在逆向工程中用神经网络技术实现自由曲面的重建

现有自由曲面的重建和还原制造是整个逆向工程中最关键的技术。当某些表面被部分损坏或者曲面模型不甚完整时，这些技术就显得非常有用。为了能在现有自由曲面基础上建立模型，首先用坐标测量机或激光扫描仪获取数字值，随后，将这些数据用于转换成模型。本文叙述以神经网络逼近方法用计算机重建模型再现已有自由曲面及制造加工这些曲面。在这里，我们设计了三个四层神经网络并使用误差反向传播法（ＢＰ）来训练网络。     

自由曲面自适应数字化及应用研究

自由曲面的数字化是自由曲面重建的关键技术之一,如何合理地对自由曲面进行采样,将关系到曲面重建精度和测量效率等重点问题,通过引入初始曲面概念,提出了基于物体重心的采样算法模型,该算法具有保存曲面拓扑信息和网络自组的功能,能够较准确地反映曲面的形状特征。     

复杂曲面重建技术应用

逆向工程是制造业产品创新设计的关键技术。通过点云数据建立曲面细分模型是曲面重建的最新思路，但是距离形成高性能应用体系还需解决很多问题。将逆向软件和专业CAD软件结合起来是针对复杂曲面模型重建的有效方法，以神舟五号载人航天飞船缓冲减震垫设计为实例，探求了复杂曲面重建规律。     

自由曲面孔域数据的拟实填补与曲面重建

为解决具有孔域的自由曲面在逆向设计中存在的数据空洞，提出了孔域测量数据的填实方法，通过孔域边界数据的光顺，截面测量曲线的端点 闭合处理，孔域的截面数据延拓，母面设计和曲面裁剪等技术，解决了自由曲面孔域数据填补和曲面的重建问题，实例应用表明，该方法可应用于逆向工程中对具有孔域的自由曲面的测量和造型，并能保证曲面重建的品质。     

逆向工程在产品曲面重建中的应用研究

逆向工程(反求工程)是CAD/CAM领域的一个研究热点,特别在工业设计学科产品外形设计的领域中得到了广泛的应用.目前产品复杂曲面重建的方法通常采用分片的小曲面片来拼接形成整张曲面,这种方法无法提取曲面的特征.本文针对复杂曲面重建这一难点,着重分析比较了逆向工程中经典的曲面重建方式,并在此次基础上提出了以点云-曲线-曲面为步骤的CAD模型整体重建方案以完成整个模型的重建过程,并用鼠标的实例综合验证了这一方法在曲面重建应用中的可行性.     

基于交互的B样条曲面重建与误差计算

基于三角网格模型的B样条曲面重建技术得到深入发展，计算与显示重建后的B样条曲面与原始测量三角网格之间的误差对分析曲面重建品质有重要作用。一种较为实用的B样条曲面重建方法是对三角网格模型进行四边界区域划分后进行栅格式采样，再根据采样点进行B样条曲面拟合。针对这种重建方法，研究了一种建立三角网格顶点与四边界区域对应关系的算法，再用离散的方法计算点到对应曲面的距离误差，最后用线性插值方法实现误差彩色．云图的显示。     

基于NURBS的扫描曲面造型方法的研究

由于非均匀有理Ｂ样条（ＮＵＲＢＳ）表示的曲线,曲面具有充分的灵活性,同时又统一了初等曲线,曲面和自由曲线曲面的表示,故在ＣＡＤ领域得到广泛应用。扫描曲面造型则是自由曲面造型的重要手段之一,介绍了ＮＵＲＢＳ表示曲线曲面的方法及特点,对扫描曲面造的各种情况进行了讨论,在此基础上给出了基于ＮＵＲＢＳ的扫描曲面造型算法。     

大型柔性曲面振动智能检测

以太空太阳能帆板的振动为对象建立大型柔性曲面振动检测样机,提供一种基于非视觉传感方法的大型柔性曲面振动智能检测方法和系统.系统将光纤光栅(Fiber bragg grating,FBG)分布式地封装于形状记忆合金基材中构成传感阵列,采用预应力封装提高FBG传感器的测量范围.根据波分复用和空分复用技术将传感阵列设计为传感网络,植入于曲面中,当被测曲面发生振动时, FBG解调仪检测到分布传感器的波长变化,转化为相应曲面上特征曲线的曲率信息.由曲率信息和弧长信息重建曲面形状,并在屏幕上显示出来,实现柔性曲面智能形状检测.试验结果表明,检测系统的FBG传感网络检测灵敏度高,重建算法速度快,重建曲面精度高,能够应用于大型柔性曲面的安全检测和监控.     

NURBS 曲面法矢量的理论探讨

从Ｂ样条曲线一阶导数公式出发，推导了非均匀Ｂ样条曲面、ＮＵＲＢＳ曲面单位法矢量的计算公式，并进行了实例验证，为复杂自由曲面数控加工系统设计以及刀具与工件相对运动轨迹的模拟奠定了基础。     

逆向系统曲面模型重建方法研究

综合国内外逆向系统曲面模型重建的方法和应用现状,深入分析了传统曲面造型和快速曲面造型两种曲面模型重建方法,并结合相关实例阐述了两种方法的建模策略、处理与重建对象及建模质量等主要问题.最后总结了两种曲面模型重建方法的主要特点,指出了将各方法相结合解决实际曲面重建问题的意义和研究方向.     

A framework for non-contact measurement and analysis of NURBS surfaces

The paper presents an implementation of a methodology for reliable and feasible dimensional measurement of engineering components containing free-form surfaces. Two main requirements had to be satisfied. First, a large number of points had to be accurately measured. Secondly, the set of corresponding points on the nominal model had to be computed within a reasonable time. The first aspect was satisfied by adopting a non-contact measurement technique based on laser triangulation. High accuracy was achieved through software prealignment for precise component localisation and through appropriate measurement planning, both based on the CAD model. Determination of the corresponding nominal points was solved by best-fitting. Significant speed improvements were achieved through an implementation of the iterative closest point algorithm, based on a dual representation of the surface. The nominal surface is defined using NURBS entities and its approximation is determined as a polyhedral mesh. A sampling criterion for complex surfaces was derived and implemented, producing encouraging results. Validity of the proposed approach is supported by experiments and by simulation studies involving real engineering components.     

曲面造型中一种快速的曲面跟踪求交算法

提出了一种新的曲面求交算法,采用精度好、效率高、计算稳定的迭代方法求得等参数网格线在曲面上的交点,并通过跟踪获得两曲面的交线。本算法由三个子算法组成,一个是求曲面上到固定点距离最近的点,一个是求参数网格线与曲面的交点,一个是求曲面与曲面的交点。为保证不遗漏交点,利用第一个算法对参数网格点进行分类,跟踪交点时利用第三个求下一个交点。与离散法求交相比,本算法具有计算稳定性、可靠性好,速度快,精度高的优点     

A new approach to C2 continuous piecewise bicubic representation of the articular surfaces of diarthrodial joints

Based on the force-deflection equation for a beam subjected to lateral point loads, a C2 continuous piecewise bicubic mathematical representation was proposed to model complicated geometrical surfaces, e.g. the articular surfaces of human joints. The method was then extended so that it could be used for mathematical modelling of incomplete nets of data points, as well as smoothing of noisy and/or filtering of erroneous data points. Mathematical techniques were also developed to calculate the required unknown parameters explicitly, with no need to solve the system of equations simultaneously. The performance of the proposed method was evaluated on a number of surface modelling problems, including two known analytical surfaces and the human femoral and patellar articular surfaces. The results indicate that the proposed method is precise, flexible, and easy to apply and has several advantages over the conventional smoothing methods, i.e. the B-spline approach.     

Adaptive tool-path generation on point-sampled surfaces

In this paper, we present a new approach to generate tool paths for machining point sampled surfaces using a direct projection algorithm, which is based on generating tool paths along planar intersection curves. In our implementation, a guide surface, with simple geometry like planes or cylinder surfaces, is first created according to the bound volume of the point cloud and initial tool paths are planned on it in terms of the motion pattern of the cutters. For each point of the initial tool paths, then, the corresponding cutter contact point (CC) of the point set surface is located by projecting the point onto the point cloud using the direct projection algorithm. In order to obtain adaptive cutter location points (CL), a least squares-based curve fitting method is applied to approximate the CC points using piecewise cubic Bezier, and a numerical method derived to estimate the length of the curve is used to adjust the position of the points along the curve, and make them evenly spaced on the curve with equal arc lengths. In addition, considering that offset curves or surfaces are necessary for locating CL points in many applications, such as machining using ball end milling cutter, torus ended milling cutters, an offset strategy for cubic Bezier curves is also studied. By testing the proposed method on several point clouds, it has been demonstrated to be promising.     

A generating method for digital gear tooth surfaces

Based on the theories of digital conjugate surface and gear meshing, a generating method for digital gear tooth surfaces (DGTS) is demonstrated in this paper. The research focuses on the conjugate motion between the DGTS, represented by discrete points, and the cutter figuration determined by analytic function in the manufacture process. Conjugate points in the cutter section corresponding to the discrete points on the digital surface and conjugate movements are solved. Automated sequence arrangements of the generating movement parameters have been performed and the discrete generating movements are interpolated in a continuous conjugate motion along the order. Strategies of error analysis and error compensation are also discussed in this paper. Computer-simulated examples of the generating machining of involute DGTS and non-standard shaped DGTS, the parameters of machining motions and real tooth surfaces verify the developed method. The research develops a new idea for the machining of DGTS, which breaks the limitations of conventional approaches based on analytic surfaces. It is of important theoretical and practical value to manufacture digital surfaces. Our method is not only be applicable in generating machining of discrete DGTS and analytic gear tooth surfaces with complex geometric design, but also in contributing to the processing of discrete digital cam and other 3-D digital surfaces .     

组合曲面叶片的螺旋加工刀位轨迹生成

为提高叶片加工质量和改进现有螺旋加工方法,提出了一种新的针对组合曲面造型叶片的四轴螺旋加工方法.该方法在叶片曲面造型过程中,将叶片曲面分割为叶盆、叶背、前缘和后缘四个区域.根据组合曲面叶片造型,提出了组合曲面叶片螺旋加工刀位轨迹生成方法和切触点的计算公式.最后,基于UG软件平台,以二次开发方式编制了相应的数控编程模块.生成了连续光滑的叶片螺旋加工刀位轨迹.试验结果表明,该方法能够实现叶片的四坐标螺旋加工,并可有效提高叶片的加工质量.     

基于自适应采样的曲面加工误差 在机测量方法

基于模具在机测量的自适应采样结果,提出一种新的获取自由曲面加工误差的方法。该方法首先基于自适应采样获取加工曲面上少量测点的坐标数据,利用NURBS曲面重构来拟合加工曲面;然后基于广义牛顿法计算重构的实际曲面和理论曲面的法向距离,获得自由曲面的加工误差,并对实验加工的模具模型曲面的轮廓度误差进行分析。实验结果表明,基于自适应采样的加工曲面重构方法能够在机测量且有效地获得自由曲面加工误差。     

An Improved Sculptured Part Surface Design Method with Jerk Continuity Consideration for Smooth Machining

This paper presents an investigation of jerk continuity in milling operations for sculptured surfaces of mechanical parts. It has been realised that chattering in machining operations can cause detrimental effects on the quality of machined parts as well as on the life of the cutting tool. One of the major reasons of chattering is known to be the rough transition of cutter accelerations when traversing through desired part sur-faces. The problem becomes serious when machining sculptured surfaces of parts. In this work, an effective computer-aided sculptured surface design technique is proposed. The ultimate goal is to achieve smooth and near chattering-free machining for producing precision parts. The proposed surface design scheme models the part’s sculptured surfaces in such a way that it warrants a smooth "jerk" transition at the boundaries of common surface patches on the part. This results in a drastic reduction of large step changes of cutter accelerations during machining operations which will in turn eliminate a good portion of the chattering effects. Three theorems concerning the necessary jerk continuity conditions for surface patches connections are developed and their proofs are presented. Examples of an aerofoil and a concept car model are implemented, using the proposed modelling approach, to demonstrate its effectiveness.     

A novel surface analytical model for cutting linearization error in fast tool/slow slide servo diamond turning

Fast tool/slow slide servo (FTS/SSS) technology plays an important role in machining freeform surfaces for the modern optics industry. The surface accuracy is a sticking factor that demands the need for a long-standing solution to fabricate ultraprecise freeform surfaces accurately and efficiently. However, the analysis of cutting linearization errors in the cutting direction of surface generation has received little attention. Hence, a novel surface analytical model is developed to evaluate the cutting linearization error of all cutting strategies for surface generation. It also optimizes the number of cutting points to meet accuracy requirements. To validate the theoretical cutting linearization errors, a series of machining experiments on sinusoidal wave grid and micro-lens array surfaces has been conducted. The experimental results demonstrate that these surfaces have successfully achieved the surface accuracy requirement of 1 μm with the implementation of the proposed model. These further credit the capability of the surface analytical model as an effective and accurate tool in improving profile accuracies and meeting accuracy requirements.