面向精密抛光的复杂模具曲面三维重构方法

针对机器人辅助模具精密抛光系统发展的要求,提出了一种复杂模具曲面三维重构方法。分析了模具抛光件型线三维重构方法的原理和实现过程,并详细讨论了面向精密抛光的复杂模具曲面三维造型方法的关键技术,包括节点的选取、端点切矢的选取等;给出了在精密抛光系统中,复杂模具自动抛光曲面的编程控制策略和实现方案。应用所提的面向精密抛光的复杂模具曲面三维重构方法能使精密抛光系统在加工的不同阶段始终蕴涵不等的模具曲面加工信息,从而提高了抛光效率和产品质量,并降低了工人劳动强度。     

面向连杆模具的混联机器人柔性抛光系统开发

为了解决连杆模具抛光过程中人工抛光时间长、劳动强度大等问题,建立了一套混联机器人柔性抛光系统。在该系统上对材料去除模型进行了研究,建立了考虑抛光工具磨损的材料去除模型,能够良好预测一定抛光参数下的材料去除量;在此基础上,对模具型腔表面自动分片,并使用UG和示教相结合的方法生成加工轨迹;根据模具抛光力的控制需要,建立了一套气动控制系统,使用自主设计的浮动恒力抛光主轴结合PID控制算法实现了恒力抛光。最后在该柔性抛光系统上进行了汽车连杆模具抛光实验,实验结果表明了该柔性抛光系统能够较好地完成连杆模具抛光任务,得到较好的抛光效果。     

基于游离磨料的机器人抛光工艺实验研究

建立了基于游离磨料和软质抛光工具的工业机器人抛光系统,研究了机器人抛光轨迹的生成方法,并研究了主要工艺参数如主轴转速、轨迹间距和机器人行走速度对表面抛光质量的影响,为确定合理的机器人抛光工艺参数提供了依据。在此基础上对等离子熔射快速制造的金属模具型腔进行了表面抛光实验验证。     

机器人模具抛光自由曲面刀具轨迹的生成研究

以HNC-IR教学机器人为对象,对机器人模具抛光中自由曲面的抛光刀具轨迹的生成和干涉处理进行了研究,提出了适合于机器人抛光的面自由曲面刀具轨迹生成算法,此算法生成的抛光刀具轨迹具有形式简单、在曲面表面分布均匀等优点,适合于机器人抛光。     

门把手抛光机器人工作站设计

在对门把手抛光加工工艺分析及对抛光加工进行轨迹设计的基础上,对门把手抛光机器人工作站进行总体设计,同时设计了门把手自动抛光用的专用夹具、砂带机及砂轮机,完成了门把手抛光机器人工作站用工业机器人的选型,解决了实现门把手工人手动抛光到机器人自动抛光的技术难题。     

气囊抛光工具的模块化设计及应用

针对主动式、磁控型和磁流变型气囊抛光工具的不同结构特点和使用功能的有效集成问题,基于模块化理论,将产品需求多变性和主体结构标准化有效结合起来,充分利用共用性和组合优化效应,完成了模块化气囊抛光工具的设计,并为产品族规划打下了基础;开展了模块化基础理论、功能模块划分、结构细化设计和产品族规划等方面的分析与研究,通过柔性工作模块、磁场发生器模块、气控容腔模块、动力模块、连接板模块和传感测控模块等,充分保证了新型气囊抛光技术自动、柔性、可控、多变的特点;在以模块化气囊抛光工具为核心的机器人辅助模具自由曲面抛光平台上,进行了相关的试验研究。研究结果表明:将模块化气囊抛光工具应用于模具钢抛光,能获得Ra0.006μm的高质量表面。     

机器人模具抛光系统中抛光工具位姿研究

为了弥补抛光机器人通过示教方式采集抛光点的不足,充分利用了模具数控加工在路径规划方面的功能,生成模具加工表面刀位点,编写算法提取在UG NX 7.5的CAM模块上生成的模具加工数控刀位数据,并在这些数据的基础之上,设计了工业机器人抛光工具的位姿算法。     

基于UG软件的芯盒内表面抛光路径生成方法

近些年,随着数控技术和CAD／CAM技术在模具工业中的广泛应用,数字化和机器人等抛光方法对复杂模具曲面进行抛光处理的应用得到了较快的发展,并成为模具曲面加工中行之有效的方法。本文针对芯盒内表面抛光过程中的不同抛光曲面,分析了UG模具曲面加工运动中各种路径的生成方法;     

工业机器人模具抛光方法研究及仿真

提出了一种针对复杂型腔模具使用工业机器人进行抛光的方法,该方法可以实现稳定的力控制和精确的位置控制,且此抛光方法很易在线实现。为了保证模具不同法矢量曲面材料去除率的一致,提出根据曲面法矢量实时地调整电主轴转速的方法。系统刚度不同的机器人抛光需要采用不同的PI参数,该自适应PI控制算法可以进行抛光系统刚度的评估和PI参数的调整。仿真结果表明该方法可以很好地实现模具的抛光。     

应用于模具自由曲面的新型气囊抛光技术

为提高模具自由曲面抛光的效率和品质,提出一种基于柔性抛光理念的新型气囊抛光技术。建立相应的机器人抛光系统,研究旋转型膨胀气囊抛光工具及抛光过程中各因素对抛光表面粗糙度的影响。对气囊抛光工具的位置和姿态控制问题以及抛光工具,以一定下陷深度和倾斜角度与被抛工件接触时的接触区域的相关特性进行分析。在机器人抛光系统上进行抛光正交试验和试验数据分析,获取表面粗糙度的不同影响因数的最优参数组合,试验中被抛光曲面平均表面粗糙度达到了0.007 μm。研究结果表明,气囊抛光技术可实现抛光工具与被抛光工件的大面积柔性接触,通过气囊内部气压的调节和机器人抛光系统对抛光工具的运动轨迹和姿态的精确控制,可有效地提升自由曲面抛光的品质和效率。     

模具的数字化制造技术

在回顾塑性成形与模具技术发展成就的基础上，指出模具工业的重要发展趋势——数字化。提出了模具数字化制造的几项主要支撑技术，即模具数字化设计、加工、分析技术以及模具数字化制造中的资源管理技术，并对这些支撑技术的现状、研究重点以及今后发展方向进行了评述，最后指出应该从战略的高度大力开展模具数字化制造技术的研究开发和加速用数字化制造技术改造传统的模具工业。     

基于制造网格平台的模具制造资源共享机制研究

介绍了制造网格的基本概念，分析了中国模具制造企业制造资源利用现状以及对信息化的需求，提出了基于制造网格平台的模具制造资源共享机制。对中小模具企业里的各种与模具全生命周期有关的资源进行分类、规划和整合，以制造网格为平台构建了制造服务协同制造网络。通过对模具制造资源进行网格化封装，实现了资源的协同共享，为中国模具制造企业实现信息化和网格化制造提供了理论支撑。     

Development and Polishing Process of a Mobile Robot Finishing Large Mold Surface

□ A novel self-determination polishing robot finishing large mold free-form surface is developed, and the finishing process method is researched. Contrary to traditional approaches, our premise is that a large mold surface can be polished by using a small robot. This robot system is mainly composed of a polishing robot part, a computer system and a visual positioning system. A type of robot with four uniform distribution wheels was designed, which has two driving wheels and two driven wheels. Active compliant control of the polishing tool was provided by a pneumatic servo system, and a new special compliant abrasive tool was proposed on the basis of robot characteristics. The process planning steps consisted of subdividing the free-form surface, choosing an abrasive tool, planning the polishing path and optimizing machining parameters. Based on the orthogonal experiment and the grey relational analysis method, the optimal parameter combination was obtained for polishing force, tool speed and feed rate. Aiming to polishing times, the surface roughness method and polishing efficiency method were studied in detail. The polishing experiments were carried out in the robot using process parameters obtained by the efficiency method. These research results provided significant theory foundation and experimental data for a mobile robot planning polishing to realize intelligible process parameter selection.     

Magnetic polishing of three dimensional die and mold surfaces

A new magnetic polishing technology applicable to die and mold manufacturing has been studied using the magnetic polishing tool. The key idea is that magnetic force is used to produce the polishing pressure so that polishing of curved surfaces can be possible without exact control of tool path. This makes the polishing automation of dimensional dies and molds very easy. In this study, experiments have been executed using the magnetic polishing tool and mini CNC milling machine without tool path control. Some mirror-like surfaces have been acquired by two stages of polishing: firstly, wheel type magnetic polishing and, secondly, magnetic abrasive polishing.     

模具敏捷制造技术研究与系统开发

论述了网络化、数字化环境下模具敏捷制造的系统框架与运行机制;开发了模具敏捷制造管理信息系统,基于网络实时采集各种模具生产资源,并对组建虚拟企业的生产资源进行优化配置、对协同工作的生产任务进行规划、对敏捷制造过程进行管理和监控;在已有C3P系统的基础上,通过CAPP、MRPII/ERP等关键系统的开发与系统集成,建立数字化制造系统,支持优化设计、制订生产计划和实施数字化制造;通过敏捷制造管理信息系统和数字化制造系统的有机结合,实现模具敏捷制造,显著提高了大型、复杂模具生产的快速响应速度。     

注塑模具高速切削抛光复合工艺

如今模具的重要性日益凸显,模具质量和制造水平都亟待提高。高速加工技术是先进制造技术的共性基础技术,其插补功能强大、配套完善、控制可靠、可自动换刀,尤其适用于自由曲面的加工。本文从模具材料,模具复杂型面加工,模具制造周期及抛光,高速加工在我国的应用以及国内外的研究进展等方面结合高速加工的特点综合考虑,探讨了高速切削实现注塑模具切削及抛光同机复合工艺的优势和可能性。     

Electrochemical mechanical polishing technology: recent developments and future research and industrial needs

Electrochemical mechanical (ECM) polishing processes are widely used in various industries such as die and mould manufacturing, turbine blades, and components with complex surfaces. They are used to improve the surface quality and get glossy surfaces with enhanced mechanical properties. In this paper, the authors first look into the fundamental principles of the ECM polishing technology. Then the main parameters that affect the ECM polishing process such as applied voltage, electrolyte concentration, rotational speed and polishing pressure are discussed, and the related research issues are raised. Studying these parameters will enhance the performance, increase the efficiency of ECM polishing technology and provide a useful reference for further developments. Up to date, automatic ECM polishing is limited for planarization process and surfaces with simple geometry such as hole-wall and rotary surfaces. In addition, in some of ECM finishing technologies, the limited available working space usually forces the manufacture to machine one part in multiple stages. Because robots have some advantages over conventional machines such as flexibility, low price and mechanical reconfigurability, they are an effective and economical solution for ECM polishing of geometrically complex workpieces. In order to advance the ECM technology for the next competitive stage where a promising quantitative and qualitative processing is required, the authors proposed that the future researches on ECM polishing should also include ECM polishing using robots. In addition, the authors propose several configurations and setups of robotic ECM polishing systems. The research topics in this area should include designing of new ECM polishing tools, investigating the synergistic effects of additional sources of energies such as magnetic field and ultrasonic vibrations besides the normal effect of ECM tools and developing models and control methods of the processes.     

电解磨料喷射复合抛光工艺的研究与应用

研究了电解磨料喷射复合抛光新工艺及抛光特点，并应用于模具抛光。     

光整光饰技术在滚动轴承加工制造中的应用

在总结目前滚动轴承加工制造的终加工工序及光整加工概念的基础上,主要论述了滚动轴承的振动抛光方法及加工机理,以及滚动轴承自修磨技术(ART)的加工机理及应用特点,并进一步提出了光整加工新技术、新工艺,如电化学加工、磁流变抛光、超声波磁流变复合抛光、电泳抛光、磨料流抛光等在滚动轴承加工制造中的应用,以期改变传统滚动轴承的抛光要求,在提高表面光洁度的基础上,进一步提高滚动轴承的几何精度和力学性能。     

Design and fabrication of a novel polishing tool for finishing freeform surfaces in magnetic field assisted finishing (MFAF) process

Surface finish is a critical requirement for different applications in industries and research areas. Freeform surfaces are widely used in medical, aerospace, and automobile sectors. Magnetic field assisted finishing process can be used very efficiently to finish freeform surfaces. In this process, magnetorheological fluid is used as the polishing medium and permanent magnet is used to control its rheological properties to generate finishing force during polishing. To avail sufficient magnetic field in the finishing zone, it is necessary to design an optimum polishing tool. In the present study, a specially designed polishing tool is designed using a finite element based software package (Ansys Maxwell^®) based on Maxwell equations. At first, dimension of the permanent magnet is determined for designing optimum tool geometry. After that, dimension and configuration of the magnet fixture are optimized. A special type of metal named mu-metal which is a nickel-iron based alloy is selected for magnet fixture due to its magnetic-field shielding property. Mu-metal directs the magnetic flux lines in such a way that in the finishing zone the magnetic flux can be concentrated on the workpiece surface required for finishing. Also, the Mu-metal magnet fixture shields the magnetic field from outside environment so that MR fluid as well as any surrounding magnetic materials do not stick to the polishing tool. Experiments are carried out to validate the Maxwell simulation results to compare the magnetic flux distribution on the workpiece surface which shows good agreement between them. Also, finishing of flat titanium workpieces are carried out and it is found that the novel polishing tool has the capability to finish the workpieces in the nanometer range.