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超精密加工高反射曲面光学非接触三维形貌测量
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摘要
高反射曲面零件的超精密加工技术已成为国防和现代高科技领域的前沿研究方向,准确测量和评价超精密加工高反射曲面零件的三维形貌,研究表面几何特性与使用性能的关系,对提高加工表面的质量和产品性能具有重要的意义。现有的接触式测量方法具有测量速度慢、易划伤测量表面的缺点,而单一的光学非接触测量方法难以完成对大面形或曲率较大的高反射曲面零件三维形貌的高精度测量。本文创新性地提出了将光栅相位偏折测量技术和白光扫描干涉测量技术相结合的异类光学传感器融合测量方法,实现了超精密加工高反射曲面三维形貌的高精度非接触测量。论文的主要研究工作包括:
     1.提出融合光栅相位偏折测量方法和白光扫描干涉测量技术的超精密加工高反射曲面光学非接触三维形貌测量方法,并完成了测量系统的设计。采用光栅相位偏折测量方法可完成尺寸为150mm×150mm×20mm超精密加工高反射曲面整体三维形貌的测量,测量精度可达到50μm~100μm,在此基础上合理规划测量路径,使用系统中的干涉测量镜头进行超精密加工高反射曲面局部区域的高精度扫描测量,搭建的白光扫描干涉测量子系统的测量范围为847μm×710μm×100μm,系统的横向分辨率为1.047μm,垂直分辨率为0.126nm。
     2.光栅相位偏折测量方法中,在深入研究光栅编码方案和相位提取算法的基础上,提出了复合光栅编码、摄动相位展开的快速相位提取算法,通过显示一幅含有摄动信息的复合光栅编码图案,由图像采集设备接收工件表面反射的变形复合光栅像,根据摄动信息可计算得到工件表面各点对应的展开相位信息,相位提取的可靠性和速度均得到了明显提高。
     3.采用基于运动靶标的标定方法,完成了对摄像机内参数的高精度标定;采用Millitron型测长干涉仪完成了白光扫描干涉测量子系统中压电移位器非线性误差的高精度标定;利用标准棋盘格平板和标准量块组合提出超精密加工高反射曲面光学非接触三维形貌测量系统的整体标定方案。
     4.在光栅相位偏折测量方法中,提出虚拟参考面的方法,在系统标定阶段,通过由LCD液晶屏幕显示一幅特殊编码图案,由CCD摄像机接收经标定用平面镜反射的特殊编码图像,在完成LCD液晶屏位置标定的同时,可直接得到计算相位偏折信息所需的两垂直方向的参考相位分布,避免了对理想参考面的测量需求,在保证测量精度的同时,提高了测量效率,降低了测量的复杂性。
     5.提出光栅相位偏折高反射曲面三维形貌测量模型,基于迭代策略,建立相位偏折信息与被测工件表面梯度和高度的对应关系,由梯度重建工件三维形貌。在梯度重建高度过程中,提出结合区域波前重构和路径积分的三维重建算法,由路径积分法获得被测工件的初始形貌,由区域波前重构法进行面形优化。提出基于编码光栅条纹相移特性的轮廓提取方法,整个重建过程仅在提取后的区域内进行。
     6.基于光栅相位偏折测量子系统的测量数据,提出路径规划方案,以引导白光扫描干涉测量子系统对被测工件局部区域进行高精度扫描测量;在深入研究白光扫描干涉测量原理的基础上,对目前广泛使用的多种白光干涉信号峰值提取算法进行了理论推导和算法实现,分析了系统误差和噪声对测量精度的影响,完成对高度变化为0.05μm,10uμm和40μm的模拟台阶面形的三维重建。
     7.由光栅相位偏折子系统对组合台阶、超精密加工平面镜及光学双曲面的表面形貌进行了三维重建,测量精度在50μm左右,该测量精度处于白光扫描干涉测量子系统的测量范围内,为后续白光干涉镜头对被测工件局部区域进行高精度扫描测量打下了基础。
Ultra-precision machining technology of specular surfaces has become one of theleading research fields in defense and high technology. Precisely measuring andevaluating the profile of the specular surfaces, studying the relationship between thesurface geometry characteristics and the usability have important significance inincreasing the quality of the surface processing and product performance. For3Dshape measurement of the ultra-precision specular surfaces, the contact measuringmethods have the disadvantages of low measurement speed and damage for thesurface while it is hard to finish high precision measurement by just one of the opticalnon-contact methods when the parts are large or have high curvature. To solve theseproblems, this paper proposed a novel method which combines the phasedeflectormetry technology and the white light scanning interferometry technology.The main work is as follows:
     1. A novel method that fuses the phase deflectormetry technology and the whitelight scanning interferometry technology for the measurement of ultra-precisionspecular surfaces was proposed. The whole profile of the measured parts could beobtained by the application of the phase deflectormetry technology with measurementaccuracy50μm~100μm. Then path planning was performed to guide the white-lightinterferometry detector finishing the high precision scanning measurement of the localregion of the measured parts. The measurement range of the white-lightinterferometry system is847μm×710μm×100μm while the lateral and verticalresolution are1.047μm and0.126nm respectively.
     2. Based on thorough research on the fringe coded scheme and the phaseextraction algorithm, a fast phase retrival algorithm by combining the compositefringe pattern and perturbation phase unwrapping method was proposed. Byprojecting only one composite fringe pattern onto the surface of the measured parts,the unwrapping phase distribution could be retrivaled by the perturbation informationmodulated in the composite fringe pattern. The dependability and speed of the newalgorithm were much better than those of the traditional methods.
     3. High precision calibration of the camera intrinsic parameters was finished byuse of the movement target calibration method. The non-linear error calibration of the piezoelectric ceramic was completed by the Millitron precision gauge. The standardcheckerboard flat and gauge blocks were used to put forward the whole calibrationscheme for the measurement system of the ultra-precision specular surfaces.
     4. A novel method of virtual reference surface was proposed. A special codedpattern was displayed on the LCD screen at the stage of system calibration and thevirtual image plane appeared on the other side of the mirror was defined as the virtualreference surface. The reference phase distribution can be calculated directly throughthe corresponding relationship between the points on the virtual reference surface andthe phase distribution on the encoded fringe patterns. Thus the procedures of fringeprojection and phase unwrapping on the real reference surface can be avoided beforethe measurement of the specular parts. With this method the three dimensional shapeof the specular surfaces could be obtained fast and precisely. The detection efficiencyhas been improved and the measurement complexity can be reduced.
     5. The3D shape measurement model of specular surfaces based on phasedeflectormetry method was proposed. The corresponding relationship between thephase deflectormetry information and the slope and height of the measured parts wasestablished based on iterative strategy. The3D profile of the measured parts could berecovered by the slope information. A3D shape reconstruction method combined thepath-integration and the zonal wave-front reconstruction algorithm was presented.The initial profile of the measured parts was reconstructed by the path-integrationmethod, and then the zonal wave-front reconstruction algorithm was performed tooptimize the profile. Contour extraction method based on phase shift characteristics ofthe encoded grating stripe was proposed, the whole process of reconstruction is onlyconducted in the extraction area.
     6. The path planning scheme was presented to guide the high precison scanningmeasurement of the local area of the measured parts by use of the white lightmicroscopic interference lens. The theoretical derivation and algorithmimplementation for the peak extraction of the white light interferometry patterns werecarried out. The system errors and noise influenced the measurement accuracy wereanalysized. The3D shape reconstruction of a step with the height variation0.5μm,10μm,40μm was completed.
     7. The3D shape measurement of steps, an ultra precision manufactured flatmirror and an optical hypoid surface were measured based on phase deflectormetrysub-system. The measurement accuracy can reach approximately50μm which is in the measurement range of the white light scanning interferometry system. Themeasurement results of the phase deflectormetry sub-system lay a foundation for thehigh accuracy scanning measurement of the local area of the parts by use of the whitelight interferometry lens.
引文
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