快速成型制造中分层处理技术的研究
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摘要
快速成型制造技术是优化产品设计、缩减产品成本的有力工具,它的出现是制造领域的一次重大技术创新和突破。尽管快速成型制造的工艺方法多种多样,但获取零件模型切平面的二维轮廓数据仍然是进行快速成型制造的第一步。因此分层处理技术始终是RP&M技术研究的一项主要内容。
     为适应现代先进集成制造模式的发展要求,提出了以STEP-NC作为统一数据接口来构建RP&M集成制造系统的方法,并指出实现这一RP&M集成制造系统的关键是实现基于STEP-NC的几何模型分层处理技术。
     提出了生成可视化的STL三维实体模型的方法,通过设置相邻三角形面片外法向量夹角的临界值来选取适当的公共顶点,并重新计算其法向量,实现了对STL模型的顶点数据冗余处理和向量光滑处理。采用Visual C++为编程语言,以OpenGL为图形开发工具,开发出一个针对STL数据模型的可视化系统,该系统为STL模型的分层处理提供了有力的支持。
     在对基于STL模型的切片处理技术进行了深入分析并吸收现有算法优点的基础上,提出了分组排序、对边求交的分层算法。该算法先根据三角面片中顶点在分层方向的最大和最小坐标值,对各面片进行排序并形成分层关系矩阵,然后对每层的三角面片采用对边依次追踪求交的方法生成切片轮廓数据。通过实际应用表明,该算法高效、稳定、可靠。
     在对STEP-NC几何模型表达方法进行了系统分析和理解的基础上,研究了EXPRESS到C++的映射方法,并将这一模块作成动态连接库,为系统的扩展创造了条件。为了保证数据采集的一致性和有效性,设计了一个AP203中性交换文件数据采集模块,实现了AP203中性文件的读入和分析,进而正确获得了几何模型的特征数据。基于STEP-NC的几何模型分层处理的核心问题是分层平面与从AP203中性文件中提取出来的模型各几何元素的交线求取问题,本文对STEP-NC几何模型中的主要几何元素设计了具有针对性的求交算法,这些求交算法使得几何图元所具有的特殊性质得到充分利用,因而提高了算法的效率和稳定性。
     对现有的扫描填充方法进行了深入分析,在综合考虑各扫描填充方法优缺点的基础上,提出了轮廓偏置和基于交点排序的分区扫描相结合的复合扫描填充算法。该扫描填充方法能够充分发挥轮廓偏置填充精度高和分区扫描填充速度快的特点,并且能够适用于多种快速成型工艺。为实现复合填充方法,利用矢量偏移的方法实现了轮廓偏置的计算。在设计分区扫描算法的过程中,提出了基于交点排序的分区算法。该分区算法大大简化了填充区域划分的实现过程,使分区效率也得到提高。
Rapid prototyping and manufacturing(RP&M) plays an important role in reducing the time required for new product development and lowering development costs. The emergence of RP&M is vitally an important technical innovation in manufacturing. Although building physical parts with different techniques has become popular, intersecting a CAD model with a plane in order to determine two dimensional contours on which material is to be deposited is the foundation for the various RP&M processes. Therefore, the study of slicing methods has become an important subject of RP&M techniques.
     To fulfil the requirements of morden integrated manufacturing system, a new method, which takes the STEP-NC as the uniform data exchange formats, is put forward. It has been pointed out that the key problem to construct integrated system of RP&M is to realize the slicing technology based on STEP-NC.
     A method of generating realistic image view for STL model has been proposed. By setting a critical angle to select appropriate common point and recalculate the vector, the redundancy problem of vertex coordinate in STL model is solved and the model looks smoother. A stereo display system is developed by calling functions from OpenGL graphic library through VC++. The developed system is conducive to slicing process of STL model.
     On the basis of analyzing the slicing technology and absorbing the merit of current algorithms for slicing STL model, a new algorithm has been put forward. In the strategy, the grouping matrix was established by sorting for the triangular facets according to the minimum and maximum z-axis value of the triangular facets. Then the contour segments were generated by marching from edge to edge. Applications are made to show that the approach is efficient, stable and reliable.
     Based on a systematic analysis and comprehension on the expression of STEP-NC geometry model, the map between EXPRESS and C++ was studied. The module of map has been developed as a dynamic link library, which facilitated the expansion of system. In order to ensure the coherence and availability of collected data, a module to obtain feature data has also been designed. The reading and analysis for AP203 neutral file has been realized so that the feature information in the geometry model could be extracted.
     The key problem of the slicing for STEP-NC geometry model is realizing the algorithm of intersection between the slicing plane and the geometry element. Different algorithms have been designed aim at various geometries so that the special property can be utilized sufficiently. Hence this algorithm is more efficient and reliable.
     Through in-depth research and analysis for the existing technique of seanning and hatching, a new composite filling method, which combined profile offset and region hatching by grouping the point of intersection, has been put forward. The presented way can make use of the property of high quality and efficiency separately in profile offset and region hatching. And it adapts to various technics in RP&M. In order to implement the proposed method, a vector excursion is utilized to compute the profile offset. The group algorithm of intersections, which reduced the process of partiton and anvanced the efficiency, is also used to relize the region hatching.
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