口腔修复体高效数控加工编程技术研究与实现
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摘要
随着三维测量、离散造型和数控加工技术的发展，CAD/CAM技术在口腔修复领域中得到了广泛的应用。口腔修复体的数控加工技术是口腔修复CAD/CAM技术中的重要组成部分。本文以口腔修复体的高效加工为主线，研究了口腔修复体数控编程中的相关理论、方法和技术。研究的主要内容和创新成果如下：
(1)研究了口腔修复体网格曲面截面线法刀轨生成技术。采用“区域划分”的方法实现了截交线的快速计算，去除了初始刀轨的自交和冗余的刀位点。提出了基于改进截平面法的等残留高度刀轨生成算法：首先根据残留高度计算刀触点轨迹投影线并对其进行修正，然后由修正的刀触点轨迹投影线构造约束曲面，通过约束曲面和网格曲面迭代求交的方法生成等残留高度刀轨。通过实验验证了等残留高度刀轨在保证加工质量的条件下比截平面法刀轨的加工效率提高了约28%。
(2)研究了口腔修复体网格曲面参数线法刀轨生成技术。提出了修复体等参数线刀轨生成算法：根据调和映射理论和参数线规划方式生成了四种类型的等参数线刀轨。提出了修复体参数螺旋刀轨生成算法：首先计算修复体模型在参数网格中的参数环，然后在相邻参数环的参数点之间进行“分组匹配”，依次计算初始和精确的对角参数螺旋线；在此基础上生成了无干涉的参数螺旋刀轨。通过实验验证了参数螺旋刀轨比截平面法刀轨的加工效率提高了约30%，且能够保证较好的加工质量。
(3)研究了口腔修复体基于样条曲线拟合的刀轨优化技术。提出了修复体分段拟合圆弧样条刀轨生成算法：采用分段拟合的方法对初始刀位点进行拟合；通过“偏差映射”的方法对刀位点处的拟合精度进行了修正。提出了修复体IDOM法NURBS刀轨生成算法：改进了DOM算法中的初始特征点选取和新特征点确定方法，并在拟合过程中对特征点参数进行了修正；在此基础上生成了拟合精度较高、控制顶点较少的NURBS切削刀轨，并通过调节过渡刀轨的节点矢量和控制顶点，保证了整条刀轨的连续性。通过实验验证了优化后刀轨比优化前刀轨的加工效率和质量均有所提高，加工效率提高约19%。
(4)研究了口腔修复体基于MMR的五轴加工刀轨生成技术。研究了基于最大材料去除率的无曲率干涉刀具方位角确定方法；提出了修复体MMR平底刀五轴加工刀轨生成算法：采用截平面法计算刀触点轨迹，以最大材料去除率、刀具无干涉为约束条件确定刀具方位角；在此基础上生成了MMR平底刀五轴加工刀轨。通过实验验证了MMR法刀轨比Sturz法刀轨的加工效率提高了约17%，同时加工质量也有所提高。
(5)研究了口腔修复体分段刀轨加减速过渡的进给速度生成技术。提出了基于曲线加减速规划和“向前修正”的刀位点处进给速度过渡处理算法。提出了基于分段刀轨加减速过渡的自适应进给速度生成算法：以刀触点处进给速度和机床的运动特性为约束，对微段刀轨进行分段并规划进给速度；采用S曲线加减速方式对相邻刀轨段的进给速度进行过渡处理，实现了数控编程进给速度的自适应生成。通过实验验证了在保证机床运动平稳的条件下自适应进给速度方法比恒定进给速度方法的加工效率可提高6%~10%。
With development of3D measurement, discrete modeling and NC machining technologies,CAD/CAM technologies are widely applied to dental medical treatment. The NC machiningtechnology of dental restoration is one of the most important parts of Dental CAD/CAM technologies.Aiming at dental restoration high efficiency machining, the relevant theories, methods andtechnologies are researched in this dissertation. The main contents and contributions are as follows:
1. Technologies for section-based tool path generation of dental restoration are researched. Thesection lines are calculated rapidly by the method of model segmentation, then self-intersections andredundant CL points are eliminated. An improved section plane algorithm for constant scallop heighttool path generation is proposed. Cutter contact projected traces are calculated and adjusted accordingto scallop height, and constraint surfaces are constructed by the adjusted projected traces, thenconstant scallop height tool paths are calculated iteratively by intersecting the constraint surfaces withmesh surface. Experimental result indicates that machining efficiency of constant scallop height toolpath is improved by about28%without reducing machining quality, compared with CL section planetool path.
2. Technologies for parameter-based tool path generation of dental restoration are researched.Algorithm for iso-parametric tool path generation is proposed for dental restoration machining. Fourtypes of iso-parametric tool paths are generated according to harmonic map theory and parametricplanning styles. Algorithm for parametric spiral tool path generation is proposed for dental restorationmachining. The parametric loops of dental restoration model are calculated in parametric mesh, thenpoints of adjacent parametric loops are matched group by group, and initial, exact diagonal parametricspiral lines are calculated in sequence. Based on these, free-interference parametric spiral tool pathsare generated. Experimental result indicates that machining efficiency of parametric spiral tool pathsis improved by about30%with better machining quality, compared with CL section plane tool path.
3. Technologies for tool path optimization of dental restoration are researched. Algorithm forarc spline tool path generation based on segment fitting is proposed for dental restoration machining.CL points of line tool paths are fitted into line-arc tool path by segment fitting, and fitting precision ofCL points is revised by method of deviation mapping.Algorithm for NURBS tool path generationbased on IDOM method is proposed for dental restoration machining. DOM fitting is improved byIDOM fitting in aspects of selection of initial dominant points, determination of new dominant points and parameters revision of the dominant points. Based on these, NURBS tool paths, whichposses higher fitting precision and fewer control points, are generated, then transition tool paths areimplemented by NURBS curves, and adjustments of knot vectors and control points are used tokeep the connections of cutting and transition tool paths continuity. Experimental result indicates thatmachining efficiency is improved by about19%after CL section plane tool path is optimized, andmachining quality is also improved.
4. Technologies for5-axis tool path generation based on MMR(Maximal Material Removal rate)of dental restoration are researched. The method of MMR-based cutter orientation anglesdetermination without curvature interference is researched. Algorithm for5-axis tool path generationof MMR with flat-end cutter is proposed. Cutter contact points are calculated by section method, thencutter orientation angles are determined with constraint of MMR and free-interference. According tothese, MMR tool paths with flat-end cutter are generated. Experimental result indicates thatmachining efficiency of MMR tool paths is improved by about17%compared with Sturz tool paths,and machining quality is also improved.
5. Technologies for feed-rates generation based on acceleration and deceleration control ofpiecewise tool paths are proposed for dental restoration machining. Algorithm for feed-rate transitionsof CL points, which is based on curve ADC (Acceleration and Deceleration Control) and adjustingahead, is proposed. Algorithm for adaptive feed-rate generation based on feed-rate transition ofsegment tool paths is proposed. With constraints of kinematic characters and actual cutting speeds,tool path segments of micro segment tool path are obtained, and feed-rates are planned in thesesegments, then feed-rates transition of the segments are processed by the method of S shape curveADC, and adaptive feed-rates generation for dental restoration machining is implemented.Experimental result indicates that machining efficiency of adaptive feed-rates method is improved by6%~10%with smooth movement of machine tool, compared with constant feed-rates method.
(1)研究了口腔修复体网格曲面截面线法刀轨生成技术。采用“区域划分”的方法实现了截交线的快速计算，去除了初始刀轨的自交和冗余的刀位点。提出了基于改进截平面法的等残留高度刀轨生成算法：首先根据残留高度计算刀触点轨迹投影线并对其进行修正，然后由修正的刀触点轨迹投影线构造约束曲面，通过约束曲面和网格曲面迭代求交的方法生成等残留高度刀轨。通过实验验证了等残留高度刀轨在保证加工质量的条件下比截平面法刀轨的加工效率提高了约28%。
(2)研究了口腔修复体网格曲面参数线法刀轨生成技术。提出了修复体等参数线刀轨生成算法：根据调和映射理论和参数线规划方式生成了四种类型的等参数线刀轨。提出了修复体参数螺旋刀轨生成算法：首先计算修复体模型在参数网格中的参数环，然后在相邻参数环的参数点之间进行“分组匹配”，依次计算初始和精确的对角参数螺旋线；在此基础上生成了无干涉的参数螺旋刀轨。通过实验验证了参数螺旋刀轨比截平面法刀轨的加工效率提高了约30%，且能够保证较好的加工质量。
(3)研究了口腔修复体基于样条曲线拟合的刀轨优化技术。提出了修复体分段拟合圆弧样条刀轨生成算法：采用分段拟合的方法对初始刀位点进行拟合；通过“偏差映射”的方法对刀位点处的拟合精度进行了修正。提出了修复体IDOM法NURBS刀轨生成算法：改进了DOM算法中的初始特征点选取和新特征点确定方法，并在拟合过程中对特征点参数进行了修正；在此基础上生成了拟合精度较高、控制顶点较少的NURBS切削刀轨，并通过调节过渡刀轨的节点矢量和控制顶点，保证了整条刀轨的连续性。通过实验验证了优化后刀轨比优化前刀轨的加工效率和质量均有所提高，加工效率提高约19%。
(4)研究了口腔修复体基于MMR的五轴加工刀轨生成技术。研究了基于最大材料去除率的无曲率干涉刀具方位角确定方法；提出了修复体MMR平底刀五轴加工刀轨生成算法：采用截平面法计算刀触点轨迹，以最大材料去除率、刀具无干涉为约束条件确定刀具方位角；在此基础上生成了MMR平底刀五轴加工刀轨。通过实验验证了MMR法刀轨比Sturz法刀轨的加工效率提高了约17%，同时加工质量也有所提高。
(5)研究了口腔修复体分段刀轨加减速过渡的进给速度生成技术。提出了基于曲线加减速规划和“向前修正”的刀位点处进给速度过渡处理算法。提出了基于分段刀轨加减速过渡的自适应进给速度生成算法：以刀触点处进给速度和机床的运动特性为约束，对微段刀轨进行分段并规划进给速度；采用S曲线加减速方式对相邻刀轨段的进给速度进行过渡处理，实现了数控编程进给速度的自适应生成。通过实验验证了在保证机床运动平稳的条件下自适应进给速度方法比恒定进给速度方法的加工效率可提高6%~10%。
With development of3D measurement, discrete modeling and NC machining technologies,CAD/CAM technologies are widely applied to dental medical treatment. The NC machiningtechnology of dental restoration is one of the most important parts of Dental CAD/CAM technologies.Aiming at dental restoration high efficiency machining, the relevant theories, methods andtechnologies are researched in this dissertation. The main contents and contributions are as follows:
1. Technologies for section-based tool path generation of dental restoration are researched. Thesection lines are calculated rapidly by the method of model segmentation, then self-intersections andredundant CL points are eliminated. An improved section plane algorithm for constant scallop heighttool path generation is proposed. Cutter contact projected traces are calculated and adjusted accordingto scallop height, and constraint surfaces are constructed by the adjusted projected traces, thenconstant scallop height tool paths are calculated iteratively by intersecting the constraint surfaces withmesh surface. Experimental result indicates that machining efficiency of constant scallop height toolpath is improved by about28%without reducing machining quality, compared with CL section planetool path.
2. Technologies for parameter-based tool path generation of dental restoration are researched.Algorithm for iso-parametric tool path generation is proposed for dental restoration machining. Fourtypes of iso-parametric tool paths are generated according to harmonic map theory and parametricplanning styles. Algorithm for parametric spiral tool path generation is proposed for dental restorationmachining. The parametric loops of dental restoration model are calculated in parametric mesh, thenpoints of adjacent parametric loops are matched group by group, and initial, exact diagonal parametricspiral lines are calculated in sequence. Based on these, free-interference parametric spiral tool pathsare generated. Experimental result indicates that machining efficiency of parametric spiral tool pathsis improved by about30%with better machining quality, compared with CL section plane tool path.
3. Technologies for tool path optimization of dental restoration are researched. Algorithm forarc spline tool path generation based on segment fitting is proposed for dental restoration machining.CL points of line tool paths are fitted into line-arc tool path by segment fitting, and fitting precision ofCL points is revised by method of deviation mapping.Algorithm for NURBS tool path generationbased on IDOM method is proposed for dental restoration machining. DOM fitting is improved byIDOM fitting in aspects of selection of initial dominant points, determination of new dominant points and parameters revision of the dominant points. Based on these, NURBS tool paths, whichposses higher fitting precision and fewer control points, are generated, then transition tool paths areimplemented by NURBS curves, and adjustments of knot vectors and control points are used tokeep the connections of cutting and transition tool paths continuity. Experimental result indicates thatmachining efficiency is improved by about19%after CL section plane tool path is optimized, andmachining quality is also improved.
4. Technologies for5-axis tool path generation based on MMR(Maximal Material Removal rate)of dental restoration are researched. The method of MMR-based cutter orientation anglesdetermination without curvature interference is researched. Algorithm for5-axis tool path generationof MMR with flat-end cutter is proposed. Cutter contact points are calculated by section method, thencutter orientation angles are determined with constraint of MMR and free-interference. According tothese, MMR tool paths with flat-end cutter are generated. Experimental result indicates thatmachining efficiency of MMR tool paths is improved by about17%compared with Sturz tool paths,and machining quality is also improved.
5. Technologies for feed-rates generation based on acceleration and deceleration control ofpiecewise tool paths are proposed for dental restoration machining. Algorithm for feed-rate transitionsof CL points, which is based on curve ADC (Acceleration and Deceleration Control) and adjustingahead, is proposed. Algorithm for adaptive feed-rate generation based on feed-rate transition ofsegment tool paths is proposed. With constraints of kinematic characters and actual cutting speeds,tool path segments of micro segment tool path are obtained, and feed-rates are planned in thesesegments, then feed-rates transition of the segments are processed by the method of S shape curveADC, and adaptive feed-rates generation for dental restoration machining is implemented.Experimental result indicates that machining efficiency of adaptive feed-rates method is improved by6%~10%with smooth movement of machine tool, compared with constant feed-rates method.
引文
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