复合材料构件数字化制造若干支撑技术研究
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摘要
复合材料构件以其高比强度、高比模量、可设计性、耐热、耐腐蚀、耐疲劳、隐身性好等独特性能而日益受到各行各业的高度重视,并在汽车、兵器、电子、航空航天等领域得到越来越广泛应用。复合材料的研究水平和应用程度是一个国家科技发展水平的重要体现,尤其在航空工业,各种先进的飞机无不与先进的复合材料技术紧密联系在一起。
为满足日益提高的飞机复合材料构件生产制造的要求,迫切需要全面应用数字化技术,改造现有的生产制造方式和流程,逐步实现复合材料构件设计、制造的数字化和一体化。本文围绕复合材料构件数字化制造的具体需求,研究数字化制造过程中的若干关键支撑技术,包括复合材料构件铺层曲面的展开预处理、复合材料构件铺层曲面的优化展开、复合材料构件模具材料的智能选择以及复合材料构件工装零组件的快速装配等,所取得的主要成果如下:
针对复合材料构件铺叠成型中预浸料的铺层展开需要,研究了曲面三角化、区域划分、剪口等曲面展开预处理技术。提出了一种基于离散高斯曲率的曲面区域划分方法,可有效实现用于铺层曲面展开的曲面区域划分。研究并实现了曲面自适应曲面剪口算法,该算法将曲面上高斯曲率大于用户所给阈值的点作为剪口起始点,再利用最短路径生成算法生成剪口路径,该算法可实现全封闭、单边界、双边界、多边界等类型曲面的自适应剪口。根据复合材料构件铺层曲面展开的实际需求,本文还提出了一种交互式曲面剪口算法,根据用户指定的剪口路径关键点,算法可生成符合用户需求的剪口路径。为了提高材料的下料效率和利用率,简化后续的排样工作,进一步提出了一种剪口路径优化算法,可有效消除锯齿状的剪口路径,实现剪口路径的平直化。
提出了一种以中心三角片为基三角片的“涟漪式”曲面展开方法,该方法能快速获得曲面的初始展开,有效减少累积误差。在获得曲面初始展开的基础上,提出了一种改进的基于弹簧-质点模型的曲面优化展开算法,算法的改进主要体现在以下几个方面:自适应时间步长的应用提高了算法的速度和稳定性;通过对模型中各质点惩罚力的计算,实现了翻转三角片的整体调整;算法还综合利用初速度和忽略初速度两种方法所具有的优点,使得展开过程中翻转三角片的快速调整、迭代的快速收敛等关键问题得到了较为圆满的解决。该算法能够快速获得网格数量较大的复杂曲面的优化展开,有效消除初始展开及优化过程中出现的翻转三角片,提高了复杂铺层曲面的展开质量。
提出了一种基于网格边的复杂曲面优化展开的新方法。该方法以曲面三角网格中各网格边长为优化变量,以展开前后网格边长误差最小为优化目标,以网格中各内部点均可展为约束条件,并采用牛顿法和矩阵分块等方法对该优化问题进行求解,构造出与原始曲面网格边长误差最小的可展曲面,并对构造出的可展曲面用“涟漪式”展开方法进行展开,从而实现复杂曲面的优化展开。该方法具有稳定、收敛速度快、展开精度高、展开操作简单等优点,可应用于网格数量较小的复杂铺层曲面的优化展开。
设计复合材料构件铺叠成型模具时,模具材料的选择至关重要。在分析研究复合材料构件模具材料选择的知识和经验的基础上,本文提出了一种模具材料选择模糊决策方法,该方法运用加权多因素模糊模式识别技术,同时结合基于规则的推理(RBR)技术和权重动态调整技术,实现了具有一定自适应功能的复合材料构件模具材料的模糊决策。
针对复合材料构件工装快速装配的要求,提出了“批装配”的概念,解决了“批装配”实现过程中装配特征的定义、零件实例化、实时预览等关键技术,实现了螺栓联接、螺钉联接、销联接等零组件的快速装配设计,大大减轻了设计人员的装配设计工作,提高了装配设计的效率。在对当前典型工装组件库中的实体模型、零组件参数表、组件的预览方法、组件实例化方法等进行分析研究的基础上,提出了组件库建库工具的总体框架,并在CATIA上开发了该组件建库工具,实现了组件的建立、查询、预览、调用以及主要参数的显示等功能。
Composite components have many inimitable performances such as high specific strength, high specific stiffness, designable, heat-resistant, corrosion-resistant, fatigue resistant and good stealthy, so they are being given more and more attention in many fields and being applied more and more widely in many domains including automobile, weapon, electron, aviation, space and so on. To some degree, the research level and application level of composite material reflect the science and technology developing level of a country. Especially in aviation industry, almost every advanced aircraft is closely related to sophisticated material technologies.
To meet the improving manufacturing requirement of composite components on aircrafts, it is urgent to apply digital technologies and improve the current manufacturing mode and manufacturing process. Digitalization and integration of designing and manufacturing of composite components should be realized gradually. Centring on digital manufacturing of composite components, this thesis dedicated its research to several support technologies in digital manufacturing of composite components. Support technologies studied in this thesis include pretreatment processing of curved surface flattening, optimal flattening of complex ply surfaces on composite components, intelligent decision-making for composite component mold material, rapid assembly designing for parts and components of composite components tools, and so on. The main contents and contributions of the thesis are as follows:
Aiming at the demands of ply surface flattening of prepreg in ply forming of composite components, some pretreatment methods of surface flattening such as triangulating, dividing, and cutting are studied. A method of surface dividing based on mesh discrete Gaussian curvatures is given. By the method, effect surface dividing results for ply surface flattening can be obtained. An adaptive method of creating cutting path is studied and realized, it takes those points whose Gaussian curvature is larger than the given threshold as start points on cutting paths and the whole cutting paths can be acquired with the shortest path generating algorithm. The adaptive method can accomplish cutting tasks on closed surfaces, one boundary surfaces, two boundaries surfaces, and multi-boundaries surfaces. To meet the requirements of flattening ply surfaces on composite components, an interactive cutting method is also given. By some key path points appointed interactively by users, it can create cutting path according to the user’s demands. For improving material utilization ratio and cutting efficiency, and simplifying the subsequent packing work, a cutting path optimization algorithm is further brought forward, and it can effectively eliminate the jagged cutting paths and make the cutting paths straight and smooth.
A ripple-style flattening method which uses the center-triangle as the base triangle is presented. By the method, an initial flattening with less cumulative error can be rapidly obtained. Based on the initial flattening results, an improved algorithm for surface optimal flattening based on spring-mass model is put forward. The main improvements of the algorithm are as follows: firstly, adaptive time-step improves the speed and stability of current algorithm; secondly, each overlapping region can be integrally adjusted through calculating the penalty forces of each mass in the model; lastly, both with and without the initial velocity being taken into account, the algorithm combines the advantages of the two cases, thus some key problems such as rapid adjusting overlapping region during optimal flattening processing and rapid convergence of optimal iteration can be solved satisfactorily. Using above algorithm, optimal flattenging results of complex ply surfaces with mass triangular grids can be rapidly attained and overlapping triangles brought by initial flattening and optimization process can be effectively eliminated, thus the quality of complex ply surfaces flattening is enhanced.
A novel Edge-based Flattening is presented for optimally flatteing complex surface. In the optimal flattening model, length of each mesh edge is selected as optimization variables, and the error of edge-lengths between the original mesh and the flattened mesh is selected as objective function, and each internal point of the mesh being developable is selected as optimization constrain. By Newton’s Method and matrix blocking technologies, the optimization problem can be solved effectively, and a developable surface which has the minimum edge-length error can be constructed. The ripple-style flattening method can be used to flatten the developable surface, thus the optimal flattening result of the original surface is obtained. Through above method, all kinds of complex ply surfaces with small quantity of triangular grids can be flattened stably, quickly and accurately, and the flattening operation can be finished more simply.
The selection of materials for ply molds is very important during designing of ply molds. Based on the study of the knowledge and experience of composite components mold materials, a fuzzy decision-making method for selecting composite component mold materials is presented. Using technologies of fuzzy pattern recognition with weights, technologies of RBR and technologies of dynamic adjusting weights, the method has possessed some self adapting abilities. The decision-making method can commendably provide rapid and intelligent decision-making for mold materials of composite component.
Aiming at the demands of rapid assembly design for parts and components of tools for composite components, the concept of Batch-Assembly is put forward, and several key technologies related to Batch-Assembly, such as the definition of assembly features, instantiation of parts and components and real time preview, are resolved. The rapid assembly design for bolt connection, screw connection, pin connection, and so on, is implemented by Batch-Assembly. It improves the efficiency of assembly design and lightens the labor of assembly designing considerably. Based on the analysis and research of entity-modelings in current component library of tools, parametric tables of parts and components, the method of component preview, and the method of component instantiation, a general frame for constructing component library is put forward, and tools for establishing the library, including querying components in the library, calling components from the library, previewing components, and showing main parameters of components, are designed and developed based on CATIA.
为满足日益提高的飞机复合材料构件生产制造的要求,迫切需要全面应用数字化技术,改造现有的生产制造方式和流程,逐步实现复合材料构件设计、制造的数字化和一体化。本文围绕复合材料构件数字化制造的具体需求,研究数字化制造过程中的若干关键支撑技术,包括复合材料构件铺层曲面的展开预处理、复合材料构件铺层曲面的优化展开、复合材料构件模具材料的智能选择以及复合材料构件工装零组件的快速装配等,所取得的主要成果如下:
针对复合材料构件铺叠成型中预浸料的铺层展开需要,研究了曲面三角化、区域划分、剪口等曲面展开预处理技术。提出了一种基于离散高斯曲率的曲面区域划分方法,可有效实现用于铺层曲面展开的曲面区域划分。研究并实现了曲面自适应曲面剪口算法,该算法将曲面上高斯曲率大于用户所给阈值的点作为剪口起始点,再利用最短路径生成算法生成剪口路径,该算法可实现全封闭、单边界、双边界、多边界等类型曲面的自适应剪口。根据复合材料构件铺层曲面展开的实际需求,本文还提出了一种交互式曲面剪口算法,根据用户指定的剪口路径关键点,算法可生成符合用户需求的剪口路径。为了提高材料的下料效率和利用率,简化后续的排样工作,进一步提出了一种剪口路径优化算法,可有效消除锯齿状的剪口路径,实现剪口路径的平直化。
提出了一种以中心三角片为基三角片的“涟漪式”曲面展开方法,该方法能快速获得曲面的初始展开,有效减少累积误差。在获得曲面初始展开的基础上,提出了一种改进的基于弹簧-质点模型的曲面优化展开算法,算法的改进主要体现在以下几个方面:自适应时间步长的应用提高了算法的速度和稳定性;通过对模型中各质点惩罚力的计算,实现了翻转三角片的整体调整;算法还综合利用初速度和忽略初速度两种方法所具有的优点,使得展开过程中翻转三角片的快速调整、迭代的快速收敛等关键问题得到了较为圆满的解决。该算法能够快速获得网格数量较大的复杂曲面的优化展开,有效消除初始展开及优化过程中出现的翻转三角片,提高了复杂铺层曲面的展开质量。
提出了一种基于网格边的复杂曲面优化展开的新方法。该方法以曲面三角网格中各网格边长为优化变量,以展开前后网格边长误差最小为优化目标,以网格中各内部点均可展为约束条件,并采用牛顿法和矩阵分块等方法对该优化问题进行求解,构造出与原始曲面网格边长误差最小的可展曲面,并对构造出的可展曲面用“涟漪式”展开方法进行展开,从而实现复杂曲面的优化展开。该方法具有稳定、收敛速度快、展开精度高、展开操作简单等优点,可应用于网格数量较小的复杂铺层曲面的优化展开。
设计复合材料构件铺叠成型模具时,模具材料的选择至关重要。在分析研究复合材料构件模具材料选择的知识和经验的基础上,本文提出了一种模具材料选择模糊决策方法,该方法运用加权多因素模糊模式识别技术,同时结合基于规则的推理(RBR)技术和权重动态调整技术,实现了具有一定自适应功能的复合材料构件模具材料的模糊决策。
针对复合材料构件工装快速装配的要求,提出了“批装配”的概念,解决了“批装配”实现过程中装配特征的定义、零件实例化、实时预览等关键技术,实现了螺栓联接、螺钉联接、销联接等零组件的快速装配设计,大大减轻了设计人员的装配设计工作,提高了装配设计的效率。在对当前典型工装组件库中的实体模型、零组件参数表、组件的预览方法、组件实例化方法等进行分析研究的基础上,提出了组件库建库工具的总体框架,并在CATIA上开发了该组件建库工具,实现了组件的建立、查询、预览、调用以及主要参数的显示等功能。
Composite components have many inimitable performances such as high specific strength, high specific stiffness, designable, heat-resistant, corrosion-resistant, fatigue resistant and good stealthy, so they are being given more and more attention in many fields and being applied more and more widely in many domains including automobile, weapon, electron, aviation, space and so on. To some degree, the research level and application level of composite material reflect the science and technology developing level of a country. Especially in aviation industry, almost every advanced aircraft is closely related to sophisticated material technologies.
To meet the improving manufacturing requirement of composite components on aircrafts, it is urgent to apply digital technologies and improve the current manufacturing mode and manufacturing process. Digitalization and integration of designing and manufacturing of composite components should be realized gradually. Centring on digital manufacturing of composite components, this thesis dedicated its research to several support technologies in digital manufacturing of composite components. Support technologies studied in this thesis include pretreatment processing of curved surface flattening, optimal flattening of complex ply surfaces on composite components, intelligent decision-making for composite component mold material, rapid assembly designing for parts and components of composite components tools, and so on. The main contents and contributions of the thesis are as follows:
Aiming at the demands of ply surface flattening of prepreg in ply forming of composite components, some pretreatment methods of surface flattening such as triangulating, dividing, and cutting are studied. A method of surface dividing based on mesh discrete Gaussian curvatures is given. By the method, effect surface dividing results for ply surface flattening can be obtained. An adaptive method of creating cutting path is studied and realized, it takes those points whose Gaussian curvature is larger than the given threshold as start points on cutting paths and the whole cutting paths can be acquired with the shortest path generating algorithm. The adaptive method can accomplish cutting tasks on closed surfaces, one boundary surfaces, two boundaries surfaces, and multi-boundaries surfaces. To meet the requirements of flattening ply surfaces on composite components, an interactive cutting method is also given. By some key path points appointed interactively by users, it can create cutting path according to the user’s demands. For improving material utilization ratio and cutting efficiency, and simplifying the subsequent packing work, a cutting path optimization algorithm is further brought forward, and it can effectively eliminate the jagged cutting paths and make the cutting paths straight and smooth.
A ripple-style flattening method which uses the center-triangle as the base triangle is presented. By the method, an initial flattening with less cumulative error can be rapidly obtained. Based on the initial flattening results, an improved algorithm for surface optimal flattening based on spring-mass model is put forward. The main improvements of the algorithm are as follows: firstly, adaptive time-step improves the speed and stability of current algorithm; secondly, each overlapping region can be integrally adjusted through calculating the penalty forces of each mass in the model; lastly, both with and without the initial velocity being taken into account, the algorithm combines the advantages of the two cases, thus some key problems such as rapid adjusting overlapping region during optimal flattening processing and rapid convergence of optimal iteration can be solved satisfactorily. Using above algorithm, optimal flattenging results of complex ply surfaces with mass triangular grids can be rapidly attained and overlapping triangles brought by initial flattening and optimization process can be effectively eliminated, thus the quality of complex ply surfaces flattening is enhanced.
A novel Edge-based Flattening is presented for optimally flatteing complex surface. In the optimal flattening model, length of each mesh edge is selected as optimization variables, and the error of edge-lengths between the original mesh and the flattened mesh is selected as objective function, and each internal point of the mesh being developable is selected as optimization constrain. By Newton’s Method and matrix blocking technologies, the optimization problem can be solved effectively, and a developable surface which has the minimum edge-length error can be constructed. The ripple-style flattening method can be used to flatten the developable surface, thus the optimal flattening result of the original surface is obtained. Through above method, all kinds of complex ply surfaces with small quantity of triangular grids can be flattened stably, quickly and accurately, and the flattening operation can be finished more simply.
The selection of materials for ply molds is very important during designing of ply molds. Based on the study of the knowledge and experience of composite components mold materials, a fuzzy decision-making method for selecting composite component mold materials is presented. Using technologies of fuzzy pattern recognition with weights, technologies of RBR and technologies of dynamic adjusting weights, the method has possessed some self adapting abilities. The decision-making method can commendably provide rapid and intelligent decision-making for mold materials of composite component.
Aiming at the demands of rapid assembly design for parts and components of tools for composite components, the concept of Batch-Assembly is put forward, and several key technologies related to Batch-Assembly, such as the definition of assembly features, instantiation of parts and components and real time preview, are resolved. The rapid assembly design for bolt connection, screw connection, pin connection, and so on, is implemented by Batch-Assembly. It improves the efficiency of assembly design and lightens the labor of assembly designing considerably. Based on the analysis and research of entity-modelings in current component library of tools, parametric tables of parts and components, the method of component preview, and the method of component instantiation, a general frame for constructing component library is put forward, and tools for establishing the library, including querying components in the library, calling components from the library, previewing components, and showing main parameters of components, are designed and developed based on CATIA.
引文
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