MULTIPARAMETER MEASUREMENT FOR RACEWAY GROOVE OF BEARING BASED ON 3D RECONSTRUCTION WITH DIGITAL STRUCTURED LIGHT

0 INTRODUCTIONBearings are standard components that are used widely mechanical products. The major technical parameters of bearingare affected not only by the manufacturing equipment and proessing technologies, but also by the measurement and gradinequipm…     

基于特征的BJCAD

从ＣＡＤ／ＣＡＰＰ／ＣＡＭ集成的角度出发,阐述了ＢＪＣＡＤ系统设计思想,描述了ＢＪＣＡＤ系统软件组成和硬件配置,最后,给出了ＢＪＣＡＤ系统总体结构。     

A fast full-field 3D measurement system for BGA coplanarity inspection

Ball-Grid-Array (BGA) has become one of the most popular packaging techniques in the electronics industry. Coplanarity inspection of BGA solder balls is critical for process and quality control in BGA manufacturing. Currently, the 3D measurement systems for BGA coplanarity inspection are mainly based on laser scanning techniques. However, they suffer from low inspection speed due to the physical line-scanning process. In this paper, a fast and cost-effective 3D measurement system for coplanarity inspection of BGA solder balls is proposed. The proposed system uses an LCD-based phase measuring technique to perform full-field 3D measurement of BGA solder balls with high accuracy. Experiments have shown that the coplanarity measurement of BGA solder balls is very efficient and effective with the proposed system. The measurement repeatability is in the micrometer range. The processing time of the proposed 3D measurement system for an image of 640×480 pixels is less than 2 s on a typical personal computer.     

基于单元等变形的复杂曲面展开算法研究

针对板壳类零件展开问题提出了一种基于单元等变形的复杂曲面展开算法。首先利用有限元网格生成算法将零件曲面划分成三角形单元 ,然后按照单元等变形假设将三角形单元映射到平面上 ,从而得到曲面的展开形状与尺寸 ,并通过重新计算单元的变形率得到曲面内的应变分布。该算法可以将各种可展曲面和不可展曲面采用统一的形式展开 ,实际应用表明采用该算法展开复杂曲面时具有快速准确的特点 ,可以显著缩短零件从设计造型到求取其毛料外形的时间 ,适用于航空航天及汽车制造等工业领域内具有复杂曲面的金属板料零件的数字化展开。     

Research and development of an accurate 3D shape measurement system based on fringe projection: Model analysis and performance evaluation

In this paper, the research and development of an accurate 3D shape measurement system based on fringe projection is presented. This system utilizes a sliding projection unit to project the desired encoding fringe patterns onto the object and the object shape can be obtained by analyzing the images captured with a camera for each projection. The sliding projection unit uses a high precision grating element fabricated by electron beam lithography to produce the accurate encoding fringe patterns thus to reduce the projection error. And a method based on gray-code and phase-period edge detection is developed to align the grating element with its sliding direction to guarantee the alignment between the projected patterns. The influence of the lens distortion of both the projection unit and the camera is also studied and an improved nonlinear system model is developed based on triangulation. This model gives a more accurate mathematical representation of the shape measurement system and thus improves the system measurement accuracy. The experimental results show that an overall measurement error of 0.04 mm with a variability of ±0.035 mm can be obtained for the developed system.     

Abrasive wear between rough surfaces in deep drawing

In tribology, many surface contact models are based on the assumption that surfaces are composed of a collection of small asperities of which the tips are equally sized and spherically shaped and have some kind of statistical height distribution. This approach was used in 1966 by Greenwood and Williamson and was successfully followed by many researchers during the following decades. The statistical representation of surface topography enables calculation of contact forces and asperity deformations with reasonable accuracy using well established equations. Although this approach has proven to be suitable for static contact situations, alternative representations of the surface topography are required when modelling abrasive wear. In the current work an elastoplastic contact model is developed in which a representation of the surface topography is obtained by best fit approximations of the micro-contacts, obtained from real, measured surface height data. In this deterministic surface representation, the tips of the contacting asperities are assumed to have an ellipsoidal shape. Given the material parameters and contact conditions, the load and deformation of a single asperity can be computed. Subsequently, the wear induced by each individual asperity is obtained by inserting its size and shape and the conditions into a “single asperity micro-abrasion model”. By summing the contributions of all individual asperities, the total abrasive wear volume is obtained. The results of the developed abrasive wear model are compared with results obtained using a statistical approach.     

Nondestructive evaluation of a crack on austenitic stainless steel using a sheet type induced current and a Hall sensor array

Austenitic stainless steels (hereafter A-STS) such as STS304 and STS316 are paramagnetic metals. However, a small amount of partial magnetization is generated in A-STS because of the imperfect final heat treatment and mechanical processing. Surface cracks on paramagnetic metal with a partially magnetized region (hereafter PMR) are difficult to inspect. In this paper, we propose a method for high speed inspection and evaluation of a crack on A-STS. Cracks can be inspected with high speed by using 64 arrayed Hall sensors (HSA) with 3.5 mm spatial resolution and a sheet type induced current (STIC). Then, a crack can be evaluated quantitatively by using the detailed distribution of the magnetic field obtained by using single Hall sensor scanning (SSS) around the inspected crack area. Several cracks on A-STS with partially magnetized areas were examined and the experimental formulas were derived.     

Quality design of fixture planning for sheet metal assembly

Fixturing plays an important role in enhancing weld quality of the sheet metal assembly process. However, traditional experience-based fixturing schemes and purely optimal fixturing schemes are often sensitive to location fluctuation of the designed locators. In this paper a mathematical representation of deterministic locating and total fixturing for a flexible workpiece is developed first, then a virtual beam model is proposed to evaluate the degree of flexibility of the locating points. A quality design model of fixture planning for sheet metal assembly with resistance spot welding is then developed; both the performance expectation and the variance are considered in the formulation of the objective function; a prescribed factor is used to weight the two objectives. The finite element model based on ANSYS software is set up with a spot weld feature employed and genetic algorithm is used in the optimization process. A simple example and an industrial case illustrate the feasibility of the developed model. This work provides a basis for improving the quality of sheet metal assembly in the design phase.     

Measurement of surface form of Johannesteijsmania altifrons leaf using phase-shift fringe projection

The design of thin-walled structures based on naturally occurring folded structures, such as the Johannesteijsmania altifrons leaf, is relatively unexplored. The main advantage of this particular type of folded leaf is that it is supported by a single main stem, which can be exploited in structural designs if the 3-D surface form is known. Since the leaf can deform if the surface form is measured using conventional contact methods, the non-contact phase-shifting fringe projection method was applied to determine the 3-D surface form of the leaf. The potential of the phase-shifting fringe projection method for reconstructing the 3-D surface of naturally occurring folded structures such as J. altifrons leaf has not been attempted in the past. The objective of this work is to investigate the potential of using this technique to measure the 3-D surface of the life folded leaf in its natural environment. Three fringe patterns were projected onto the leaf with phase-shifts of 0, 2π/3 and 4π/3, captured using a CCD camera and processed to obtain a phase map. The 3-D data of the leaf surface were successfully reconstructed from the phase map using a phase-unwrapping algorithm.     

车身覆盖件的曲面重构及数控加工

汽车车身覆盖件由于曲面复杂,表面面积大,其设计在新车型的开发过程中尤为关键.利用三维激光扫描仪和Pro/E软件对现有的汽车模型的车身进行了反求,完成了反求工程中的数据测量、数据处理及曲面重构技术,得到了车身覆盖件较为准确的CAD模型,同时用数控雕铣机进行真实加工,这为简化模型的创建难度,缩短建模周期提供依据.     

线切割机床装夹自动化的研究

讨论了在线切割机床上使用的一种自行设计的三坐标通用数控夹具,可实现工件自动找正,扩大现有机床的三维加工能力,介绍了夹具的硬件和软件结构。     

三维激光视觉系统的研究现状及在汽车工业的应用

三维激光视觉系统是以计算机、信息处理三维图象处理、激光为基础的高新技术、介绍三激光视觉系统的原理、研究现状及在汽车工业界的应用。     

3D打印再制造目前存在问题与应对措施

3D打印技术是一种节材、节能且经济效益突出的绿色先进制造技术,已在金属零件直接成形、生物医疗等行业得到了广泛应用,但其在装备零部件再制造领域的应用目前还处于初级阶段。介绍了3D打印再制造的内涵,并通过对3D打印再制造技术流程的分析指出：相比3D打印直接制造,3D打印再制造涉及技术领域更广,过程更复杂;3D打印再制造目前还存在技术相对单一、设备便携性差、效率低下等问题。最后,针对这些问题,提出了构建一体化再制造软件系统、开发桌面化3D打印系统以及大力开展远程3D打印再制造等相应的应对措施。     

浅谈3D技术在个性化产品定制中的应用

定制个性化的产品已经越来越受到人们的关注与向往,个性化的产品的定制离不开先进的3D技术,在定制过程中,需要综合运用产品测绘、三维扫描、工业设计、3D建模、设计变更与优化、数据处理及转换等技术来把个性化的产品进行呈现,然后通过3D打印技术将产品模型数据打印出来,实现产品的个性化定制。     

无缝线路磨损钢轨激光熔覆自动修复方式的研究

由于列车的高速化和重载化,钢轨磨损问题越来越严重,采用修复质量高、修复速度快的激光熔覆技术可以对其进行在线快速修复。为此,采用三维扫描仪首先对磨损钢轨进行扫描,然后将扫描点云数据进行三维重构、路径规划及数据格式转换,最后利用优化的数据驱动机器手臂和激光熔覆装置对磨损钢轨进行自动修复。修复工艺结果表明,对5 mm的磨耗层进行7层修复,利用修复道与道之间和层与层之间的回火作用,修复层的组织马氏体含量少,硬度为330~360 HV;经过600℃回火处理10 min后,加入钒元素的铁基合金粉末激光熔覆修复后钢轨母材、热影响区、修复层硬度均在300~340 HV,组织为回火索氏体;修复钢轨的耐磨性约为钢轨母材的87%,达到修复目的。     

基于SaaS模式的零件库系统设计与开发

考虑到中小企业难以承担建立零件库的费用,开发了面向多用户的零件库系统.系统采用SaaS模式提供服务,具有水平扩展性,通过X3D展示零件模型.用户通过租用系统空间而不必自己建库,可以节省大量费用.系统可以帮助中小企业宣传和销售零件,降低了企业信息化建设的门槛.     

基于OpenCASCADE内核的三维钣金系统研究

传统的商用软件二次开发模式难以满足钣金设计的灵活性和交互性要求,基于造型内核开发三维设计环境是可行的方案。在分析OpenCASCADE三维造型内核的开发模式和数据结构的基础上,将钣金展开方法与OpenCASCADE相结合,使用VC++开发出三维钣金设计系统。针对常用钣金件展开方法建立了数学模型,以模型数据和算法为基础,调用OpenCASCADE造型函数,实现了底层数据与显示模块的融合。无论在设计灵活性还是系统扩展性方面都优于传统的商用软件二次开发模式。     

非Lambert表面从明暗恢复形状技术的研究进展

传统的从明暗恢复形状(Shape from Shading,SFS)技术通常假定物体表面为Lambert表面,然而对于实际的物体表面来说,上述简化造成了重构结果误差较大.近年来,许多学者开始关注于非Lambert表面下的SFS技术的研究.结合作者自身的研究,从成像过程建模、图像辐照度方程的建立及求解数值算法出发,介绍了非Lambert表面从明暗恢复形状技术的研究进展.首先,简要介绍了非Lambert表面下典型的SFS技术;其次,以OrenNayer模型为例详细说明了非Lambert表面SFS方法的关键技术;最后,对非Lambert表面SFS技术的发展趋势进行了探讨.     

SolidWorks的零件三维模型快速设计方法

现代企业已经转向多品种、小批量的生产模式,但是并非每种新产品都需要进行重新设计。中高端三维CAD软件不仅提供了强大的零件特征造型功能,而且提供了实用性很好的零件三维建模快速设计方法和产品设计重用方法。