基于光栅相位法三维重构技术研究

投影光栅相位法（PMP）是一种基于光栅投影和相位测量的光学三维轮廓测量技术,可实现物体表面三维轮廓的自动测量。提出了结合投影仪移轴技术的平行光轴系统,利用计算机编程生成具有高对比度和高亮度、有相差的正弦光栅,用数字投影仪LCD将这些条纹依次投射到被测物体表面,由CCD摄像机获取受物体表面面形调制的变形光栅像,根据数字相移算法计算出相位分布再通过相位展开恢复出连续相位分布,由相位．高度关系最终求出物体轮廓的三维数据信息。针对该原理进行了阐述,并给出了详尽的算法及实验结果。通过MATLAB实验仿真,对条纹图像进行处理和轮廓重构。模拟实验证明,这种测量方法快速高效、分辨率高,且易于实现。     

基于偏转法的物体三维形貌测量

基于数字散斑干涉测量技术,组建一套基于偏转法的物体三维形貌测量系统。首先,通过精密旋转平台使被测物体偏转微小角度,在其表面引入包含该物体形貌信息的弯曲干涉条纹。然后由散斑干涉条纹图提取其相位分布,对滤波后的包裹相位图进行相位解包裹运算,得到相位的真实分布图。最后根据相位分布与物面高度的关系求解出被测物体的高度信息。实验结果表明采用偏转法的散斑干涉技术可以实现物体三维形貌测量,具有测量精度较高、易于实现等优点。     

三灰度编码相位展开方法条纹投影轮廓术

为了通过减少条纹投影轮廓术所需投影和采集的条纹图像数量,提高三维测量速度,提出了一种用于条纹投影轮廓术的三灰度编码相位展开方法.投影仪投射5幅条纹图像到被测物体表面,包括三幅正弦相移条纹图像和两幅三灰度编码图像,由相机采集经物体表面调制的变形条纹图.通过相机采集到的三幅变形正弦相移条纹图像计算包裹相位.通过相机采集的三...     

微小高度检测系统设计

高度信息是分析物体三维形貌的最重要信息。为了研究微小焊点的三维形貌,需要对焊点高度进行测量。针对传统测量技术的缺点,设计了一种检测系统。系统应用白光平行照射条纹板,将其像投影到被测物体上,受到物体高度轮廓的调制作用,形成变形的亮暗相间的条纹。该条纹图携带着焊点的三维信息,再用照相系统把变形的条纹图拍摄在CCD上,通过对CCD上像的处理,可以还原出高度信息。该方法可将条纹板的像等间距地投射到被测物体的表面上,避免了由于投影条纹宽度不同所带了的图像处理过程的误差。实现了测量范围大、重复性好、图像处理简单的优点,为微小高度的测量提供了新方法。     

一种基于相移技术的物体表面三维轮廓测量方法

提出一种将阴影莫尔条纹法与相位测量技术相结合的物体表面三维轮廓测量方法 ,该方法利用电磁铁和精密机械部件对光栅进行定位控制以实现精确相移 ,并采用三步相移技术对CCD摄像机采集的物体表面形貌莫尔条纹进行相位解调 ,可有效实现物体表面三维轮廓的高速、高精度自动测量。     

用于强反射表面形貌测量的投影栅相位法

为了实现强反射表面三维形貌的光学非接触测量,提出一种改进的投影栅相位法。分析了强反射表面的反射光特点及其对相位解算的影响,指出了反射光亮度范围与相机动态范围的不一致是导致传统投影栅相位法测量失效的主要原因;提出了亮暗条纹投射、多曝光时间采集图像和图像合成等技术,使相机亮度测量范围与强反射表面的反射光亮度范围相一致,并分析了此方法的可行性和适应范围。最后,给出了改进投影栅相位法的条纹投射与图像采集步骤。实验结果表明,改进的投影栅相位法克服了强反射表面引起的条纹图像饱和或过暗问题,能够成功测量出99.6%以上的三维点云,有效解决了测量点云缺失问题,能够实现强反射表面三维形貌光学非接触测量。     

基于彩色条纹投影术的三维形貌测量

物体表面三维形貌数据的获取在智能制造、航空航天、文物保护、医疗卫生、远程教育等领域有着广泛的应用。三维形貌数据的获取受限于系统硬件的性能,特别是现有数字投影系统的投影速度,无法快速测得物体面形的三维形貌。彩色成像和投影系统的出现,为并行多颜色通道三维成像系统提供了新的研究方向。详细综述了基于彩色条纹投影术的三维形貌数据测量研究的现状。具体包括彩色条纹投影术的基本原理、彩色条纹调制和解调相关技术、三维成像系统的标定、以及未来的研究方向。接着给出几个利用彩色条纹投影术获取物体表面三维形貌和彩色纹理的实例。为彩色条纹投影术测量物体表面三维形貌数据提供了详尽的综述,并指明了未来潜在的研究新方向。     

互补格雷码双 N 步相移的彩色编码光栅投影轮廓术

在三维轮廓测量领域,互补格雷码相移法能够得到连续的展开相位,然而,单组相移条纹导致其测量精度极易受到周围环境变化的影响,且传统投影方式增加了干扰的引入。针对此问题,本文提出了一种基于彩色编码光栅投影的互补格雷码双N步相移法。首先将双N步相移条纹和互补格雷码条纹混合编码成彩色条纹,然后依次投射到目标表面,最后从采集的彩色条纹中提取相位信息分别进行相位解算、融合后求得表面三维形貌。为了验证本文所提方法,将该方法与传统互补格雷码N步相移法以及三频外差法进行了对比实验。实验结果证明,本文方法能够获得高精度表面形貌信息,有效降低测量误差,同时检测效率提高50%。     

基于全场条纹反射的镜面物体三维面形测量综述

随着集成电路、汽车行业、先进制造和天文学的发展,条纹反射术被广泛应用于测量镜面物体的三维形貌。条纹反射术通过反射条纹图中的相位信息计算被测镜面物体的局部斜率或深度信息来恢复物体的三维形貌。为全面了解条纹反射术研究的最新进展,本文综述了条纹反射的基本原理、反射条纹产生的方式、相位的计算方法、系统参数的标定和斜率积分获得深度数据,同时介绍了不依赖积分过程的直接条纹反射术。通过具体的应用和实例,指出了条纹反射术的优缺点。最后,指出了条纹反射术未来的研究方向。该综述文章为深入研究镜面反射物体的三维面形测量提供了有益的参考。     

基于RGB三基色的实时相位测量轮廓术

提出一种基于彩色三步相移算法和DLP Light Crafter 4500的实时相位测量轮廓术。在测量系统中,DLP Light Crafter 4500快速有序地投影MATLAB生成的三帧相移量为2π/3的R、G、B调制正弦相移光栅条纹到被测物体表面,一台与DLP Light Crafter 4500投影光栅条纹信号同步的高速黑白CMOS相机拍摄受被测物体面形调制的变形条纹。由于捕获的变形条纹间存在颜色失衡,需要采用校正算法进行校正。基于传统的三步相移技术,利用校正后的三帧变形条纹图像可以实时重建被测物体的三维形貌。     

单晶金刚石微型刀具刃磨试验研究

采用金刚石砂轮对单晶金刚石微型刀具进行了刃口机械刃磨试验,利用莱卡光学显微镜观察了单晶金刚石刀具刃口和表面形貌,以研究不同参数对磨削过程的影响,通过优化相关参数来获得更好的单晶金刚石微型刀具并提高刃磨效率。试验选择砂轮粒度、磨削速度以及进给速率作为刃磨参数。通过正交试验设计,比较磨削力、刃口半径和表面形貌,从而筛选出最优参数。试验得出小粒度砂轮、较高磨削速度和中等进给速度可以得到较好的刃磨结果。     

Effects of cutting edge geometry, workpiece hardness, feed rate and cutting speed on surface roughness and forces in finish turning of hardened AISI H13 steel

In this study, the effects of cutting edge geometry, workpiece hardness, feed rate and cutting speed on surface roughness and resultant forces in the finish hard turning of AISI H13 steel were experimentally investigated. Cubic boron nitrite inserts with two distinct edge preparations and through-hardened AISI H13 steel bars were used. Four-factor (hardness, edge geometry, feed rate and cutting speed) two-level fractional experiments were conducted and statistical analysis of variance was performed. During hard turning experiments, three components of tool forces and roughness of the machined surface were measured. This study shows that the effects of workpiece hardness, cutting edge geometry, feed rate and cutting speed on surface roughness are statistically significant. The effects of two-factor interactions of the edge geometry and the workpiece hardness, the edge geometry and the feed rate, and the cutting speed and feed rate also appeared to be important. Especially honed edge geometry and lower workpiece surface hardness resulted in better surface roughness. Cutting-edge geometry, workpiece hardness and cutting speed are found to be affecting force components. The lower workpiece surface hardness and honed edge geometry resulted in lower tangential and radial forces.     

Sustainability analyses of cutting edge radius on specific cutting energy and surface finish in side milling processes

The aim of this work is to determine the influence of cutting edge radius on the specific cutting energy and surface finish in a mechanical machining process. This was achieved by assessing the direct electrical energy demand during side milling of aluminium AW6082-T6 alloy and AISI 1018 steel in a dry cutting environment using three different cutting tool inserts. The specific energy coefficient was evaluated as an index of the sustainable milling process. The surface finish of the machined parts was also investigated after machining. It was observed that machining with the 48.50-μm cutting edge radius insert resulted in lower specific cutting energy requirements when compared with the 68.50 and 98.72-μm cutting edge radii inserts, respectively. However, as the ratio of the undeformed chip thickness to cutting edge radius is less than 1, the surface roughness increases. The surface roughness values gradually decrease as the ratio of undeformed chip thickness to cutting edge radius (h/r _e) tends to be 1 and at minimum surface roughness values when the ratio of h/r _e equalled to 1. However, the surface roughness values increased as h/r _e becomes higher than 1. This machining strategy further elucidates the black box and trade-offs of ploughing and rubbing characteristics of micro machining and optimization strategy for minimum energy and sustainable manufacture.     

Surface integrity in broaching of AA 7075-T651 aluminum alloys

Special features as noncircular hole shapes are manufactured by the broaching process. The rise per tooth varies in different zones of the broaching tool. In this article, the effects of the two main process parameters (cutting speed and rise per tooth) on surface integrity (surface roughness, micro-hardness) and chip morphology will be studied. The experiments have been done on AA7075-T651 aluminum alloy. To investigate the effect of rise per tooth, one of the cutting edges of broaching tool is separated and the broaching process is implemented for nine samples. The samples are broached with three different cutting speeds (6, 12 and 18 m/min) and three rise per tooth (0.02, 0.05 and 0.1?mm). Also, the effect of cutting speed is investigated with a broaching needle (rise per tooth 0.1?mm). The results show that best surface roughness is obtained at cutting speed 12 m/min. The surface roughness will be improved by decreasing the rise per tooth. Also, the surface hardness decreases by increasing the cutting speed. The surface integrity (surface roughness and surface hardness) is comparable for single edge cutting tool and broaching needle. Continuous chips are formed during the broaching process and decreasing the cutting speed cause more compression of the chips.     

Distribution of unit forces on the tool edge rounding in the case of finishing turning

An experimental investigation was conducted to determine the effects of tool cutting edge geometry on the cutting forces in finish turning, where the applied feed and depth of cut are small and often comparable with the tool edge radius. If a tool with large tool edge radius is used in finish turning, the ploughing effect begins to determine the machined surface. This paper presents the results of analytical considerations concerning the unit forces on a cutting edge. The aim of this paper is to indicate possibilities of modelling the unit forces and stress distribution based on cutting resistance. The forces calculated in the feed and cutting speed directions were projected onto the tangential and normal directions of the rounded cutting edge surface. An important assumption in all the considerations was that the thermo-mechanical properties of the materials used remained constant. The minimum thickness of cut was defined, and some characteristic points were identified dividing the cutting zone into three subregions: where a chip is formed, where the machined surface is formed and an unstable region.     

Specific cutting force, tool wear and chip morphology characteristics during dry drilling of austempered ductile iron (ADI)

Dry machining is being recognized as ecological machining due to its less environmental impact and manufacturing cost. However, the choice of dry machining is mainly influenced by the workpiece material properties, machining operation and cutting conditions. The recent emergence of austempered ductile iron (ADI) can be considered a significant economic advantage to the increasing industrial demand for cost- and weight-efficient materials. However, due to its microstructure-induced inherent properties, ADI is considered hard-to-machine material. Thus, the dry drilling of ADI is investigated in this paper. The ADI material used in the present study is produced using an innovative process route for near net shape casting production. Drilling experiments are conducted on a DMU80P Deckel Maho five-axis machining centre using PVD-coated carbide tools under dry cutting environment. The dry drilling of ADI under different cutting conditions is evaluated in terms of specific cutting force and tool wear analysis. The influence of cutting conditions on chip morphology and surface roughness is also investigated. The experimental results revealed that the combination of the low feed rate and higher cutting speed leads to the higher mechanical and thermal loads on the tool's cutting edge, resulting in higher specific cutting force values. This behaviour is further supported by the chip morphology analysis, which revealed the formation of segmented chips at higher cutting speed with segment spacing increase with an increase in feed rate. Depending upon the cutting parameters, different modes of tool failures including crater wear, flank wear, chipping, breakage and built-up edge were observed. Surface roughness analysis revealed the influence of tool wear and chip morphology on the machined surface finish.     

Chip morphology study in high speed drilling of Al�CSi alloy

Chip formation during drilling operation is greatly influenced by the cutting parameters such as cutting speed, feed rate, and drill geometry. However, not many studies have focused on the direct observation of the chip formation during high speed drilling. This paper investigates the effect of cutting speed and feed rate on the chip morphology during high speed drilling of aluminum?Csilicon alloys using carbide drill. Observation on the multiview characterization of the chips was carried out which includes free surface, back surface, and cross-section of top surface. Structure and shape alterations of the free and back surfaces were analyzed using a scanning electron microscope. Finally, different geometrical parameters of chip cross-section were measured in order to study the effect of cutting parameters on chip compression ratio and thrust force. It was found that increase in cutting speed significantly affects the chip morphology especially on the structure of free surface and cross-section of the chips. Results also showed that built-up edge on the rake face of tool played an important role on the formation of irregular pattern on the chip back surface.     

Influence of cutting edge radius on surface integrity and burr formation in milling titanium

The influence of the cutting edge micro geometry on cutting process and on tool performance is subject to several research projects. Recently, published papers mainly focus on the cutting edge rounding and its influence on tool life and cutting forces. For applications even more important, however, is the influence of the cutting edge radius on the integrity of the machined part. Especially for titanium, which is used in environments requiring high mechanical integrity, the information about the dependency of surface integrity on cutting edge geometry is important. This paper therefore studies the influence of the cutting edge radius on surface integrity in terms of residual stress, micro hardness, surface roughness and optical characterisation of the surface and near surface area in up and down milling of the titanium alloy Ti–6Al–4V. Moreover, the influence of the cutting edge radius on burr formation is analysed. The experiments show that residual stresses increase with the cutting edge radius especially in up milling, whereas the influence in down milling is less pronounced. The influence of the cutting edge radius on surface roughness is non-uniform. The formation of burr increases with increasing cutting edge radius, and is thus in agreement with the residual stress tests.     

PTFE材料正交切削切屑成形特性研究

为了研究PTFE材料在切削过程中的成屑机理,设计了单因素正交切削实验以及准静态力学实验。首先,基于剪切平面理论和断裂理论,以切削速度、切削厚度为变量,提出了PTFE材料的连续切屑及切屑毛边成形机理;然后通过分析毛边高度和间距,探究切削参数对毛边形态的影响规律;最后,利用分形理论对切削力稳定性进行分析,揭示了毛边数量、出现频率与切削力稳定性的关系。结果表明,PTFE连续切屑的产生是因为切削过程中材料真实压缩应变未超过断裂屈服应变,毛边的产生则是因为切屑边缘片层状结构处裂纹的形核与扩展。此外,切削参数会影响毛边生成,在切削速度100 mm/min、切削厚度0.3 mm工况下,切屑毛边数量最少、出现频率最小,切削力最稳定。研究结果可为PTFE材料切削过程毛边抑制和表面加工质量优化提供参考。     

TC4钛合金铣削刀具C形刃几何参数优化实验研究

通过对TC4钛合金进行侧铣加工,采用正交设计方法研究了硬质合金立铣刀侧刃几何参数对切削力和表面粗糙度的影响,用极差法分析了刀具几何参数对铣削力的影响;并以最小表面粗糙度为目标,采用田口法对刀具几何参数进行了优选。结果表明:螺旋角对铣削力的影响最大,对F_x、F_z,C形刃宽度影响次之,C形刃角度的影响最小;对于F_y,C形刃角度次之,C形刃宽度的影响最小;当螺旋角为25°、C形刃宽度为0.2mm、角度为-25°时可获得最小表面粗糙度。