【摘要】：復(fù)雜環(huán)形結(jié)構(gòu)產(chǎn)品的應(yīng)用相當(dāng)廣泛,具有回轉(zhuǎn)對(duì)稱、幾何形狀耦合、整體尺寸較大、局部結(jié)構(gòu)復(fù)雜的特點(diǎn)。由于產(chǎn)品的普遍特性以及對(duì)功能的特殊要求,環(huán)形零件的質(zhì)量評(píng)價(jià)方式不同于一般的薄板零件或者其他形狀的零件,圓度、平行度、支板的角向分布均勻度等形位誤差是質(zhì)量評(píng)價(jià)必須控制的對(duì)象。形位誤差的考慮導(dǎo)致環(huán)形零件的質(zhì)量評(píng)價(jià)體系中測點(diǎn)與功能尺寸的數(shù)量十分驚人,測量效率低下。同時(shí)由于傳統(tǒng)的偏差分析算法較少考慮形位誤差的因素,現(xiàn)階段還缺乏一個(gè)針對(duì)環(huán)形零件的可行的偏差分析體系,在實(shí)際的生產(chǎn)過程中,缺乏對(duì)環(huán)形零件質(zhì)量評(píng)價(jià)的理論模型,導(dǎo)致難以實(shí)現(xiàn)生產(chǎn)前對(duì)批次產(chǎn)品質(zhì)量的預(yù)測以及故障的診斷。 針對(duì)復(fù)雜環(huán)形結(jié)構(gòu)產(chǎn)品這一特殊對(duì)象所帶來的偏差分析的諸多問題,本文首先對(duì)環(huán)形零件定位穩(wěn)定性以及定位的自由度限制程度進(jìn)行了推導(dǎo),為環(huán)形零件定位優(yōu)化提供了理論支持;然后基于優(yōu)化的定位方式提出了一種極坐標(biāo)系下針對(duì)復(fù)雜環(huán)形結(jié)構(gòu)產(chǎn)品偏差分析的確定性定位偏差分析算法,統(tǒng)一了環(huán)形零件的坐標(biāo)系與定位方式的表征方式;最后將該模型的裝配偏差計(jì)算結(jié)果與零件的形位誤差聯(lián)系起來,建立了針對(duì)環(huán)形零件的關(guān)鍵形位誤差求解模型并將提出的理論模型并在某大型復(fù)雜薄壁鑄件上進(jìn)行實(shí)踐應(yīng)用。本文的主要研究工作如下: 1)提出了針對(duì)復(fù)雜環(huán)形結(jié)構(gòu)產(chǎn)品的生產(chǎn)組裝過程的定位方式量化表征方法,為定位方式的優(yōu)化選擇提供了理論依據(jù)。 基于確定性定位夾具偏差模型,推導(dǎo)了定位方式穩(wěn)定性參數(shù)表達(dá)式。將機(jī)器人學(xué)中自由度限制度引入定位方式分析中,推導(dǎo)出定位雅可比矩陣病態(tài)指數(shù)表達(dá)式。通過這兩個(gè)定位方式量化表征參數(shù),對(duì)環(huán)形零件定位方式優(yōu)化選取進(jìn)行了實(shí)例分析。 2)根據(jù)復(fù)雜環(huán)形結(jié)構(gòu)產(chǎn)品的功能特點(diǎn),建立了針對(duì)于復(fù)雜環(huán)形結(jié)構(gòu)產(chǎn)品的基于極坐標(biāo)系下的確定性定位偏差分析模型 以極坐標(biāo)系作為工具,改進(jìn)傳統(tǒng)的確定性定位偏差分析模型,避免了在線性偏差與角向偏差轉(zhuǎn)換過程中,由于坐標(biāo)系與定位方式之間的耦合關(guān)系以及坐標(biāo)變換的數(shù)學(xué)計(jì)算所帶來的偏差。簡化了模型的輸入操作,提高了偏差分析的計(jì)算效率。 3)提出了新的形位誤差表達(dá)方法 建立了基于極坐標(biāo)系下的圓度計(jì)算模型與面角向偏差計(jì)算模型,該模型可根據(jù)極坐標(biāo)系下復(fù)雜環(huán)形結(jié)構(gòu)產(chǎn)品偏差分析模型計(jì)算出來的測點(diǎn)徑向與角向偏差,直接對(duì)復(fù)雜環(huán)形結(jié)構(gòu)產(chǎn)品的圓度、平行度、支板角度均勻度等形位誤差進(jìn)行評(píng)價(jià),將偏差分析模型與形位誤差評(píng)價(jià)聯(lián)系起來。 4)大型薄壁環(huán)形鑄件上進(jìn)行了偏差分析實(shí)例應(yīng)用 對(duì)某大型薄壁環(huán)形鑄件蠟?zāi)＝M裝過程進(jìn)行了全過程的偏差分析,對(duì)蠟?zāi)６ㄎ环绞竭M(jìn)行優(yōu)化,設(shè)計(jì)與優(yōu)化了蠟?zāi)５臏y點(diǎn)與功能尺寸;求解關(guān)鍵測點(diǎn)的徑向偏差與角向偏差,對(duì)大型薄壁環(huán)形鑄件蠟?zāi)＝M裝過程的法蘭圓度與支板角度均勻度進(jìn)行評(píng)定。分析結(jié)果表明,本文模型能夠很好的進(jìn)行偏差區(qū)域預(yù)測以及快速故障診斷,使得工程上環(huán)形件的質(zhì)量評(píng)價(jià)效率得到了提高。
[Abstract]:Complex annular structure products are widely used, which have the characteristics of rotational symmetry, geometric coupling, large overall size and complex local structure. The angular distribution uniformity isomorphic error of support plate is the object that must be controlled in quality evaluation. The number of measuring points and functional dimensions in the quality evaluation system of annular parts is astonishing and the measuring efficiency is low due to the consideration of the geometric error. A feasible deviation analysis system for annular parts lacks a theoretical model for evaluating the quality of annular parts in the actual production process, which makes it difficult to predict the quality of batch products and diagnose faults before production.
Aiming at the deviation analysis problems caused by the special object of complex annular structure products, this paper firstly deduces the stability and degree of freedom restriction of annular parts positioning, which provides theoretical support for the optimization of annular parts positioning, and then proposes a pin in polar coordinate system based on the optimized positioning method. For the deterministic positioning deviation analysis algorithm of the product deviation analysis of complex ring structure, the coordinate system and the representation of the positioning mode of the ring parts are unified; finally, the assembly deviation calculation results of the model are linked with the shape and position errors of the parts, and a key shape and position error solution model for the ring parts is established and put forward. The theoretical model is applied to a large complex thin-walled castings. The main research work of this paper is as follows:
1) A quantitative characterization method of positioning mode for manufacturing and assembling process of complex ring structure products is proposed, which provides a theoretical basis for the optimization of positioning mode.
Based on the deviation model of deterministic positioning fixture, the stability parameter expression of positioning mode is deduced, and the ill-conditioned exponential expression of positioning Jacobian matrix is deduced by introducing the degree of freedom in robotics into positioning mode analysis. Example analysis.
2) According to the functional characteristics of complex ring structure products, a deterministic positioning deviation analysis model based on polar coordinates for complex ring structure products is established.
The traditional deterministic positioning deviation analysis model is improved by using polar coordinate system as a tool to avoid the deviation caused by the coupling relationship between coordinate system and positioning mode and the mathematical calculation of coordinate transformation in the process of linear deviation and angular deviation transformation. Rate.
3) put forward a new expression method of form and position error.
A model for calculating roundness and plane angular deviation based on polar coordinate system is established. The model can directly evaluate the roundness, parallelism and support angle uniformity of complex annular structure products according to the radial and angular deviation calculated from the product deviation analysis model of complex annular structure under polar coordinate system. The deviation analysis model is combined with the geometric error evaluation.
4) example analysis of deviation analysis for large thin-walled ring castings.
The whole process deviation analysis of wax mold assembly for a large thin-walled ring casting was carried out. The wax mold positioning method was optimized, the measuring points and functional dimensions of wax mold were designed and optimized; the radial deviation and angular deviation of the key measuring points were solved, and the flange roundness and the angle uniformity of support plate in the wax mold assembly process for a large thin-walled ring casting were studied. The analysis results show that the model can predict the deviation region and diagnose the fault quickly, which improves the efficiency of quality evaluation of ring parts.
【學(xué)位授予單位】：上海交通大學(xué)
【學(xué)位級(jí)別】：碩士
【學(xué)位授予年份】：2012
【分類號(hào)】：TH165.3

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