面向增材制造的模型重建方法与成型工艺研究
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摘要
随着现代制造业全球化与市场化的发展,能在更短的时间内开发出新产品并推向市场是企业保持竞争力的关键所在。增材制造技术的应用加速了产品的设计开发过程,降低了产品设计验证成本。与传统去除材料的加工方式不同,增材制造是一个分层累积材料的过程,将三维零件降维到二维平面或者一维的点线,消除了复杂形状对加工制造的限制。
从上世纪的八十年代增材制造技术出现开始,目前已经有多种增材制造加工工艺,也有光敏树脂、金属与陶瓷粉末等多种材料可供应用。但其加工精度、表面质量与所得零件的性能与传统的切削加工、铸造锻压成型、注塑成型等工艺还有较大的差距,这些都限制了增材制造的大范围应用。相对于传统的加工技术,增材制造加工零件的单个成本相对较高,不适合大批量零件的制造。针对上述问题,本文从集成数控增材制造工艺与基于掩膜图像投影的增材制造工艺两方面进行了研究,以期提高增材制造的加工质量、扩展其应用范围。主要研究内容与成果如下：
(1)基于双轴旋转微镜的可集成模型数字化技术研究。以实现集成模型三维测量系统的增材制造工艺为目标,以德州仪器的TALPIOOOB双轴旋转微镜镜和摄像机为核心部件,设计了三维激光测量系统。该系统通过控制双轴旋转微镜来控制激光点的移动,实现一次固定,区域测量,可作为集成部件方便的安装到增材制造系统当中,实现对待加工表面的在线测量。测量系统中采用分层离散的定标算法对摄像机和激光位置进行标定,基于双线性插补算法计算图像像素点位置和激光点位置。由双轴旋转微镜与摄像机分别获取经过被测点的两条空间直线,然后通过空间直线的三角化求交来计算测量点位置。通过测量实例,分析了测量误差产生的原因及提高措施。
(2)基于代数点集曲面APSS与多层深度法矢图像LDNIs的模型重建算法研究。采用代数点集曲面APSS拟合测量点集,进行去噪平滑,然后通过投影运算将APSS曲面转化为LDNIs表达的实体模型,进而采用轮廓线算法生成三角网格曲面,实现模型的重建。
(3)研究了集成数控增材制造系统。针对传统分层增材制造工艺所得零件在不同方向上物理性能不一致的问题,开发基于数控技术的无分层增材制造工艺CNCA。将所开发的三维测量系统与模型重建算法集成到该工艺当中,实现对待加工表面的在线测量与模型重建。结合基于多层深度法矢图像的布尔运算与偏置运算,实现激光头的路径规划,输入数字控制系统,实现在给定曲面上的固化加工
(4)基于MIP-SLA的大面积微细加工制造工艺研究。对基于DLP投影机的MIP-SLA(?)曾材制造工艺的加工原理、工艺流程及系统组成进行了研究,重点研究了基于约束液面的MIP-SLA增材制造工艺。设计开发了基于MIP-SLA的大面积微细制造工艺系统,研究了制造系统的图像生成与工艺规划。基于商业投影机,重构光学系统实现掩膜图像在微小区域内的聚焦,通过对光路与加工基座在平面内的扩展,实现大面积微细零件的制造。
(5)基于LDNIs的掩膜图像切片生成算法研究。提出了基于LDNIs模型的掩膜图像生成算法,该算法首先对实体模型进行采样离散生LDNIs模型,然后采用离散的一维布尔运算代替传统的轮廓求交运算得出二维的掩膜图像。该算法在处理复杂模型与小层厚图像生成时与基于轮廓的算法有更高的运算效率。研究DLP投影机的标定算法,提出采用分层离散的方式对其进行空间定标。并根据定标数据实现了投影图像的反算。在基于MIP-SLA工艺的光滑表面制造系统中，应用空间投影图像反算算法生成该工艺中的二次投影图像。
(6) MIP-SLA原型机系统设计。设计搭建了大面积微细制造工艺的硬件系统,对微细加工的曝光时间、加工分辨率等因素进行了研究。基于EtherMAC运动控制系统及WindowsCE (?)沃入式操作系统开发了约束液面式MIP-SLA原型机系统。开发了了基于PC的掩膜图像切片软件与基于WindowsCE嵌入式系统的控制软件,并设计了分离拉力的在线测量系统。通过实验验证了掩膜图像切片算法的正确性,测定了系统的加工精度、加工效率以及加工过程中分离拉力随加工面积的变化趋势。
论文对面向增材制造的模型数字化技术与模型重建方法的研究,实现了集成的数控增材制造系统。该系统创新性地提出了无分层的制造方式,解决了分层制造工艺所加工零件在各个方向物理性能不一致的问题。基于多层深度法矢图像的掩膜图像生成算法与传统的基于轮廓的算法相比,在处理复杂模型方面具有更高的计算效率。所设计的大面积微细制造工艺系统克服了MIP-SLA工艺加工分辨率与加工面积之间的矛盾,可实现高分辨大面积零件的制造,对扩展MIP-SLA工艺的应用范围,提高零件的加工精度有重要的意义。
With the globalization and marketization of the modern manufacturing industry, to develop a new product in a shorter time and put it on the market is more and more important for a company, which can help them keep competitive strength. Application of additive manufacturing technology for product design can shorter the developing period and lower the verification cost. Different from the traditional process of removing material, additive manufacturing is a process of adding materials. By change the three dimensional model into two dimensional plane or points and lines, there is no restrictions for building complicated parts.
From the invention of additive manufacturing process in later last80s, there have been lots kinds of fabrication technologies, with many kinds of materials, like photosensitive resin, metal and ceramic powder, etc. But there is still a big gap between the additive manufacturing process and traditional processes on the fabrication accuracy, surface quality, and the physical properties of the built parts. Also, compared with the traditional methods, it's much more expensive for the additive manufacturing process to fabricate one part, resulting to its improper usage for mass production. Based on these problems, the topic of this thesis is research on integrated computer numerical control accumulation process and mask image projection stereolithography apparatus based additive manufacturing process, aiming for improving the part quality and extending the using area of additive manufacturing process. The main contents and results are as follows:
(1) Research on the modeling digitalizing method based on two-axis rotation micro-mirror. For the purpose of setting up an additive manufacturing system integrated with three dimensional scanning system, a three dimensional scanning system is developed based on the TALP1000b two-axis rotation micro-mirror form Texas Instruments and a simple web camera. By control the movement of the laser dot by the rotation mirror, a rectangle area can be scanned one time. So it can be easily integrated into the additive manufacturing system and measure the surface of the part to be built on immediately. A layered based discrete method was used for the camera calibration and laser position calibration. By using the bi-linear interpolation algorithm, the world coordinates of the pixels in the captured images and the world coordinates of the laser dots from the rotation mirror can be computed, which defines two spatial lines both passing through the scanned points. Then by calculating the intersection between these two lines, we can get the world coordinates of the scanned point. By doing some experiments, the reasons of the measured errors are analyzed and the improvement methods are proposed.
(2) Research on the model reconstruction algorithm based on algebraic point set surface (APSS) and layered depth normal images (LDNls). First, by fitting the scanned points into APSS surface, the noisy points can be removed and smoothed. Then, by using the projecting operation, convert the APSS surface into LDNIs models, which can be converted into mesh based surface by contouring algorithm and finishing the model reconstruction process.
(3) Research on the integrated computer numerical control accumulation manufacturing system. There is much non-uniformity of their physical properties between different directions in the parts built by layered fabrication processes. To solve this problem, a new non-layered additive manufacturing process based on computer numerical control system was developed. By integrating the designed three dimensional scanning system and the model reconstruction algorithm into this process, it can get the model of the unknown surface online. Together with the Boolean and offsetting computation based on layered depth normal images, the tool path of the laser can be generated. With the computer numerical control system, it can build parts on the given surface.
(4) Research on large-area and micro-structure fabrication system based on mask image projection stereolithography apparatus. Some research job was done on the principle of MIP-SLA based additive manufacturing process, its building steps and system structure, especially the bottom-up projection based MIP-SLA process. A new system for large-area and micro-structure fabrication was designed, with its mask image generation and building process planning. In the system, a commercial projector was used, and the optical system was rebuilt to make the image focused in a very small area. By extending the optical path and building base in the X and Y directions, parts of large area with micro-structures can be built.
(5) Research on mask image generation algorithm based on LDNIs. A new algorithm of mask image generation based on LDNIs was proposed. First, the LDNIs models are generated by discrete sampling of a solid model, and then use one dimensional Boolean operation instead of contouring intersecting to generate the mask image. This algorithm is much more efficient in processing complicated models with small layer thickness than the contour intersection based algorithm. A DLP based projector was spatially calibrated by layered database, which can be used for the mask image compensation and reverse computation. A new smooth surface fabrication process was introduced, which uses the mask image reverse computation algorithm to generate the second exposure images.
(6) Design of MIP-SLA prototyping systems. A new prototyping system for large-area and micro-structure fabrication was built, and the curing time, building resolution of the micro fabrication system was tested by doing some experiments. Also a bottom-up projection based MIP-SLA prototyping system was developed using the EtherMAC motion control system and Windows CE embedded system, which contains an online measuring system of the peeling force during the building process. Some experiments were made to verify the accuracy, the curing time of the system. Also the relationship between the peeling force and the area of the part is established by the online force measuring system.
In this thesis, an integrated computer numerical control accumulation system was developed with the research on three dimensional model digitalizing technology and the model reconstruction algorithm. This system can be used for fabricating parts without layers, which is helpful in improving the physical properties of the part in different directions. The proposed mask image generation algorithm based on LDNIs is much more efficient in the slicing operation of complicated models than the traditional algorithm based on contouring method. The designed large-area and micro-structure fabrication system overcomes the contradictions between the building resolution and building area by MIP-SLA process, which can build large-area parts with micro-structures on them. This ability is significant for extending the usage of MIP-SLA process and improving the accuracy of its fabricated parts.
从上世纪的八十年代增材制造技术出现开始,目前已经有多种增材制造加工工艺,也有光敏树脂、金属与陶瓷粉末等多种材料可供应用。但其加工精度、表面质量与所得零件的性能与传统的切削加工、铸造锻压成型、注塑成型等工艺还有较大的差距,这些都限制了增材制造的大范围应用。相对于传统的加工技术,增材制造加工零件的单个成本相对较高,不适合大批量零件的制造。针对上述问题,本文从集成数控增材制造工艺与基于掩膜图像投影的增材制造工艺两方面进行了研究,以期提高增材制造的加工质量、扩展其应用范围。主要研究内容与成果如下：
(1)基于双轴旋转微镜的可集成模型数字化技术研究。以实现集成模型三维测量系统的增材制造工艺为目标,以德州仪器的TALPIOOOB双轴旋转微镜镜和摄像机为核心部件,设计了三维激光测量系统。该系统通过控制双轴旋转微镜来控制激光点的移动,实现一次固定,区域测量,可作为集成部件方便的安装到增材制造系统当中,实现对待加工表面的在线测量。测量系统中采用分层离散的定标算法对摄像机和激光位置进行标定,基于双线性插补算法计算图像像素点位置和激光点位置。由双轴旋转微镜与摄像机分别获取经过被测点的两条空间直线,然后通过空间直线的三角化求交来计算测量点位置。通过测量实例,分析了测量误差产生的原因及提高措施。
(2)基于代数点集曲面APSS与多层深度法矢图像LDNIs的模型重建算法研究。采用代数点集曲面APSS拟合测量点集,进行去噪平滑,然后通过投影运算将APSS曲面转化为LDNIs表达的实体模型,进而采用轮廓线算法生成三角网格曲面,实现模型的重建。
(3)研究了集成数控增材制造系统。针对传统分层增材制造工艺所得零件在不同方向上物理性能不一致的问题,开发基于数控技术的无分层增材制造工艺CNCA。将所开发的三维测量系统与模型重建算法集成到该工艺当中,实现对待加工表面的在线测量与模型重建。结合基于多层深度法矢图像的布尔运算与偏置运算,实现激光头的路径规划,输入数字控制系统,实现在给定曲面上的固化加工
(4)基于MIP-SLA的大面积微细加工制造工艺研究。对基于DLP投影机的MIP-SLA(?)曾材制造工艺的加工原理、工艺流程及系统组成进行了研究,重点研究了基于约束液面的MIP-SLA增材制造工艺。设计开发了基于MIP-SLA的大面积微细制造工艺系统,研究了制造系统的图像生成与工艺规划。基于商业投影机,重构光学系统实现掩膜图像在微小区域内的聚焦,通过对光路与加工基座在平面内的扩展,实现大面积微细零件的制造。
(5)基于LDNIs的掩膜图像切片生成算法研究。提出了基于LDNIs模型的掩膜图像生成算法,该算法首先对实体模型进行采样离散生LDNIs模型,然后采用离散的一维布尔运算代替传统的轮廓求交运算得出二维的掩膜图像。该算法在处理复杂模型与小层厚图像生成时与基于轮廓的算法有更高的运算效率。研究DLP投影机的标定算法,提出采用分层离散的方式对其进行空间定标。并根据定标数据实现了投影图像的反算。在基于MIP-SLA工艺的光滑表面制造系统中，应用空间投影图像反算算法生成该工艺中的二次投影图像。
(6) MIP-SLA原型机系统设计。设计搭建了大面积微细制造工艺的硬件系统,对微细加工的曝光时间、加工分辨率等因素进行了研究。基于EtherMAC运动控制系统及WindowsCE (?)沃入式操作系统开发了约束液面式MIP-SLA原型机系统。开发了了基于PC的掩膜图像切片软件与基于WindowsCE嵌入式系统的控制软件,并设计了分离拉力的在线测量系统。通过实验验证了掩膜图像切片算法的正确性,测定了系统的加工精度、加工效率以及加工过程中分离拉力随加工面积的变化趋势。
论文对面向增材制造的模型数字化技术与模型重建方法的研究,实现了集成的数控增材制造系统。该系统创新性地提出了无分层的制造方式,解决了分层制造工艺所加工零件在各个方向物理性能不一致的问题。基于多层深度法矢图像的掩膜图像生成算法与传统的基于轮廓的算法相比,在处理复杂模型方面具有更高的计算效率。所设计的大面积微细制造工艺系统克服了MIP-SLA工艺加工分辨率与加工面积之间的矛盾,可实现高分辨大面积零件的制造,对扩展MIP-SLA工艺的应用范围,提高零件的加工精度有重要的意义。
With the globalization and marketization of the modern manufacturing industry, to develop a new product in a shorter time and put it on the market is more and more important for a company, which can help them keep competitive strength. Application of additive manufacturing technology for product design can shorter the developing period and lower the verification cost. Different from the traditional process of removing material, additive manufacturing is a process of adding materials. By change the three dimensional model into two dimensional plane or points and lines, there is no restrictions for building complicated parts.
From the invention of additive manufacturing process in later last80s, there have been lots kinds of fabrication technologies, with many kinds of materials, like photosensitive resin, metal and ceramic powder, etc. But there is still a big gap between the additive manufacturing process and traditional processes on the fabrication accuracy, surface quality, and the physical properties of the built parts. Also, compared with the traditional methods, it's much more expensive for the additive manufacturing process to fabricate one part, resulting to its improper usage for mass production. Based on these problems, the topic of this thesis is research on integrated computer numerical control accumulation process and mask image projection stereolithography apparatus based additive manufacturing process, aiming for improving the part quality and extending the using area of additive manufacturing process. The main contents and results are as follows:
(1) Research on the modeling digitalizing method based on two-axis rotation micro-mirror. For the purpose of setting up an additive manufacturing system integrated with three dimensional scanning system, a three dimensional scanning system is developed based on the TALP1000b two-axis rotation micro-mirror form Texas Instruments and a simple web camera. By control the movement of the laser dot by the rotation mirror, a rectangle area can be scanned one time. So it can be easily integrated into the additive manufacturing system and measure the surface of the part to be built on immediately. A layered based discrete method was used for the camera calibration and laser position calibration. By using the bi-linear interpolation algorithm, the world coordinates of the pixels in the captured images and the world coordinates of the laser dots from the rotation mirror can be computed, which defines two spatial lines both passing through the scanned points. Then by calculating the intersection between these two lines, we can get the world coordinates of the scanned point. By doing some experiments, the reasons of the measured errors are analyzed and the improvement methods are proposed.
(2) Research on the model reconstruction algorithm based on algebraic point set surface (APSS) and layered depth normal images (LDNls). First, by fitting the scanned points into APSS surface, the noisy points can be removed and smoothed. Then, by using the projecting operation, convert the APSS surface into LDNIs models, which can be converted into mesh based surface by contouring algorithm and finishing the model reconstruction process.
(3) Research on the integrated computer numerical control accumulation manufacturing system. There is much non-uniformity of their physical properties between different directions in the parts built by layered fabrication processes. To solve this problem, a new non-layered additive manufacturing process based on computer numerical control system was developed. By integrating the designed three dimensional scanning system and the model reconstruction algorithm into this process, it can get the model of the unknown surface online. Together with the Boolean and offsetting computation based on layered depth normal images, the tool path of the laser can be generated. With the computer numerical control system, it can build parts on the given surface.
(4) Research on large-area and micro-structure fabrication system based on mask image projection stereolithography apparatus. Some research job was done on the principle of MIP-SLA based additive manufacturing process, its building steps and system structure, especially the bottom-up projection based MIP-SLA process. A new system for large-area and micro-structure fabrication was designed, with its mask image generation and building process planning. In the system, a commercial projector was used, and the optical system was rebuilt to make the image focused in a very small area. By extending the optical path and building base in the X and Y directions, parts of large area with micro-structures can be built.
(5) Research on mask image generation algorithm based on LDNIs. A new algorithm of mask image generation based on LDNIs was proposed. First, the LDNIs models are generated by discrete sampling of a solid model, and then use one dimensional Boolean operation instead of contouring intersecting to generate the mask image. This algorithm is much more efficient in processing complicated models with small layer thickness than the contour intersection based algorithm. A DLP based projector was spatially calibrated by layered database, which can be used for the mask image compensation and reverse computation. A new smooth surface fabrication process was introduced, which uses the mask image reverse computation algorithm to generate the second exposure images.
(6) Design of MIP-SLA prototyping systems. A new prototyping system for large-area and micro-structure fabrication was built, and the curing time, building resolution of the micro fabrication system was tested by doing some experiments. Also a bottom-up projection based MIP-SLA prototyping system was developed using the EtherMAC motion control system and Windows CE embedded system, which contains an online measuring system of the peeling force during the building process. Some experiments were made to verify the accuracy, the curing time of the system. Also the relationship between the peeling force and the area of the part is established by the online force measuring system.
In this thesis, an integrated computer numerical control accumulation system was developed with the research on three dimensional model digitalizing technology and the model reconstruction algorithm. This system can be used for fabricating parts without layers, which is helpful in improving the physical properties of the part in different directions. The proposed mask image generation algorithm based on LDNIs is much more efficient in the slicing operation of complicated models than the traditional algorithm based on contouring method. The designed large-area and micro-structure fabrication system overcomes the contradictions between the building resolution and building area by MIP-SLA process, which can build large-area parts with micro-structures on them. This ability is significant for extending the usage of MIP-SLA process and improving the accuracy of its fabricated parts.
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