CN106874624B - Method for online virtual detection and evaluation of forming quality of ultrathin-wall easily-deformable cylindrical part - Google Patents
Method for online virtual detection and evaluation of forming quality of ultrathin-wall easily-deformable cylindrical part Download PDFInfo
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Abstract
The invention discloses a method for online virtual detection and evaluation of the forming quality of an ultrathin-wall easily-deformable cylindrical part, which virtually and uniformly distributes pressure inside the cylindrical part according to a curved surface model of the easily-deformable cylindrical part reconstructed by online detection data and by combining the relation among materials, the cylindrical part and elastic deformation, so that the cylindrical part overcomes the self gravity and the residual elastic deformation, achieves the real state in actual use, obtains a quality evaluation model of the part to be measured, and compares the quality evaluation model with an ideal processing state model to finish quality evaluation. The invention innovatively provides a finite element-based quality (form and position precision) evaluation method for an ultrathin-wall easily-deformable cylindrical part, and provides a processing state of the ultrathin-wall cylindrical part and a real-time state of the forming quality (form and position precision) of the ultrathin-wall cylindrical part. The invention is a high-efficiency and high-precision quality evaluation method, and has the characteristics of higher accuracy and higher speed. The method can be popularized and applied to the quality (form and position precision) evaluation of other workpieces which are easy to deform, have ultra-thin walls and high precision.
Description
Technical Field
The invention belongs to a quality (form and position precision) evaluation method of an easily deformable ultrathin-wall cylindrical part after processing, and particularly relates to a method for reconstructing an easily deformable cylindrical part model according to online detection data, virtually pressurizing the inside of the cylindrical part by a finite element method according to the relation between materials, the cylindrical part and elastic deformation to enable the cylindrical part to reach an elastic deformation critical state, correspondingly defining according to form and position precision, obtaining a quality evaluation model, and comparing with an ideal model to finish quality evaluation. The method for evaluating the processing quality (form and position accuracy) of the cylindrical part is particularly suitable for the ultra-thin wall cylindrical part with smooth change of a cylindrical section curve.
Background
When the ultra-thin-wall cylindrical part related to spinning has the characteristics of large diameter, easy deformation and the like (for example, the diameter is 600-624 mm, the wall thickness is about 0.4-0.5 mm, the length is about 4000mm, the requirement of the diameter tolerance is +/-0.05 mm, and the requirement of the detection precision is +/-0.01 mm), the high requirement of spinning processing is determined by the structural particularity, the detection mode is required to be high standard, and direct detection of the forming quality (form and position precision) cannot be directly measured or is inaccurate due to factors such as size, processing state, flexibility, deformation and the like. In order to ensure the molding quality, an on-line or on-machine quality (form and position accuracy) evaluation method is urgently needed.
In the field of detecting the quality (deformation precision) of the easily-deformed part, three modes, namely an online mode, an online mode and an offline mode, are mainly provided according to the requirements of product structure and precision. Due to the fact that the product structure is ultra-flexible and easy to deform, an on-line detection mode and an off-line detection mode under a special tool supporting mode are adopted. Such as a detection panel, a height ruler with a dial indicator (for measuring parallelism), a square box (for measuring verticality), a yaw instrument (for measuring coaxiality and run-out), a feeler gauge (for measuring planeness), a roundness meter, a three-coordinate measuring machine and the like. For the easily deformable ultrathin cylindrical part, the stability and the repairability of the molding quality are considered, the off-line detection may face to secondary clamping and correction, the secondary clamping can cause the factors of non-coincidence of processing references, deformation and the like, and the product manufacturing requirement is not met. Thus, online or on-machine detection becomes a priority.
The existing method for evaluating the forming quality of a machined part mainly takes off-line and direct detection as main steps, and mainly aims at workpieces which are rigid and have small sizes and uncomplicated shapes. For easily deformed thin-wall parts, complex curved surfaces and large-size workpieces, the quality state after processing cannot be accurately obtained. In the prior art, the forming quality of the easily deformable flexible cylindrical part is not evaluated on line, and the actual engineering application is not yet achieved. Based on the above problems, a new quality evaluation method is urgently needed in the aspect of detecting the forming quality (form and position accuracy) of a large-diameter ultrathin cylindrical part in the spinning process, so that the forming quality (form and position accuracy) of the spinning part is detected, and a data basis and a feedback correction basis are provided for the machining process.
Disclosure of Invention
The invention aims to solve the technical problem of providing an online virtual detection and evaluation method for the forming quality of an ultrathin-wall easily-deformable cylindrical part, aiming at the defects of the prior art.
In order to solve the technical problems, the technical scheme adopted by the invention is as follows: according to the curved surface model of the easily-deformable cylindrical part reconstructed from the online detection data, by combining the relationship among materials, the cylindrical part and elastic deformation, pressurization is virtually and uniformly distributed in the cylindrical part, so that the self gravity and the residual elastic deformation of the cylindrical part are overcome, the actual state in actual use is achieved, a quality evaluation model of the part to be detected is obtained, and the quality evaluation is completed by comparing the model with an ideal processing state model.
The quality evaluation method of the easily-deformed cylindrical part in the spinning process comprises the following steps:
(a) and (3) reconstructing the model based on the online detection data. Acquiring the profile information of the processing state of the workpiece by using a non-contact measuring device in a stepping or spiral data measuring mode; acquiring real displacement data of the cross section outline of the piece to be measured through data analysis, elimination and processing, and converting the real displacement data into initial three-dimensional coordinates of measuring points at each position of the outline of the piece to be measured; utilizing a curve reconstruction algorithm to complete the reconstruction of the section profile, and then completing the reconstruction of the axial curved surface profile according to the axial position to obtain partial and whole profile curved surface models of the piece to be measured;
(b) based on CAE analysis of a measurement model, the obtained measurement reconstruction model is combined with the relation between the material performance, stress and elastic deformation of the easily-deformable cylindrical part, pressure is virtually and uniformly distributed in the cylindrical part, the cylindrical part is enabled to reach a real using state in a finite element mode, so that a real quality model is obtained, a part concerned by the quality model is selected and compared with an ideal model section, and quality evaluation is completed according to deformation precision definition.
Step 1: designing a processed ideal model according to spinning characteristics and corresponding spinning parameters, and importing the model into quality evaluation system software;
step 2: performing circle center constraint and uniform internal pressurization on each section of the reconstructed workpiece curved surface model by using a finite element analysis (CAE) method, and recovering to obtain a finite element model in real use in an elastic range by combining the relation of workpiece material performance, stress and elastic deformation to form a quality evaluation model;
and step 3: selecting a model segment of the concerned position according to the model state by using the axial coordinate;
and 4, step 4: mapping the initial on-line detection trajectory to the picked quality evaluation model, and calculating the central points O of the n cross sections according to the finite element model of the quality evaluation model1',O'2,...,O'nCoordinates;
and 5: determining cross section center point coordinate O by initially established ideal quality modelK(x0,y0,z0) And radius R of the thin-walled part structureK；
Step 6, determining the coordinates (x) of the corresponding m measuring points according to the evaluation model after finite element analysis when the contour line of the L th cross section has the m measuring points for collecting datai,yi,z0)i＝1,2,...,m；
And 7: according to the evaluation model after finite element analysis, calculating the coordinates of the center point of the P cross section as follows: o's'P(x0+XC,y0+YC,z0) Wherein:
step 7.1: and (5) cylindricity evaluation.
(1) Taking the center point O of each cross-section of interest1'and O'mDetermining line L and determining that line L passes through O1'and O'mTwo points are included;
(2) calculating the distance D from the point on the corresponding cross section contour line to the straight line L according to the m measuring point of each section and the point mapped on the to-be-evaluated model by the measuring point, and calculating a data set of the distance, taking the maximum value and the minimum value in the set, and subtracting the minimum value from the maximum valueAnd obtaining cylindricity error, namely cylindricity quality evaluation information, of the section concerned by the ultrathin-wall cylindrical part. Wherein D ═ { D ═ D11,d12,...,d1m；...；dn1,dn2,...,dnm}；
Step 7.2: and evaluating the size, the run-out and the roundness.
(1) Taking a cross section of a position at a distance of Z from the reference coordinate system, setting the circle center position of the cross section to be coincident with the ideal circle center position in the early analysis, and setting the center point of the cross section to be O'ZCalculating m measuring points to a central point O 'by combining m measuring points of the section and measuring points and three-dimensional coordinates mapped on the to-be-measured evaluation model according to the measuring points'ZR of (A) to (B)ZmR of whichZmIs RZm＝{Rz1,Rz2,...,Rzm}; the set is used to know the corresponding workpiece size condition;
(2) get RZmSubtracting the minimum value from the maximum value to obtain the section roundness information of the concerned position of the ultrathin-wall cylindrical part so as to realize roundness error evaluation;
(3) when the ideal model is calculated, the ideal radius of the corresponding section is RKCombining the measuring point m of the section and mapping the measuring point m to the central point O 'on the to-be-measured evaluation model according to the measuring point'ZR of (A) to (B)ZmSet of RZmSet minus RKObtaining a jitter set value, and setting T ═ Rz1-RK,Rz2-RK,...,Rzm-RKThe sum of the absolute values of the maximum value and the minimum value in the set is the maximum bounce of the cross section, and the corresponding set is the information state of the bounce of the cross section;
(c) through the steps and the incorporation into a developed software system, corresponding quality information can be obtained according to the selected section information. The rest quality evaluation methods are similar and are not repeated.
Compared with the prior art, the invention has the beneficial effects that: the invention innovatively provides a method for evaluating the quality (deformation precision) of a workpiece on line or on machine by extracting a forming real quality model based on the spinning of an easily-deformed ultrathin cylindrical part by using a CAE (computer aided engineering) method; the online evaluation of the forming precision of the ultrathin-wall cylindrical part is realized, the problem of inaccuracy of offline quality detection of the structure is solved, an online mode is realized, the accuracy is improved, and the efficiency is improved; by utilizing the method, the workpiece to be detected can be comprehensively detected at one time, so that the quality information of the formed part can be obtained, other special detection equipment (such as measuring tools such as a roundness detector, an outer micrometer and the like) is not needed except the detection equipment for initially detecting the surface information profile, and the production cost is saved; the invention is a high-efficiency and high-precision method for evaluating the forming precision of the ultrathin-wall cylindrical part, and compared with the traditional method for directly measuring and evaluating the quality, the method has the characteristics of higher accuracy and higher speed.
Drawings
Fig. 1 is a flow chart of quality evaluation (form and position accuracy) of an ultra-thin wall cylindrical part structure in an embodiment of the invention.
Detailed Description
As shown in fig. 1, according to the curved surface model of the easily deformable cylindrical part reconstructed from the online detection data, and in combination with the relationship between the material, the cylindrical part and the elastic deformation, the pressure is virtually and uniformly distributed in the cylindrical part to overcome the self gravity and the residual elastic deformation, so as to achieve the real state in actual use, obtain the quality evaluation model of the part to be detected, and compare the quality evaluation model with the ideal processing state model to finish quality evaluation. The typical quality evaluation method mainly comprises the following steps:
step 1: and (3) reconstructing the model based on the online detection data. Acquiring the profile information of the processing state of the workpiece by using a non-contact measuring device in a stepping or spiral data measuring mode; acquiring real displacement data of the cross section outline of the piece to be measured through data analysis, elimination and processing, and converting the real displacement data into initial three-dimensional coordinates of measuring points at each position of the outline of the piece to be measured; utilizing a curve reconstruction algorithm to complete the reconstruction of the section profile, and then completing the reconstruction of the axial curved surface profile according to the axial position to obtain partial and whole profile curved surface models of the piece to be measured;
step 2: based on CAE analysis of a measurement model, the obtained measurement reconstruction model is combined with the relation between the material performance, stress and elastic deformation of the easily-deformable cylindrical part, pressure is virtually and uniformly distributed in the cylindrical part, the cylindrical part is enabled to reach a real using state in a finite element mode, so that a real quality model is obtained, a part concerned by the quality model is selected and compared with an ideal model section, and quality evaluation is completed according to deformation precision definition.
Step 2.1: designing a processed ideal model according to spinning characteristics and corresponding spinning parameters, and importing the model into quality evaluation system software;
step 2.2: performing circle center constraint and uniform internal pressurization on each section of the reconstructed workpiece curved surface model by using a finite element analysis (CAE) method, and recovering to obtain a finite element model in real use in an elastic range by combining the relation of workpiece material performance, stress and elastic deformation to form a quality evaluation model;
step 2.3: selecting a model segment of the concerned position according to the model state by using the axial coordinate;
step 2.4: mapping the track line of the initial online detection to the picked quality evaluation model, and calculating the central points O 'of the n cross sections according to the finite element model of the quality to be evaluated'1,O'2,...,O'nCoordinates;
step 2.5: determining cross section center point coordinate O by initially established ideal quality modelK(x0,y0,z0) And radius R of the thin-walled part structureK；
Step 2.6, determining the coordinates (x) of the corresponding m measuring points according to the evaluation model after finite element analysis when the contour line of the L th cross section has m measuring points for collecting datai,yi,z0)i＝1,2,...,m；
Step 2.7: according to the evaluation model after finite element analysis, calculating the coordinates of the center point of the P cross section as follows: o's'P(x0+XC,y0+YC,z0) Wherein:
step 2.7.1: and (5) cylindricity evaluation.
(1) Taking the center point O of each cross-section of interest1'and O'mDetermining line L and determining that line L passes through O1'and O'mTwo points are included;
(2) calculating the distance D from the point on the corresponding cross section contour line to the straight line L according to the m measuring points of each section and the point mapped on the to-be-evaluated model by the measuring points, and calculating a data set of the distance, taking the maximum value and the minimum value in the set, and subtracting the minimum value from the maximum value to obtain the cylindricity error of the section concerned by the ultrathin-wall cylindrical part, namely cylindricity quality evaluation information11,d12,...,d1m；...；dn1,dn2,...,dnm}；
Step 2.7.2: and evaluating the size, the run-out and the roundness.
(1) Taking a cross section of a position at a distance of Z from the reference coordinate system, setting the circle center position of the cross section to be coincident with the ideal circle center position in the early analysis, and setting the center point of the cross section to be O'ZCalculating m measuring points to a central point O 'by combining m measuring points of the section and measuring points and three-dimensional coordinates mapped on the to-be-measured evaluation model according to the measuring points'ZR of (A) to (B)ZmR of whichZmIs RZm＝{Rz1,Rz2,...,Rzm}; the set is used to know the corresponding workpiece size condition;
(2) get RZmSubtracting the minimum value from the maximum value to obtain the section roundness information of the concerned position of the ultrathin-wall cylindrical part so as to realize roundness error evaluation;
(3) when the ideal model is calculated, the ideal radius of the corresponding section is RKCombining the measuring point m of the section and mapping the measuring point m to the central point O 'on the to-be-measured evaluation model according to the measuring point'ZR of (A) to (B)ZmSet of RZmSet minus RKObtaining a jitter set value, and setting T ═ Rz1-RK,Rz2-RK,...,Rzm-RKThe sum of the absolute values of the maximum value and the minimum value in the set is the maximum bounce of the cross section, and the corresponding set is the information state of the bounce of the cross section; and step 3: through the steps and the incorporation into a developed software system, corresponding quality information can be obtained according to the selected section information. The rest quality evaluation methods are similar and are not repeated.
Claims (1)
1. The method for online virtual detection and evaluation of the forming quality of the easily-deformed ultrathin-wall cylindrical part is characterized by comprising the following steps of:
1) acquiring the processing state profile information of the piece to be measured by using a non-contact measuring device in a stepping or spiral data measuring mode; acquiring real displacement data of the cross-sectional profile of the to-be-detected part through data analysis and elimination, and converting the real displacement data into initial three-dimensional coordinates of the measuring points at each position of the outer profile of the to-be-detected part; realizing model reconstruction by using a curve surface reconstruction algorithm to obtain a contour surface model;
2) combining the spinning forming characteristics and the technological parameters of the ultrathin-wall easily-deformable cylindrical part to obtain an ideal model after the ultrathin-wall easily-deformable cylindrical part is formed;
3) based on CAE analysis of a measurement model, for an obtained contour curved surface model, combining the material performance, stress and elastic deformation relation of the easily-deformable cylindrical part, virtually and uniformly distributing repeated pressurization and pressure relief in the cylindrical part, and obtaining a stable quality evaluation model through multiple times of virtual uniform pressurization and pressure relief; selecting a part concerned by a stable quality evaluation model, comparing the part with the ideal model, and finishing quality evaluation according to form and position precision definition;
the specific implementation process of the step 3) comprises the following steps:
a) importing the ideal model into quality evaluation system software;
b) performing circle center constraint and uniform internal pressurization on each section of the reconstructed workpiece curved surface model by adopting a finite element analysis method, and combining the relation between the material performance, stress and elastic deformation of the workpiece to enable the reconstructed outline curved surface model to be in an elastic deformation range to form a quality evaluation model;
c) selecting a model segment of a concerned position according to the quality evaluation model state by using an axial coordinate;
d) mapping the track line detected on line to the picked quality evaluation model, and calculating the central points O 'of the n cross sections according to the finite element model of the quality to be evaluated'1,O'2,...,O'nCoordinates;
e) determining the center point coordinate O of the kth cross section by the initially established ideal modelK(x0,y0,z0) And radius R of thin-walled part structureK；
f) In the contour line of the L th cross section, m measuring points for collecting data are provided, and the coordinates (x) of the corresponding m measuring points are determined according to an evaluation model after finite element analysisi,yi,z0),i＝1,2,...,m；
g) Center points O 'of two sections of interest'1And O'mDetermining line L and determining that line L passes through O1And O'mTwo points, calculating the distance D from the point on the corresponding cross section contour line to a straight line L according to m measuring points of each section and the point mapped on the to-be-measured evaluation model by the measuring points to obtain a data set of the distance D, obtaining the maximum value and the minimum value in the data set, subtracting the minimum value from the maximum value to obtain the cylindricity error of the section concerned by the ultrathin-wall cylindrical piece, namely cylindricity quality evaluation information, and taking the position section with the distance of Z from a reference coordinate system for size, jitter and roundness, wherein in the early analysis, the circle center position of the quality evaluation model is set to be coincident with the ideal circle center position, and the center point of the quality evaluation model is set to be O'ZCalculating m measuring points to a center point O 'by combining m measuring points of the section and measuring points and three-dimensional coordinates mapped on the to-be-measured evaluation model according to the measuring points'ZR of (A) to (B)ZmR of whichZmIs RZm＝{Rz1,Rz2,...,Rzm}，RZmThe distance value from the measuring point to the central point is a set; using the set RZmAcquiring the size condition of a corresponding workpiece; get RZmThe maximum value and the minimum value in the set are subtracted from the maximum value to obtain the ultrathin-wall cylindrical partThe section roundness information of the position is concerned, and roundness error evaluation is realized; when the ideal model is calculated, the ideal radius of the corresponding section is RKCombining m measuring points of the section and mapping the measuring points to a central point O 'on the to-be-measured evaluation model according to the measuring points'ZR of (A) to (B)ZmSet of RZmSet minus RKObtaining a jitter set value, and setting T ═ Rz1-RK,Rz2-RK,...,Rzm-RKAnd the sum of the absolute values of the maximum value and the minimum value in the set T is the maximum jitter of the cross section, and the corresponding set is the state of the jitter information of the cross section.
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