出了基于参数线法的曲面片域内刀具轨迹规划策略。基于二叉离散算法,通过引入刀具沿进给方向的误差补偿值获取行距,并利用一阶泰勒展开式引入误差补偿值来获得各插补周期末的参数增量值,进而求得各插补点坐标值及法向矢量。经过对插补点的平移、旋转变换,得到了准确的位置增量值。最后通过引入离散能量法对曲面片域间直凸多边形边界的光顺技术进行了研究。
3.对面向自由曲面数控加工的刀具轨迹智能决策及自动规划策略进行了研究。在对复杂曲面五轴数控铣削加工的无干涉刀具组合优选策略研究的基础上,提出了基于曲面片中心点的干涉处理策略。进而基于专家系统与神经网络的结合优势提出了一种建立自由曲面铣削参数智能决策系统的结构模型,可实现自由曲面数控铣削加工走刀参数与切削参数的智能决策。
4.针对复杂曲面的海量数据管理及高可靠性要求,对嵌入式数控系统的Flash文件系统管理技术进行了研究,提出了扇区磨损均衡策略以及基于存储内容的坏损管理策略,实现了对Flash存储空间的合理利用和有效管理。提出了一种基于文件信息双链表结构的数据管理策略,给出了空闲扇区的自动获取与回收机制,进而实现了对程序数据的有效维护。最后针对大型零件程序的存储与分布式加工问题,对嵌入式数控系统的串行通讯技术进行了研究。该文件系统已在课题组TDNC-L4数控系统的研发工作中取得了成功应用。
In the field of mechanical manufacturing, the constant enlargement of the market requirements and the rapid development of production technology lead to the increasment of demands for NC machining of complex shape part. The curvatures of free-form surfaces mostly present irregular distribution. As a result, it is difficult for feature information extraction and analysis. Moreover, it puts forward higher requirements for the related technology like NC machining planning, data management, and etc. Accordingly, this dissertation makes deep research on subdivision planning of complex surface, tool path generation, milling parameter intelligent strategy, and file management based on embedded system. Main research achievements are as follows:
(1) An algorithm of boundary extraction and subdivision planning of complex parametric surface is proposed. On the basis of the complex surface feature recognition and feature surface patches division, further research of subdivision surface patch is carried out based on subtractive clustering and fuzzy c-means clustering algorithm. Firstly, the number and the center position of surface patches which can characterize a certain specific shape of surface domain are determined. Secondly, optimization treatment for the center position of clustering surface patches is carried out. Thirdly, surface boundary is constructed by the introduction of Voronoi diagram. Finally, an analysis example is given to illustrate the application of the method.
(2) A strategy of tool path planning is proposed on the basis of parametric line method for surface patch machining. Binary tree subdivision algorithm is adopted. And then cutter path interval is calculated through the introduction of error compensation along feeding direction, and parameter increment value is obtained by introducing error compensation on the basis of studying the first order Taylor expansion. Based on this, the calculative precision of the interpolation point’s parameter value of the complex parametric curved surface can be increased. Then by translation, rotation transformation for the interpolation point accurate, the accurate position incremental value is available. Finally, fairing operations are done on the straight convex polygon boundary.
(3) A thorough research of intelligent decision and automatic planning of tool path of free-form surface NC machining is conducted. On the basis of studying the optimum strategy of interference-free tool combination for 5-axis NC milling of complex surface, an interference treatment strategy based on center points of surface patches is proposed. Furthermore, a structural model based on integrating artificial neural network and expert system is designed for establishing milling parameter intelligent decision system of free-form surface, which can realize intelligent decision of feeding and cutting parameters of free-form surface NC machining.
(4) According to the requirements of massive data management and high reliability, technology of Flash file management system applied in embedded CNC system is researched. A strategy of wear-leveling for Flash sectors and damage management based on storage contents is proposed. With this strategy, rational utilization and effective management of the Flash storage space can be achieved. In addition, a data management strategy based on doubly-linked list structure for file information is put forward, on the basis of which, program data are effectively maintained. Finally, aiming at program storage for large-scale parts and distributed processing, serial communication between CNC system and PC is realized. A CNC system prototype of TDNC-L4 is developed based on the foregoing research achievements.
引文
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