一种基于自适应均值平滑算法的三维重绘技术

传感器工艺仿真的计算基础是体素模型,但是由于体素模型分辨率所限可能造成阶梯效应,以致体素模型的可视化效果不好。因此我们需要将体素模型转化为三角面片模型,但是通过常见的转化方法所得到的三角面片模型表面粗糙。本文提出了一种基于自适应均值平滑算法的三维重绘技术,对体素模型进行程度不同的平滑滤波,再利用marching cubes算法得到三角面片模型。经仿真实验表明文章中方法得到的三角面片模型表面光滑可视化效果更好。     

基于分层切片原理的三维雕刻算法

分析了多种基于STL模型的快速分层算法。在综合多种算法优点的基础上,首先提出了对三角面片的顶点按其切片方向进行从小到大排序,以快速滤除冗余顶点;并在此基础上建立三角面片的顶点链表及面向量,以实现STL模型的拓扑信息重构;最后基于所重构的拓扑信息,结合几何连续性分层算法实现高效的自适应分层算法。并通过C+〖KG-*3〗+实现了这一算法,证明了快速成型技术的分层制造思想可应用于三维雕刻的CAD/CAM,在技术上是可行的。     

嵌入式数控系统中3D加工仿真模块的实现

基于Cortex-A8和Android软硬件嵌入式数控平台,提出一种集成到中低端数控车床加工系统的仿真模块设计方法。在三角网格离散法建模的基础上,提出利用顶点平移算法计算三角片的顶点坐标值,大大减少复杂的三角函数计算量,并且基于强大的嵌入式三维图形Open GL-ES2.0接口绘制毛坯;基于NC代码特征解释译码,有效提取出刀具驱动数据信息;在刀具切削过程中,对扩展DDA圆弧插补算法进行改进,提高了切削精度。动态仿真测试表明:基于改进的算法进行加工仿真,3D效果逼真,插补点径向误差减小30%左右,加工仿真精度高。     

三维模型有向三角面片链码压缩方法

首先提出一种适用于三角面片链码算法的改进MC规格化方法,使用单位为2的体素作为改进MC算法中的单位体素,并使用其中的27个顶点重新构建等值面,最终获取高质量的规格化三角网格模型.在新的规格化模型上提出一种新的面片遍历方式,在三角面片链码算法的基础上,采用优先遍历右连接面片原则,控制面片的遍历方向,该方法能够减少面片遍历...     

钛合金铣削温度的有限元仿真研究

针对钛合金铣削加工中刀具磨损严重,加工效率低等问题,应用专用金属切削有限元仿真软件Advant Edge FEM,对钛合金TC4的铣削加工过程进行二维切削仿真。研究切削过程中切削温度的分布情况,及刀-屑接触区温度随切削速度变化的规律,为提高刀具寿命以及切削参数的优化提供一定的参考依据。     

基于手绘线条的三维模型雕刻

为了生成复杂模型表面的几何纹理,提出一种三维模型的高效雕刻方法.首先根据用户交互方式生成手绘线条,通过曲线细化操作确定手绘曲线经过的三维模型表面边点,并去除手绘曲线经过的模型三角面片,将去除部分经三角剖分成小三角面片之后再插入到原始模型中;然后计算三维模型上的顶点到手绘线条集的距离,确定三维模型上与手绘曲线集的距离小于等于特定纹理宽度的顶点,并根据用户选取的轮廓函数计算顶点平移距离以及平移方向;最后对三维模型上手绘线条附近的顶点进行平移,得到模型的雕刻效果.实验结果表明,该方法能够方便、高效地实现三维模型表面的线条雕刻效果.     

虚拟切削加工系统的设计与实现

虚拟制造是近年出现的一种先进制造技术,虚拟切削加工在虚拟制造中占有重要地位。为了提供虚拟的加工环境和验证工艺设计的正确性,对切削加工过程的计算机仿真方法进行了研究,以OSG作为图形支持系统,用VC++开发了切削加工仿真系统。该系统实现了对毛坯切割的仿真,可对刀具运动切割情况进行实时监控,较好的再现了加工中毛坯的成型过程。     

布料仿真中基于精确力学公式的粒子模型

推导了一种用于布料仿真的粒子模型。该模型使用精确的力学公式构建布料模型平面内的拉伸与剪切变形,以及平面外的弯曲变形方程,并加以适当的简化。模型使用的参数全部具有物理意义,并且适用于任何三角面片网格,克服了传统的弹簧一质点模型中弹簧的弹性系数没有物理意义,并且只适用于规整网格的缺点。实验表明该模型具有良好的仿真效果。     

基于STL文件的Laplacian网格优化算法

针对三角网格模型优化算法对模型几何细节描述不够精确的问题,提出一种基于Laplacian坐标的网格模型全局优化算法。模型几何细节描述方面,采用网格顶点Laplacian坐标。网拓扑结构不变的前提下,可精确描述网格曲面局部几何特性。顶点重新定位方面,采用在最小二乘意义下求解由权重控制的包含顶点位置,以及Laplacian坐标双重约束的线性系统最优解的方法。实验结果表明,该算法在优化提高模型三角面片质量的同时,可较好地保留原始模型的几何细节。     

基于特征面的分层次CAD模型快速传输*

为了解决同步协同设计中共享模型数据传输量过大的问题,提出了一种基于特征面的分层次数据传输方法。该方法在进行共享模型传输时,首先只传输该模型的三角面片信息,当需要进行协同装配时,将参与装配的部件具体指定到某一特征面,且仅对于这一特征面传输全部的特征信息。为快速提取任一特征面,将笔者所在实验室自主研发的HUSTCAID系统的体系结构进行了二次开发,增加了特征面模型和面片模型,实现了HUSTCAID与UG系统间共享模型的实时传输。     

数控车削零件的仿真加工

本文介绍了数控车削零件的仿真加工技术。它采用CAXA软件生成NC代码,利用CAXA软件的CAM功能进行数控仿真,加载到VNUC仿真软件的计算机模拟机床里,模拟真实机床运动,最后通过数据线将G代码传输到实际机床,形成＂虚拟＋现实＂的仿真模式。这种模式弥补了CAD/CAM软件数控仿真的不足,将虚拟的机床运动与实际的数控操作融为一体,可使用户既掌握数控铣削加工的基本原理,又掌握数控系统操作的基本技能。     

Analysis of improved positioning in five-axis ruled surface milling using envelope surface

This article covers side milling of ruled surfaces using a milling cutter. Flank milling is useful for machining objects such as impellers, turbine blades, fan vanes and all workpieces defined by non-developable, ruled surfaces. In the present article, we first introduce two types of positioning on ruled surfaces developed within the Toulouse Mechanical Engineering Laboratory. The positioning studied is taken from the geometric situation not taking the instantaneous speed of rotation of the milling cutter into account. The swept profile of the tool is then determined based on the tool motion. Having defined the envelope surface, we seek to analyse improved and standard positioning errors comparing envelope surfaces with the ruled surface. We then introduce an example to illustrate positioning developed through a first theoretical study before experimentation including machining and measurement of the test piece. Finally, we give our conclusions as to the validity of improved positioning without taking the instantaneous speed of rotation of the milling cutter into account.     

A geometrical model for surface roughness prediction when face milling Al 7075-T7351 with square insert tools

Surface quality is important in engineering and a vital aspect of it is surface roughness, since it plays an important role in wear resistance, ductility, tensile, and fatigue strength for machined parts. This paper reports on a research study on the development of a geometrical model for surface roughness prediction when face milling with square inserts. The model is based on a geometrical analysis of the recreation of the tool trail left on the machined surface. The model has been validated with experimental data obtained for high speed milling of aluminum alloy (Al 7075-T7351) when using a wide range of cutting speed, feed per tooth, axial depth of cut and different values of tool nose radius (0.8 mm and 2.5 mm), using the Taguchi method as the design of experiments. The experimental roughness was obtained by measuring the surface roughness of the milled surfaces with a non-contact profilometer. The developed model can be used for any combination of material workpiece and tool, when tool flank wear is not considered and is suitable for using any tool diameter with any number of teeth and tool nose radius. The results show that the developed model achieved an excellent performance with almost 98% accuracy in terms of predicting the surface roughness when compared to the experimental data.     

球头铣刀柔性铣削力建模与仿真

本文建立了球头铣刀柔性铣削力模型,研究了任意进给方向的球头铣刀铣削力模型,在模型建立过程中考虑了刀具偏心、刀具变形和刀具振动物理影响因素,推导出了综合物理因素影响下的瞬时切屑厚度表达式.在此基础上对球头铣刀瞬时铣削力进行仿真对比分析,验证了建立模型的正确性.     

Improved positioning of cylindrical cutter for flank milling ruled surfaces

An optimized positioning procedure for flank milling ruled surfaces with cylindrical cutter is described in the paper. The tool axis trajectory surface is a ruled surface, which is generated by moving the tool axis. The proposition that the envelope surface of cylindrical cutter is the offset surface of tool axis trajectory surface is proved using kinematics approach. It is a complement of Bedi's [Bedi S, Mann S, Menzel C. Flank milling with flat end cutter. Comput Aided Des 2003; 35:293-300] analysis about the envelope surface of cylindrical cutter. Subsequently, we get another proposition that the deviation at extremum point between the designed surface and the envelope surface of cylindrical cutter is equal to that between the offset surface of designed surface and the tool axis trajectory surface. Based on this proposition, we propose three points offset (TPO) strategy to approximate the offset surface. In order to reduce errors further, a simple least square approximation scheme is established to make the tool axis trajectory surface fit the offset surface of designed surface as much as possible. By solving the linear system of equations, the tool axis trajectory surface is deformed. Simultaneously, the corresponding envelope surface is deformed to approximate the designed surface better. Two examples are given to verify the effectiveness of the developed 5-axis flank milling technique.     

Optimal and collision free tool posture in five-axis machining through the tight integration of tool path generation and machine simulation

The generation of collision free NC-programs for multi-axis milling operations is a critical task, which leads to multi-axis milling machines being exploited below their full capacities. Today, CAM systems, generating the tool path, do not take the multi-axis machine movements into account. They generate a multi-axis tool path, described by a sequence of tool postures (tool tip+tool orientation), which is then converted by a NC-postprocessor to a machine specific NC-program. As the postprocessing is normally done in batch mode, the NC-programmer does not know how the machine will move and the chance for having collisions between (moving) machine components is often very high. The execution of a machine test run or the application of a machine simulation system (NC-simulation) is the only solution to inform the NC-programmer about possible machine collisions during operation.This paper describes a multi-axis tool path generation algorithm where the tool orientation is optimised to avoid machine collisions and at the same time to maximise the material removal rate along the tool track. To perform efficient collision avoidance, the tool path generation module (traditional CAM), the postprocessing (axes transformation) and machine simulation has been integrated into one system. Cutting tests have been carried out to define the allowable tool orientation changes for optimisation and collision avoidance without disturbing the surface quality.The developed multi-axis tool path generation algorithm is applicable for the machining of several part surfaces within one operation. This, together with tool path generation functionality to adapt the tool orientation for both, maximal material removal and avoidance of collisions between (moving) machine components, are the innovative aspects of the presented research work.     

Profile error-oriented optimization of the feed direction and posture of the end-effector in robotic free-form milling

In robotic milling of free-form surfaces, most existing studies tried to reduce the profile errors by optimizing the robot stiffness. However, the stiffness could not directly and rigorously reflect the milling performance to some content, especially, when the significant influence of feed direction on the profile error was ignored for robotic milling of free-form surfaces with large curvatures. In order to solve these problems, direct optimization of the feed directions and end-effector postures is theoretically formulated to seek the solution of a new profile error-oriented optimization model. This model characterizes the profile error in relation to the robot deformation caused by cutting forces, called force-induced profile error. The force-induced profile error is calculated and reduced at each cutter contact point on the free-form surface by comprehensively considering robot stiffness, free-form surface features, feed directions and cutting forces for generating feed direction and posture of the end-effector. The surface is partitioned into multiple sub-regions, in each of which the principle for determining the initial feed direction is proposed to ensure the smooth milling without abrupt change of feed direction. Robotic milling process of the workpiece with saddle contour is experimented. Feed direction and posture of the end-effector are generated by the proposed method and the existing method for comparative studies. Measured profile errors and photographs of machined surface indicate that the developed method can greatly improve the milling performance.     

5-axis flank milling free-form surfaces considering constraints

A new tool path generation method of flank milling considering constraints is proposed for ball-end cutters in this paper. It will not only reduce the machining error range but also meet the following two constraints: (a) The ball end of the milling tool is tangential to the constraint surface; (b) There is no overcut and the minimum error is zero, which is called nonnegative-error constraint. The two constraints are very useful in some situations of engineering applications, such as flank milling impeller blades. Based on the proposed method, two types of cutter will be used to generate tool paths for the same designed surface and constraint surface. The effectiveness and accuracy of the proposed method will be finally proved with some examples.     

立铣加工过程中的微元铣削力建模分析

针对单纯通过高速切削技术制造某些大型飞机零件过程中,存在难以控制的加工变形和较强表面残余拉应力分布等突出问题,以直齿和螺旋齿立铣加工过程为研究对象,基于微元切削机理,通过对刀齿铣削过程的分析,建立动态铣削加工仿真模型,导出铣削面积、铣削力、主轴扭矩、铣削功率与切削用量的关系.数值模拟结果与试验值较吻合,表明该模型可以实现动态铣削力预测,优化切削用量.     

基于dyna971的数控镗铣机床动态模拟仿真

落地式数控镗铣机床结构复杂,为保证机床具有良好的动态性能,在开发设计该类机床时要进行整机的动态模拟仿真分析。针对这一要求,提出一种实际设计中实用化程度较高的机床动态模拟仿真思路,首先对数控落地镗铣机床样机进行模态试验,获取床身〖CD*2〗滑座、滑座〖CD*2〗立柱、立柱〖CD*2〗主轴箱等结合面的模态参数,在对模态参数进行有限元方法优化识别后,利用COMBIN14单元模拟优化后的结合部参数建立机床整机有限元模型。在dyna971软件平台对整机有限元模型进行动态模拟仿真,从模拟仿真分析结果可以看出机床在受到外界作用力时,其输出的应力和应变变化波形平稳,说明经过上述分析而设计出的机床具有良好的动态性能。目前,该研究成果已应用于此类型机床的批量生产。