五轴多工序加工检测夹具下的误差成本优化分析
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摘要
为平衡多工序制造系统中质量与成本的问题,提出一种在机检测夹具间接影响质量与成本的求解方式。在该求解方式中,分析了在机检测夹具变量误差的特点,采用状态空间法建立了误差传递模型;分析了在机检测夹具的成本,采用显著性检验的方法建立了检测成本模型,并将检测成本融入包含公差成本和质量损失成本的成本模型中。在此基础上,提出以成本模型为目标函数、误差传递模型为约束条件的优化函数,找出零件满足质量的最优成本。以两类零件加工的质量成本为例,验证了在机检测夹具方式的有效性。
To balance the problems of quality and cost in a multi-process manufacturing system,the solution of online test fixture which had affected the quality and cost indirectly was proposed.In this solution method,the characteristics of error in the testing fixture were analyzed,and the error transfer model was established with the state space method.The cost of on-machine testing fixture was analyzed,the testing cost model was established by significance test method,and the testing cost was integrated into the cost model including the tolerance cost and the quality loss cost.On this basis,the optimization function which took the cost model as the objective function and the error transfer model as the constraint condition was proposed,and the optimal cost for the part to meet the quality was found out.By taking the quality cost of two kinds of parts processing as an example,the validity of on-machine testing fixture was verified.
To balance the problems of quality and cost in a multi-process manufacturing system,the solution of online test fixture which had affected the quality and cost indirectly was proposed.In this solution method,the characteristics of error in the testing fixture were analyzed,and the error transfer model was established with the state space method.The cost of on-machine testing fixture was analyzed,the testing cost model was established by significance test method,and the testing cost was integrated into the cost model including the tolerance cost and the quality loss cost.On this basis,the optimization function which took the cost model as the objective function and the error transfer model as the constraint condition was proposed,and the optimal cost for the part to meet the quality was found out.By taking the quality cost of two kinds of parts processing as an example,the validity of on-machine testing fixture was verified.
引文
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[19] LIU D,JIAN P.Modelling of machining error flow based on form features for multistage processes[J].International Journal of Computer Integrated Manufacturing,2009,22(9),857-876.
[20] ABELLAN-NEBOT J V,LIU J,SUBIRON F R,et al.State space modeling of variation propagation in multistation machining processes considering machining-induced variations[J].Journal of Manufacturing Science&Engineering,2012,134(2):02100201-021002-13.
[21] NEBOT A,VICENTE J.Prediction and improvement of part quality in multi-station machining systems applying the stream of variation model[D].Castelln,Valencian,Spain:Universitat Jaume I,2011.
[2] LIU N B,LI G Y,WU L H,et al.Research on the variation propagation model for complex mechanical product processing[J].Procedia CIRP,2015,27:270-275.
[3] YU Luyun,JIAO Li,WANG Xibin,et al.Modeling and analysis for multi-stage manufacturing error of meso-scale parts based on size effect[J].Computer Integrated Manufacturing Systems,2015,21(4):971-980(in Chinese).[余璐云,焦黎,王西彬,等.基于尺度效应的介观尺度零件多工位制造误差建模与分析[J].计算机集成制造系统,2015,21(4):971-980.]
[4] ZHU L M,HE G Y,SONG Z J.Improved quality prediction model for multistage machining process based on geometric constraint equation[J].Chinese Journal of Mechanical Engineering,2016,29(2):430-438.
[5] CHEN Bing,LI Shan,WU Baohai,et al.Multistage manufacturing quality analysis and forecasting on dimension association and partial least square regression[J].Computer Integrated Manufacturing Systems,2009,15(2):390-399(in Chinese).[陈冰,李山,吴宝海,等.基于尺寸关联和偏最小二乘回归的多工序质量分析与预测[J].计算机集成制造系统,2009,15(2):390-399.]
[6] DU Shichang,WANG Meng,XI Lifeng.Modeling of dimensional errors propagation in multi-stage machining system[J].Journal of Mechanical Engineering,2011,47(16):143-149(in Chinese).[杜世昌,王猛,奚立峰.多工序加工系统产品尺寸误差传递建模[J].机械工程学报,2011,47(16):143-149.]
[7] JIA Feng,JIANG Pingyu,LIU Daoyu,et al.Error propagation control method for multistage bathes machining processes of blades[J].Computer Integrated Manufacturing Systems,2012,18(1):76-86(in Chinese).[贾峰,江平宇,刘道玉,等.叶片批量加工过程的误差传递控制方法[J].计算机集成制造系统,2012,18(1):76-86.]
[8] DIAO G Z,ZHAO L P,YAO Y Y.A weighted-coupled network-based quality control method for improving key features in product manufacturing process[J].Journal of Intelligent Manufacturing,2016,27(3):535-548.
[9] ZHANG J,LI S P,BAO N S A,et al.Robust design approach to determination of tolerances of mechanical products[J].CIRP Annals-Manufacturing Technology,2010,59(1):195-198.
[10] ZONG Yi,MAO Jian.Tolerance optimization design based on the manufacturing-costs of assembly quality[C]//Proceedings of the 13th CIRP Conference on Computer Aided Tolerancing. Amsterdam, the Netherlands:Elsevier,2015:324-329.
[11] SANZ-LOBERA,EMILIO GOMEZ,JESUS PEREZ,et al.A proposal of cost-tolerance models directly collected from the manufacturing process[J].International Journal of Production Research,2016,54(15):4584-4598.
[12] YANN L,DENIS T,PATRICK S.Global optimisation of functional requirements and tolerance allocations based on designer preference modelling[J].Journal of engineering design,2016,27(9):591-612.
[13] RENISHAW.SPRINT on-machine contact scanning system[EB/OL].(2014-07-07)[2016-03-20].http://www.renishaw.com/en/sprint-on-machine-contact-scanning-system-20908.
[14] HUANG N D,BI Q Z,WANG Y H et al.5-Axis adaptive flank milling of flexible thin-walled parts based on the on-machine measurement[J].International Journal of Machine Tools and Manufacture,2014,84(6):1-8.
[15] GIOVANNI M,STEFANO P,TULLIO T.Early cost estimation for tolerance verification[J].CIRP Annals Manufacturing Technology,2011,60(1):195-198.
[16] GIOVANNI M,STEFANO P.Inspection strategies and multiple geometric tolerances[C]//Proceedings of the 12th CIRP Conference on Computer Aided Tolerancing.Amsterdam,the Netherlands:Elsevier,2013:54-60.
[17] GIOVANNI M,STEFANO P.Optimal inspection strategy planning for geometric tolerance verification[J].Precision Engineering,2014,38(1),71-81.
[18] ZHANG Weimin,LI Guowei,CHEN Can.Optimal allcocation of tolerance based on jacobian-torsor theory[J].Transactions of the Chinese Society for Agricultural Machinery,2011,42(4):216-219(in Chinese).[张为民,李国伟,陈灿.基于雅可比旋量理论的公差优化分配[J].农业机械学报,2011,42(4):216-219.]
[19] LIU D,JIAN P.Modelling of machining error flow based on form features for multistage processes[J].International Journal of Computer Integrated Manufacturing,2009,22(9),857-876.
[20] ABELLAN-NEBOT J V,LIU J,SUBIRON F R,et al.State space modeling of variation propagation in multistation machining processes considering machining-induced variations[J].Journal of Manufacturing Science&Engineering,2012,134(2):02100201-021002-13.
[21] NEBOT A,VICENTE J.Prediction and improvement of part quality in multi-station machining systems applying the stream of variation model[D].Castelln,Valencian,Spain:Universitat Jaume I,2011.