面向数控加工的复杂曲面反求工程的研究
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摘要
反求工程指在没有技术资料的情况下获得产品初始设计意图的技术过程。本文在全面总结和分析目前制造业领域中反求工程的基本理论及关键技术、研究及应用状况的基础上，结合电话听筒外壳型面及其它实例，对目前复杂曲面反求工程的全过程及其关键技术进行了研究和探索，内容包括数据测量、数据处理、曲面重构和数控加工编程。本论文的主要工作在以下几个方面：
分析与比较了目前常用的数字化测量方法及各种三维数字测量设备，着重介绍了本课题所用到的LK G90CS15.10.8型三坐标测量机的机械结构、软硬件配置、规格参数及环境要求，并用该机器对某电话机听筒外壳的三维表面进行扫描测量；
阐述了反求工程的测量数据类型及各种数据点的处理方法，提出了利用Coons曲面原理剔除噪声点的方法，采用中值滤波方法对测量数据进行平滑，提出了用弦高差等方法和特征曲率法对电话听筒外壳数据进行了数据点的精简和特征点的提取的方法；
论述了曲面造型技术的发展过程，比较了自由曲面和各种生成算法，应用NURBS算法重构了电话听筒的外壳曲面，并利用特征线对生成曲面进行了裁剪；
分析比较了复杂曲面数控加工的切削方式、切削用量、走刀方式进退刀方式、编程零点和加工坐标系的确定，推导出用残留刀痕法来控制加工步长的关系式，阐述了在MasterCAM环境下如何选定待加工曲面的切削参数和刀具参数，并根据所选刀具和切削参数分别生成了电话听筒外壳型面的粗加工和精加工过程的刀具路径。
Reverse Engineering (RE) refers to the process of acquiring the original technical information of the product without any technical data. In this thesis, basic theory, key technique, present research and applying status of RE in manufacture field are comprehensively summarized and analyzed, on the basis of which the whole process and key technique of complex surface's RE are researched, including data measuring, data processing, surface reconstruction and numerical control machining, taking the telephone hand-receiver as example. Main work is as following:
The digitized measuring methods and devices that are generally used at present are analyzed and compared. Among them, the mechanical structure, the configuration of hardware and software, the specification parameter and the environmental request of LK G90CS15.10.8 thiee-CMM mat are used in this thesis are introduced specially. By using LK G90CS15.10.8 three-CMM, the measuring data of the telephone hand-receiver are acquired.
The types and the processing methods of measured data are discussed. Aiming at the error points in points data, a method using Coons surface is put forward. Filtration is commonly used in data smoothing, and median method is adopted in this article. Moreover, the chord method and the curvature method are used here to compress the data and extract the feature points of the telephone hand-receiver measured data.
The developing process of surface molding is introduced and the formation algorithm of free-form surfaces is compared By using NURBS algorithm in mis article, the telephone hand-receiver surface is reconstructed. In addition, the surface of the telephone hand-receiver is cut according to the feature curve created by the feature points.
The craft of numerical control machining program of complex surface is analyzed and compared. These craft are machining method, cutting dosage, machining remainder, cuter walking mode, the cuter advance, the retreat mode, programming zero, and machining
coordinate so on. The conclusion that the layer cutting is fitter for rough machining is made. The formula of scallop-height method controlling machining step is deduced. Finally, the cutting and cutter parameter for rough machining and finish machining of complex surface is put forward in the MasterCAM software, according to which the cutter route for rough machining and finish machining are produced respectively.
分析与比较了目前常用的数字化测量方法及各种三维数字测量设备，着重介绍了本课题所用到的LK G90CS15.10.8型三坐标测量机的机械结构、软硬件配置、规格参数及环境要求，并用该机器对某电话机听筒外壳的三维表面进行扫描测量；
阐述了反求工程的测量数据类型及各种数据点的处理方法，提出了利用Coons曲面原理剔除噪声点的方法，采用中值滤波方法对测量数据进行平滑，提出了用弦高差等方法和特征曲率法对电话听筒外壳数据进行了数据点的精简和特征点的提取的方法；
论述了曲面造型技术的发展过程，比较了自由曲面和各种生成算法，应用NURBS算法重构了电话听筒的外壳曲面，并利用特征线对生成曲面进行了裁剪；
分析比较了复杂曲面数控加工的切削方式、切削用量、走刀方式进退刀方式、编程零点和加工坐标系的确定，推导出用残留刀痕法来控制加工步长的关系式，阐述了在MasterCAM环境下如何选定待加工曲面的切削参数和刀具参数，并根据所选刀具和切削参数分别生成了电话听筒外壳型面的粗加工和精加工过程的刀具路径。
Reverse Engineering (RE) refers to the process of acquiring the original technical information of the product without any technical data. In this thesis, basic theory, key technique, present research and applying status of RE in manufacture field are comprehensively summarized and analyzed, on the basis of which the whole process and key technique of complex surface's RE are researched, including data measuring, data processing, surface reconstruction and numerical control machining, taking the telephone hand-receiver as example. Main work is as following:
The digitized measuring methods and devices that are generally used at present are analyzed and compared. Among them, the mechanical structure, the configuration of hardware and software, the specification parameter and the environmental request of LK G90CS15.10.8 thiee-CMM mat are used in this thesis are introduced specially. By using LK G90CS15.10.8 three-CMM, the measuring data of the telephone hand-receiver are acquired.
The types and the processing methods of measured data are discussed. Aiming at the error points in points data, a method using Coons surface is put forward. Filtration is commonly used in data smoothing, and median method is adopted in this article. Moreover, the chord method and the curvature method are used here to compress the data and extract the feature points of the telephone hand-receiver measured data.
The developing process of surface molding is introduced and the formation algorithm of free-form surfaces is compared By using NURBS algorithm in mis article, the telephone hand-receiver surface is reconstructed. In addition, the surface of the telephone hand-receiver is cut according to the feature curve created by the feature points.
The craft of numerical control machining program of complex surface is analyzed and compared. These craft are machining method, cutting dosage, machining remainder, cuter walking mode, the cuter advance, the retreat mode, programming zero, and machining
coordinate so on. The conclusion that the layer cutting is fitter for rough machining is made. The formula of scallop-height method controlling machining step is deduced. Finally, the cutting and cutter parameter for rough machining and finish machining of complex surface is put forward in the MasterCAM software, according to which the cutter route for rough machining and finish machining are produced respectively.
引文
[1] 王文深等．反求工程技术及其应用．河南机电高等专科学校学报，2001(6)：6～9
[2] 刘影，杭九全等．反求工程与现代设计．机械设计，1998(2)：1～4
[3] 杜永平，滕启．反求工程技术．起重运输机械，2003(1)：1～4
[4] 苏海，杨跃奎等．快速原型制造技术中的反求工程．昆明理工大学学报，2001(4)：68～72
[5] 陈满意等．基于反求设计和虚拟设计的复杂设备的研制．武钢技术，2002(2)：10～14
[6] Tamas Varady, Ralph R Martin, Jordan Coxt. Reverse engineering of geometric models-an introduction. Computer-Aided Design, 1997, 29(4): 255～267
[7] 赖建康，钟燕锋．反求工程与CAD／CAM系统集成及应用开发研究．机械开发，2000(1)：36～40
[8] 史桂蓉，刑渊等．反求工程应用现状及研究方向．机械科学与技术，2000(4)：653～655
[9] Yasser Hosni, Labiche Ferrerira. Laser based for reverse engineering. Computers Industry Engineering, 1994, 21(2): 387～394
[10] T.Varady, R.R.Martin, J.Cox. Reverse engineering of geometric models-an introduction. Computer-Aided Design, 1997, 29(4): 255～268
[11] Baining Guo. Surface reconstrction:from points to splines. Computer-Aided Design, 1997, 29(4): 269～277
[12] Xin Chen, Francis Schmitt. Surface modeling of range data by constrained triangulation. Computer-Aided Design, 1994, 26(8): 632～645
[13] Hoppe H. Generate of 3D geometric models from unstructured 3D points. SPIE. 1995, 24(10): 424～431
[14] Hoppe H, DeRose T, and Duchamp T et al. Surface Reconstruction from Unorganized points. Computer Oraphics, 1992, 26(2): 71～78
[15] Hoppe H, DeRose T, Duchamp T et al. Mesh Optimization. SIDRAPH-Computer Graphics Proceeding. Annual conference series, 1993: 19～26
[16] 黄小平，杜小明等．逆向工程中的建模技术．中国机械工程，2001(5)：539～542
[17] Pramod N. Chivate, Andrel G. Jablokow. Solid-model generation from measured point data. Computer-Aided Design, 1993, 25(9): 587～599
[18] 李钒，武殿梁等．基于工业设计和先进制造技术的产品快速开发．制造业自动化，2002(4)：25～29
[19] 沈惠平．机械创新设计及其研究．机械科学与技术，1997(5)：791～795
[20] 丁黎光．机械创新设计的研究．广西工学院学报，2000(2)：30～32
[21] 杨宗德．论机械工程中的创新设计．机械研究与应用，2001(1)：53～55
[22] 方新国．机械工程设计中和概念设计、创新设计与系统设计．西北轻工业学院学报，2000(4)：60～64
[23] 童时中．时代呼唤工业设计．电子机械工程，1997(1)：6～12
[24] 邹慧君等．机械产品概念设计及其方法综述．机械设计与研究，1998(2)：9～12
[25] 马淑梅，张曙等．以逆向工程为基础的数控模具加工．制造业自动化，2001(9)：11～13
[26] 郭良刚，陈勇等．反求工程在复杂型面模具设计中的应用研究．模具工业，2002(1)：12～17
[27] 王宗彦，潘宏侠等．风扇叶片及其模具快速反求设计和制造．华北工学院学报，2002(2)：143～146
[28] 李真，刑渊．反向工程在实际生产中的应用．造船技术，2001(3)：34～36
[29] 曾晓华，刘静华等．基于STL数据模型的刀具轨迹生成．工程图学学报，2002(1)：8～14
[30] 程俊廷，张树林等．反求工程在快速成型中的应用．制造业自动化，2003(1)：20～21
[31] 崔汉锋，许鹏等．反求工程在无损检测中的应用研究．机械与电子，2000(4)：57～59
[32] 金涛，陈建良等．逆向工程技术研究进展．中国机械工程：2002(16)：1430～1436
[33] 李忠杰，涂劲松等．逆向工程技术探讨．橡塑技术与装备，2001(10)：17-21
[34] 贾全庆，王宏等．实物反求的关键技术分析．机械设计，1999(6)：4～6
[35] 三坐标测量机操作手册．英国LK公司．2000
[36] 陈勇，刘雄伟．反求工程CAD建模技术．华侨大学学报，2001(4)：376～379
[37] P.Veron, J.C Leon. Static polyhedron simplification using error measumments. Computer-Aided Design, 1997, 15(3): 287～298
[38] 朱心雄．自由曲线曲面造型技术．北京：科学出版社，2000年
[39] Hyungjun Park, Kwangsoon Kim. An adaptive method for smooth surface approximation to scattered 3D points. Computer-Aided Design, 1995, 27(12): 929～939
[40] 吕震，贾明．三角曲面数字样品的特征提取与再现技术．计算机辅助设计与图形学学报，2002(8)：1～4
[41] 邵建萍，陈少良．CAD／CAM关键技术——曲面造型．机械工程师，2003(1)：23～25
[42] 巨泽建等．Mastercam 8.x使用速成．北京：清华大学出版社
[2] 刘影，杭九全等．反求工程与现代设计．机械设计，1998(2)：1～4
[3] 杜永平，滕启．反求工程技术．起重运输机械，2003(1)：1～4
[4] 苏海，杨跃奎等．快速原型制造技术中的反求工程．昆明理工大学学报，2001(4)：68～72
[5] 陈满意等．基于反求设计和虚拟设计的复杂设备的研制．武钢技术，2002(2)：10～14
[6] Tamas Varady, Ralph R Martin, Jordan Coxt. Reverse engineering of geometric models-an introduction. Computer-Aided Design, 1997, 29(4): 255～267
[7] 赖建康，钟燕锋．反求工程与CAD／CAM系统集成及应用开发研究．机械开发，2000(1)：36～40
[8] 史桂蓉，刑渊等．反求工程应用现状及研究方向．机械科学与技术，2000(4)：653～655
[9] Yasser Hosni, Labiche Ferrerira. Laser based for reverse engineering. Computers Industry Engineering, 1994, 21(2): 387～394
[10] T.Varady, R.R.Martin, J.Cox. Reverse engineering of geometric models-an introduction. Computer-Aided Design, 1997, 29(4): 255～268
[11] Baining Guo. Surface reconstrction:from points to splines. Computer-Aided Design, 1997, 29(4): 269～277
[12] Xin Chen, Francis Schmitt. Surface modeling of range data by constrained triangulation. Computer-Aided Design, 1994, 26(8): 632～645
[13] Hoppe H. Generate of 3D geometric models from unstructured 3D points. SPIE. 1995, 24(10): 424～431
[14] Hoppe H, DeRose T, and Duchamp T et al. Surface Reconstruction from Unorganized points. Computer Oraphics, 1992, 26(2): 71～78
[15] Hoppe H, DeRose T, Duchamp T et al. Mesh Optimization. SIDRAPH-Computer Graphics Proceeding. Annual conference series, 1993: 19～26
[16] 黄小平，杜小明等．逆向工程中的建模技术．中国机械工程，2001(5)：539～542
[17] Pramod N. Chivate, Andrel G. Jablokow. Solid-model generation from measured point data. Computer-Aided Design, 1993, 25(9): 587～599
[18] 李钒，武殿梁等．基于工业设计和先进制造技术的产品快速开发．制造业自动化，2002(4)：25～29
[19] 沈惠平．机械创新设计及其研究．机械科学与技术，1997(5)：791～795
[20] 丁黎光．机械创新设计的研究．广西工学院学报，2000(2)：30～32
[21] 杨宗德．论机械工程中的创新设计．机械研究与应用，2001(1)：53～55
[22] 方新国．机械工程设计中和概念设计、创新设计与系统设计．西北轻工业学院学报，2000(4)：60～64
[23] 童时中．时代呼唤工业设计．电子机械工程，1997(1)：6～12
[24] 邹慧君等．机械产品概念设计及其方法综述．机械设计与研究，1998(2)：9～12
[25] 马淑梅，张曙等．以逆向工程为基础的数控模具加工．制造业自动化，2001(9)：11～13
[26] 郭良刚，陈勇等．反求工程在复杂型面模具设计中的应用研究．模具工业，2002(1)：12～17
[27] 王宗彦，潘宏侠等．风扇叶片及其模具快速反求设计和制造．华北工学院学报，2002(2)：143～146
[28] 李真，刑渊．反向工程在实际生产中的应用．造船技术，2001(3)：34～36
[29] 曾晓华，刘静华等．基于STL数据模型的刀具轨迹生成．工程图学学报，2002(1)：8～14
[30] 程俊廷，张树林等．反求工程在快速成型中的应用．制造业自动化，2003(1)：20～21
[31] 崔汉锋，许鹏等．反求工程在无损检测中的应用研究．机械与电子，2000(4)：57～59
[32] 金涛，陈建良等．逆向工程技术研究进展．中国机械工程：2002(16)：1430～1436
[33] 李忠杰，涂劲松等．逆向工程技术探讨．橡塑技术与装备，2001(10)：17-21
[34] 贾全庆，王宏等．实物反求的关键技术分析．机械设计，1999(6)：4～6
[35] 三坐标测量机操作手册．英国LK公司．2000
[36] 陈勇，刘雄伟．反求工程CAD建模技术．华侨大学学报，2001(4)：376～379
[37] P.Veron, J.C Leon. Static polyhedron simplification using error measumments. Computer-Aided Design, 1997, 15(3): 287～298
[38] 朱心雄．自由曲线曲面造型技术．北京：科学出版社，2000年
[39] Hyungjun Park, Kwangsoon Kim. An adaptive method for smooth surface approximation to scattered 3D points. Computer-Aided Design, 1995, 27(12): 929～939
[40] 吕震，贾明．三角曲面数字样品的特征提取与再现技术．计算机辅助设计与图形学学报，2002(8)：1～4
[41] 邵建萍，陈少良．CAD／CAM关键技术——曲面造型．机械工程师，2003(1)：23～25
[42] 巨泽建等．Mastercam 8.x使用速成．北京：清华大学出版社