模具曲面气囊进动抛光技术及实现研究
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摘要
在模具制造过程中,为提高模具的精度和品质,光整加工必不可少。而随着产品的个人化、精致化,曲面的设计和应用越来越多,加工难度相对提高。目前,模具曲面抛光主要采用手工操作,生产效率低,且难以保证稳定的抛光质量,使得抛光作业成为模具自动化制造的瓶颈。
本文针对实现模具曲面自动化抛光这一难点和热点问题,结合国家自然科学基金项目(No.50575208)的研究,提出一种基于气囊抛光工具的模具曲面气囊进动抛光技术。该技术基于柔性可控的气囊抛光工具与模具曲面顺从接触和机器人对抛光工具的位姿与抛光路径控制,保证了对曲面的面形修正精度,获得高表面质量,实现了模具曲面高效、精密、自动化抛光。
本文的主要工作如下：
1)气囊进动抛光时变材料去除特性研究。对气囊非进动和进动抛光的原理与效果进行了对比研究,分析了定点进动和连续进动抛光,为抛光工具在机器人控制下实现连续进动运动奠定了理论基础：对气囊进动抛光过程中的磨粒运动趋势、分布状态、作用机理等进行了理论分析和实验研究,为时变材料去除模型、加工主动控制和轨迹优化研究奠定了基础；提出基于磨粒群损耗因子的气囊进动抛光时变材料去除模型,并进行了补偿实验研究,实现了材料的均匀去除,获得稳定的表面质量。
2)气囊进动抛光进动比和初始姿态角研究。对不同下乐量和充气压力与不同曲率半径工件接触时的气囊接触力进行实验研究与分析,为抛光接触力控制提供了理论依据；对不同气囊下压量、充气压力、倾角、壁厚和橡胶弹性模量的气囊进行接触力和接触压力均匀性的正交仿真和分析,获得了灵敏度排序和结果预测模型,为正确选择加工工艺参数和橡胶气囊提供了应用依据：进行等壁厚和非等壁厚气囊对接触力、压力分布均匀性和自身形变的影响研究,为优化气囊结构提供了依据；对气囊进动抛光速度场进行研究,给出切向速度和切削方向表达式,定义进动比和初始姿态偏转角,并进行影响作用分析,确定了初始姿态偏转角优化组合,为气囊进动抛光轨迹优化研究提供了保证；在气囊接触力、压力分布和速度场等分析基础上,给出材料去除模型建模方法,实现MATLAB环境下的材料去除仿真。
3)气囊进动抛光轨迹优化研究。对去除任意外形轮廓的气囊进动抛光工艺规划策略、驻留时间、进给速度和接触边缘效应等问题进行研究和分析；对不同进动比时的切削方向分布和材料去除特性进行分析,给出优化进动比和对应的进给速度,为气囊进动抛光叠加次数优化和行间距优化奠定了基础；对不同初始姿态角组合叠加对材料去除特性的影响进行研究,给出叠加次数优化值；提出一种基于概率技术的气囊进动抛光轨迹规划二分优化方法,对气囊进动抛光行间距优化问题进行研究,给出优化值。
4)气囊进动抛光系统及工艺的实现研究。对六自由度机器人辅助实现气囊连续进动抛光问题进行研究,建立气囊连续进动抛光离线规划原型系统,为实现自动化抛光和轨迹规划奠定了重要基础；基于LabVIEW建立了气囊进动抛光接触力神经网络控制系统,进行气囊输入气压的预测和抛光接触力控制,并通过抛光接触力跟踪仿真和实验研究,验证了气囊进动抛光接触力控制平台的跟踪特性：基于建立的气囊连续进动抛光离线规划原型系统和气囊抛光接触力神经网络控制系统,进行气囊进动抛光工艺实验研究,获得了高质量的表面。
本文研究成果对于推进模具曲面精密、高效、自动化抛光技术的发展具有一定的理论指导意义和技术借鉴价值。
In order to improve the precision and quality of the mould, polishing is necessary in the mould manufacturing process. Well, with the products become personalized and refined, curved design and application is more and more and processing difficult relatively improve. At present, curved surface mould polishing is mainly manual with low production efficiency and unstable polishing quality. This makes polishing become the biggest bottleneck in the automated mould polishing.
Focusing on the crux and hot topic of polishing curved surface mould and combing the research supported by the National Natural Science Foundation of China (No.50575208), a novel curved surface mould polishing with contimuous precession process technique is proposed based on the gasbag polishing tool. This kind of technique is based on compliant contact between controllable flexibility gasbag polishing tool and mould free-from surface and the polishing tool pose and path planning control, which guarantees the local surface shape amendment precision and the quality of curved surface. The efficiency, accuracy and automation of polishing can be realized.
Main works of this dissertation are shown as follows:
1) The time-varying material removal characteristic of gasbag polishing with continuous precession process is analyzed. Comparative study of the principle and effect of the gasbag polishing with continuous precession process and without continuous precession process is carried out. The gasbag sentinel precession and continuous precession are analyzed and laid a theoretical foundation for the polishing tool to achieve continuous precession in the robot control. The abrasive movement trend, distribution state, mechanism of action and time-varying characteristics of the polishing with continuous precession process are researched through the experiments and simulation, which laid a foundation for time-varying material removal model, processing active control and trajectory optimization study. The time-varying material removal model is proposed based on the loss factor of abrasive group and a uniform removal of material is realized. The stable surface quality is obtained.
2) The feed rate and initial posture deflection angle of gasbag polishing with continuous precession process are studied. The polishing contact force with different downward depth, inflation pressure and radius of curvature is researched through experiments, which provides the theoretical basis for the polishing contact force compensation experiments. The contact force and contact pressure's uniformity orthogonal simulation and analysis are done for sensitivity sort and forecast the result with different downward depth, inflation pressure, angle, thickness and the rubber elastic modulus of the gasbag and provide the basis for the correct selection of the process parameters and gasbag. The influence of the equal wall thickness and unequal wall thickness gasbag to the contact force and the uniformity of pressure distribution are studied. Based on the velocity field research, the tangential velocity and the cutting direction expression are given. The feed rate and initial posture deflection angle are defined and the optimized combination method of the initial posture deflection angle is determined, which provide guarantee for the trajectory optimization study of the gasbag polishing with continuous precession process. Based on the analysis of the contact force, pressure distribution and velocity field, the material removal modeling idea is given and the material removal simulation is realized in the MATLAB environment.
3) The trajectory optimization of the gasbag polishing with continuous precession process is studied. The process planning strategy, dwell time, feed rate and contact edge effect of gasbag polishing with continuous precession process are studied and analyzed. The cutting direction distribution and material removal characteristics are studied on the different precession ratio. The optimized precession ratio and the corresponding feed rate is given, which laid a foundation for optimize the stacking fold and line space. The material removal characteristic under different initial posture deflection angles stacking is analyzed and the optimized stacking fold is given. A binary optimization method of trajectory planning based on probability technology is proposed. The line space optimization problem is studied and the optimization value is given.
4) The gasbag polishing precession system and the polishing process are studied. Establish the offline planning prototype system of the gasbag polishing with continuous precession process based on the study of the robot-assisted gasbag polishing with continuous precession process, which laid an important foundation for realizing the automation polishing and trajectory planning. The gasbag polishing contact force network control system is designed based on LabVIEW. It can realize the forecast of gasbag input pressure and the control of polishing contact force. The tracking characteristic of the gasbag polishing contact force control platform is verified through the tracking simulation and experiment of the contact force. The process experiment research of the gasbag continues precession is done and the ideal results are achieved based on the offline planning prototype system and the gasbag polishing contact force network control system.
This dissertation has some significant theoretical guidance and technical reference value for propelling the development of polishing technology with high level of efficiency, accuracy and automation for curved surface mould.
本文针对实现模具曲面自动化抛光这一难点和热点问题,结合国家自然科学基金项目(No.50575208)的研究,提出一种基于气囊抛光工具的模具曲面气囊进动抛光技术。该技术基于柔性可控的气囊抛光工具与模具曲面顺从接触和机器人对抛光工具的位姿与抛光路径控制,保证了对曲面的面形修正精度,获得高表面质量,实现了模具曲面高效、精密、自动化抛光。
本文的主要工作如下：
1)气囊进动抛光时变材料去除特性研究。对气囊非进动和进动抛光的原理与效果进行了对比研究,分析了定点进动和连续进动抛光,为抛光工具在机器人控制下实现连续进动运动奠定了理论基础：对气囊进动抛光过程中的磨粒运动趋势、分布状态、作用机理等进行了理论分析和实验研究,为时变材料去除模型、加工主动控制和轨迹优化研究奠定了基础；提出基于磨粒群损耗因子的气囊进动抛光时变材料去除模型,并进行了补偿实验研究,实现了材料的均匀去除,获得稳定的表面质量。
2)气囊进动抛光进动比和初始姿态角研究。对不同下乐量和充气压力与不同曲率半径工件接触时的气囊接触力进行实验研究与分析,为抛光接触力控制提供了理论依据；对不同气囊下压量、充气压力、倾角、壁厚和橡胶弹性模量的气囊进行接触力和接触压力均匀性的正交仿真和分析,获得了灵敏度排序和结果预测模型,为正确选择加工工艺参数和橡胶气囊提供了应用依据：进行等壁厚和非等壁厚气囊对接触力、压力分布均匀性和自身形变的影响研究,为优化气囊结构提供了依据；对气囊进动抛光速度场进行研究,给出切向速度和切削方向表达式,定义进动比和初始姿态偏转角,并进行影响作用分析,确定了初始姿态偏转角优化组合,为气囊进动抛光轨迹优化研究提供了保证；在气囊接触力、压力分布和速度场等分析基础上,给出材料去除模型建模方法,实现MATLAB环境下的材料去除仿真。
3)气囊进动抛光轨迹优化研究。对去除任意外形轮廓的气囊进动抛光工艺规划策略、驻留时间、进给速度和接触边缘效应等问题进行研究和分析；对不同进动比时的切削方向分布和材料去除特性进行分析,给出优化进动比和对应的进给速度,为气囊进动抛光叠加次数优化和行间距优化奠定了基础；对不同初始姿态角组合叠加对材料去除特性的影响进行研究,给出叠加次数优化值；提出一种基于概率技术的气囊进动抛光轨迹规划二分优化方法,对气囊进动抛光行间距优化问题进行研究,给出优化值。
4)气囊进动抛光系统及工艺的实现研究。对六自由度机器人辅助实现气囊连续进动抛光问题进行研究,建立气囊连续进动抛光离线规划原型系统,为实现自动化抛光和轨迹规划奠定了重要基础；基于LabVIEW建立了气囊进动抛光接触力神经网络控制系统,进行气囊输入气压的预测和抛光接触力控制,并通过抛光接触力跟踪仿真和实验研究,验证了气囊进动抛光接触力控制平台的跟踪特性：基于建立的气囊连续进动抛光离线规划原型系统和气囊抛光接触力神经网络控制系统,进行气囊进动抛光工艺实验研究,获得了高质量的表面。
本文研究成果对于推进模具曲面精密、高效、自动化抛光技术的发展具有一定的理论指导意义和技术借鉴价值。
In order to improve the precision and quality of the mould, polishing is necessary in the mould manufacturing process. Well, with the products become personalized and refined, curved design and application is more and more and processing difficult relatively improve. At present, curved surface mould polishing is mainly manual with low production efficiency and unstable polishing quality. This makes polishing become the biggest bottleneck in the automated mould polishing.
Focusing on the crux and hot topic of polishing curved surface mould and combing the research supported by the National Natural Science Foundation of China (No.50575208), a novel curved surface mould polishing with contimuous precession process technique is proposed based on the gasbag polishing tool. This kind of technique is based on compliant contact between controllable flexibility gasbag polishing tool and mould free-from surface and the polishing tool pose and path planning control, which guarantees the local surface shape amendment precision and the quality of curved surface. The efficiency, accuracy and automation of polishing can be realized.
Main works of this dissertation are shown as follows:
1) The time-varying material removal characteristic of gasbag polishing with continuous precession process is analyzed. Comparative study of the principle and effect of the gasbag polishing with continuous precession process and without continuous precession process is carried out. The gasbag sentinel precession and continuous precession are analyzed and laid a theoretical foundation for the polishing tool to achieve continuous precession in the robot control. The abrasive movement trend, distribution state, mechanism of action and time-varying characteristics of the polishing with continuous precession process are researched through the experiments and simulation, which laid a foundation for time-varying material removal model, processing active control and trajectory optimization study. The time-varying material removal model is proposed based on the loss factor of abrasive group and a uniform removal of material is realized. The stable surface quality is obtained.
2) The feed rate and initial posture deflection angle of gasbag polishing with continuous precession process are studied. The polishing contact force with different downward depth, inflation pressure and radius of curvature is researched through experiments, which provides the theoretical basis for the polishing contact force compensation experiments. The contact force and contact pressure's uniformity orthogonal simulation and analysis are done for sensitivity sort and forecast the result with different downward depth, inflation pressure, angle, thickness and the rubber elastic modulus of the gasbag and provide the basis for the correct selection of the process parameters and gasbag. The influence of the equal wall thickness and unequal wall thickness gasbag to the contact force and the uniformity of pressure distribution are studied. Based on the velocity field research, the tangential velocity and the cutting direction expression are given. The feed rate and initial posture deflection angle are defined and the optimized combination method of the initial posture deflection angle is determined, which provide guarantee for the trajectory optimization study of the gasbag polishing with continuous precession process. Based on the analysis of the contact force, pressure distribution and velocity field, the material removal modeling idea is given and the material removal simulation is realized in the MATLAB environment.
3) The trajectory optimization of the gasbag polishing with continuous precession process is studied. The process planning strategy, dwell time, feed rate and contact edge effect of gasbag polishing with continuous precession process are studied and analyzed. The cutting direction distribution and material removal characteristics are studied on the different precession ratio. The optimized precession ratio and the corresponding feed rate is given, which laid a foundation for optimize the stacking fold and line space. The material removal characteristic under different initial posture deflection angles stacking is analyzed and the optimized stacking fold is given. A binary optimization method of trajectory planning based on probability technology is proposed. The line space optimization problem is studied and the optimization value is given.
4) The gasbag polishing precession system and the polishing process are studied. Establish the offline planning prototype system of the gasbag polishing with continuous precession process based on the study of the robot-assisted gasbag polishing with continuous precession process, which laid an important foundation for realizing the automation polishing and trajectory planning. The gasbag polishing contact force network control system is designed based on LabVIEW. It can realize the forecast of gasbag input pressure and the control of polishing contact force. The tracking characteristic of the gasbag polishing contact force control platform is verified through the tracking simulation and experiment of the contact force. The process experiment research of the gasbag continues precession is done and the ideal results are achieved based on the offline planning prototype system and the gasbag polishing contact force network control system.
This dissertation has some significant theoretical guidance and technical reference value for propelling the development of polishing technology with high level of efficiency, accuracy and automation for curved surface mould.
引文
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