【摘要】：隨著現(xiàn)代制造業(yè)全球化與市場(chǎng)化的發(fā)展,能在更短的時(shí)間內(nèi)開發(fā)出新產(chǎn)品并推向市場(chǎng)是企業(yè)保持競(jìng)爭(zhēng)力的關(guān)鍵所在。增材制造技術(shù)的應(yīng)用加速了產(chǎn)品的設(shè)計(jì)開發(fā)過(guò)程,降低了產(chǎn)品設(shè)計(jì)驗(yàn)證成本。與傳統(tǒng)去除材料的加工方式不同,增材制造是一個(gè)分層累積材料的過(guò)程,將三維零件降維到二維平面或者一維的點(diǎn)線,消除了復(fù)雜形狀對(duì)加工制造的限制。 從上世紀(jì)的八十年代增材制造技術(shù)出現(xiàn)開始,目前已經(jīng)有多種增材制造加工工藝,也有光敏樹脂、金屬與陶瓷粉末等多種材料可供應(yīng)用。但其加工精度、表面質(zhì)量與所得零件的性能與傳統(tǒng)的切削加工、鑄造鍛壓成型、注塑成型等工藝還有較大的差距,這些都限制了增材制造的大范圍應(yīng)用。相對(duì)于傳統(tǒng)的加工技術(shù),增材制造加工零件的單個(gè)成本相對(duì)較高,不適合大批量零件的制造。針對(duì)上述問(wèn)題,本文從集成數(shù)控增材制造工藝與基于掩膜圖像投影的增材制造工藝兩方面進(jìn)行了研究,以期提高增材制造的加工質(zhì)量、擴(kuò)展其應(yīng)用范圍。主要研究?jī)?nèi)容與成果如下： (1)基于雙軸旋轉(zhuǎn)微鏡的可集成模型數(shù)字化技術(shù)研究。以實(shí)現(xiàn)集成模型三維測(cè)量系統(tǒng)的增材制造工藝為目標(biāo),以德州儀器的TALPIOOOB雙軸旋轉(zhuǎn)微鏡鏡和攝像機(jī)為核心部件,設(shè)計(jì)了三維激光測(cè)量系統(tǒng)。該系統(tǒng)通過(guò)控制雙軸旋轉(zhuǎn)微鏡來(lái)控制激光點(diǎn)的移動(dòng),實(shí)現(xiàn)一次固定,區(qū)域測(cè)量,可作為集成部件方便的安裝到增材制造系統(tǒng)當(dāng)中,實(shí)現(xiàn)對(duì)待加工表面的在線測(cè)量。測(cè)量系統(tǒng)中采用分層離散的定標(biāo)算法對(duì)攝像機(jī)和激光位置進(jìn)行標(biāo)定,基于雙線性插補(bǔ)算法計(jì)算圖像像素點(diǎn)位置和激光點(diǎn)位置。由雙軸旋轉(zhuǎn)微鏡與攝像機(jī)分別獲取經(jīng)過(guò)被測(cè)點(diǎn)的兩條空間直線,然后通過(guò)空間直線的三角化求交來(lái)計(jì)算測(cè)量點(diǎn)位置。通過(guò)測(cè)量實(shí)例,分析了測(cè)量誤差產(chǎn)生的原因及提高措施。 (2)基于代數(shù)點(diǎn)集曲面APSS與多層深度法矢圖像LDNIs的模型重建算法研究。采用代數(shù)點(diǎn)集曲面APSS擬合測(cè)量點(diǎn)集,進(jìn)行去噪平滑,然后通過(guò)投影運(yùn)算將APSS曲面轉(zhuǎn)化為L(zhǎng)DNIs表達(dá)的實(shí)體模型,進(jìn)而采用輪廓線算法生成三角網(wǎng)格曲面,實(shí)現(xiàn)模型的重建。 (3)研究了集成數(shù)控增材制造系統(tǒng)。針對(duì)傳統(tǒng)分層增材制造工藝所得零件在不同方向上物理性能不一致的問(wèn)題,開發(fā)基于數(shù)控技術(shù)的無(wú)分層增材制造工藝CNCA。將所開發(fā)的三維測(cè)量系統(tǒng)與模型重建算法集成到該工藝當(dāng)中,實(shí)現(xiàn)對(duì)待加工表面的在線測(cè)量與模型重建。結(jié)合基于多層深度法矢圖像的布爾運(yùn)算與偏置運(yùn)算,實(shí)現(xiàn)激光頭的路徑規(guī)劃,輸入數(shù)字控制系統(tǒng),實(shí)現(xiàn)在給定曲面上的固化加工 (4)基于MIP-SLA的大面積微細(xì)加工制造工藝研究。對(duì)基于DLP投影機(jī)的MIP-SLA(?)曾材制造工藝的加工原理、工藝流程及系統(tǒng)組成進(jìn)行了研究,重點(diǎn)研究了基于約束液面的MIP-SLA增材制造工藝。設(shè)計(jì)開發(fā)了基于MIP-SLA的大面積微細(xì)制造工藝系統(tǒng),研究了制造系統(tǒng)的圖像生成與工藝規(guī)劃�；谏虡I(yè)投影機(jī),重構(gòu)光學(xué)系統(tǒng)實(shí)現(xiàn)掩膜圖像在微小區(qū)域內(nèi)的聚焦,通過(guò)對(duì)光路與加工基座在平面內(nèi)的擴(kuò)展,實(shí)現(xiàn)大面積微細(xì)零件的制造。 (5)基于LDNIs的掩膜圖像切片生成算法研究。提出了基于LDNIs模型的掩膜圖像生成算法,該算法首先對(duì)實(shí)體模型進(jìn)行采樣離散生LDNIs模型,然后采用離散的一維布爾運(yùn)算代替?zhèn)鹘y(tǒng)的輪廓求交運(yùn)算得出二維的掩膜圖像。該算法在處理復(fù)雜模型與小層厚圖像生成時(shí)與基于輪廓的算法有更高的運(yùn)算效率。研究DLP投影機(jī)的標(biāo)定算法,提出采用分層離散的方式對(duì)其進(jìn)行空間定標(biāo)。并根據(jù)定標(biāo)數(shù)據(jù)實(shí)現(xiàn)了投影圖像的反算。在基于MIP-SLA工藝的光滑表面制造系統(tǒng)中，，應(yīng)用空間投影圖像反算算法生成該工藝中的二次投影圖像。 (6) MIP-SLA原型機(jī)系統(tǒng)設(shè)計(jì)。設(shè)計(jì)搭建了大面積微細(xì)制造工藝的硬件系統(tǒng),對(duì)微細(xì)加工的曝光時(shí)間、加工分辨率等因素進(jìn)行了研究。基于EtherMAC運(yùn)動(dòng)控制系統(tǒng)及WindowsCE (?)沃入式操作系統(tǒng)開發(fā)了約束液面式MIP-SLA原型機(jī)系統(tǒng)。開發(fā)了了基于PC的掩膜圖像切片軟件與基于WindowsCE嵌入式系統(tǒng)的控制軟件,并設(shè)計(jì)了分離拉力的在線測(cè)量系統(tǒng)。通過(guò)實(shí)驗(yàn)驗(yàn)證了掩膜圖像切片算法的正確性,測(cè)定了系統(tǒng)的加工精度、加工效率以及加工過(guò)程中分離拉力隨加工面積的變化趨勢(shì)。 論文對(duì)面向增材制造的模型數(shù)字化技術(shù)與模型重建方法的研究,實(shí)現(xiàn)了集成的數(shù)控增材制造系統(tǒng)。該系統(tǒng)創(chuàng)新性地提出了無(wú)分層的制造方式,解決了分層制造工藝所加工零件在各個(gè)方向物理性能不一致的問(wèn)題�；诙鄬由疃确ㄊ笀D像的掩膜圖像生成算法與傳統(tǒng)的基于輪廓的算法相比,在處理復(fù)雜模型方面具有更高的計(jì)算效率。所設(shè)計(jì)的大面積微細(xì)制造工藝系統(tǒng)克服了MIP-SLA工藝加工分辨率與加工面積之間的矛盾,可實(shí)現(xiàn)高分辨大面積零件的制造,對(duì)擴(kuò)展MIP-SLA工藝的應(yīng)用范圍,提高零件的加工精度有重要的意義。
[Abstract]:With the development of globalization and marketization of modern manufacturing industry, it is the key for enterprises to develop new products and push them to the market in a shorter time. The application of augmented material manufacturing technology accelerates the process of product design and development and reduces the cost of product design verification. Manufacturing is a process of layered accumulation of materials, which reduces the dimension of three-dimensional parts to two-dimensional plane or one-dimensional point and line, eliminating the restriction of complex shape on machining.
Since the appearance of augmented materials manufacturing technology in the 1980s, there have been many kinds of augmented materials manufacturing processes, as well as photosensitive resins, metal and ceramic powders and other materials for application. Compared with the traditional machining technology, the single cost of manufacturing parts by adding materials is relatively high, which is not suitable for manufacturing large quantities of parts. The main research contents and achievements are as follows:1.
(1) Research on the digitization technology of integrated model based on Two-axis rotating micromirror. Aiming at the manufacturing process of the integrated model three-dimensional measuring system, a three-dimensional laser measuring system was designed with TALPIOOOB dual-axis rotating micromirror and camera as the core components. The moving of the light point can be fixed once and the area measurement can be carried out. It can be easily installed into the augmented material manufacturing system as an integrated part to realize the on-line measurement of the machined surface. The position of laser point is calculated by triangulating the intersection of the two space lines which pass through the measured point. The cause of measurement error and the improvement measures are analyzed through a measurement example.
(2) Research on model reconstruction algorithm based on algebraic point set surface APSS and multi-layer depth normal image LDNIs. Using algebraic point set surface APSS to fit measurement point set, denoising and smoothing are carried out, then APSS surface is transformed into solid model expressed by LDNIs through projection operation, and then triangular mesh surface is generated by contour algorithm to realize the model. Reconstruction.
(3) The integrated NC augmentation manufacturing system is studied. Aiming at the problem of inconsistent physical properties in different directions of parts produced by traditional layered augmentation manufacturing process, a NC-based non-layered augmentation manufacturing process CNCA is developed. On-line surface measurement and model reconstruction. Combining Boolean operation and offset operation based on multi-layer depth normal vector image, path planning of laser head is realized, digital control system is inputted, and curing machining on a given surface is realized.
(4) Research on large area micro-fabrication process based on MIP-SLA. The principle, process flow and system composition of MIP-SLA based on DLP projector are studied. The MIP-SLA based on constrained liquid level is emphatically studied. A large area micro-fabrication process system based on MIP-SLA is designed and developed. The image generation and process planning of manufacturing system are studied. Based on commercial projector, the optical system is reconstructed to focus the mask image in a small area. By expanding the light path and the machining base in the plane, large area micro parts are manufactured.
(5) Research on Algorithm of mask image Slicing Based on LDNIs. A mask image generating algorithm based on LDNIs model is proposed. Firstly, the solid model is sampled and the discrete LDNIs model is generated. Then the discrete one-dimensional Boolean operation is used instead of the traditional contour intersection operation to get the two-dimensional mask image. This paper studies the calibration algorithm of DLP projector and proposes a method of spatial calibration by layered discrete method. The projection image is inversely computed according to the calibration data. In the smooth surface manufacturing system based on MIP-SLA technology, the spatial projection map is applied. The inverse algorithm is used to generate the two projection image in the process.
(6) The design of MIP-SLA prototype system. The hardware system of large area micro-fabrication process is designed and built. The exposure time and processing resolution of micro-fabrication are studied. The constrained liquid-level MIP-SLA prototype system is developed based on EtherMAC motion control system and Windows CE (?) Wordin operating system. The mask image slicing software and the control software based on the embedded system of Windows CE are designed, and the on-line measurement system of the separating tension is designed.
The integrated NC augmented material manufacturing system is realized by the research of model digitization technology and model reconstruction method for incremental material manufacturing. The system innovatively proposes a layered-free manufacturing method, which solves the problem of inconsistent physical properties of parts processed by layered manufacturing process in different directions. Compared with the traditional contour-based algorithm, the proposed mask image generation algorithm has higher computational efficiency in dealing with complex models. The large-area micro-manufacturing process system overcomes the contradiction between the processing resolution and the processing area of MIP-SLA, and can realize the manufacturing of high-resolution large-area parts. The application scope of art is of great significance to improve the machining accuracy of parts.
【學(xué)位授予單位】：山東大學(xué)
【學(xué)位級(jí)別】：博士
【學(xué)位授予年份】：2013
【分類號(hào)】：TH166;TP391.72

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