CN108646669B - Approximate evaluation method for surface contour error of curved surface machining part - Google Patents
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Abstract
The invention belongs to the field of contour error calculation in numerical control machining, and discloses an approximate evaluation method for surface contour errors of curved surface machining parts. Which comprises the following steps: (a) respectively recording an instruction interpolation point and a feedback tool location point in each period by taking an interpolation period as a unit, and connecting all adjacent instruction interpolation points to form a triangular mesh curved surface; (b) calculating the shortest distance from each feedback tool location point in the feedback tool location point set to the triangular mesh curved surface; (c) selecting a plurality of feedback tool positions from the feedback tool position set, actually measuring the contour error of the selected feedback tool positions, calculating a calibration coefficient to enable the actual contour error of each feedback tool position to be equal to the shortest distance calibrated by the feedback tool position, and calculating the contour error by utilizing the calibration coefficient. By the method and the device, one hundred percent of detection of the machined part is realized, and the tracing to the surface quality defect reasons is realized.
Description
Technical Field
The invention belongs to the field of contour error calculation in numerical control machining, and particularly relates to an approximate evaluation method for surface contour errors of curved surface machining parts.
Background
The surface profile error is the deviation of the actual machined surface of the part from the design surface. In the surface quality detection and machining precision evaluation of complex parts, the contour error is an important evaluation index, and therefore, calculating or evaluating the contour error of a complex curved surface is extremely important and meaningful.
The measurement and calculation of the surface profile error of the curved surface part are generally finished by adopting a coordinate measuring machine, and the working principle of the coordinate measuring machine is as follows: after the parts are machined, the parts are taken down from the numerical control machine tool and placed on a coordinate measuring machine, the coordinate measuring machine measures the actual machined surfaces of the parts according to the planned measuring paths, and then the contour error of each measuring position is calculated by using special software according to a certain algorithm according to the measuring results. At present, a plurality of researches for measuring and calculating the contour error of a curved surface based on a coordinate measuring machine mainly focus on the research and improvement aspects of a measuring path planning algorithm and a contour error calculation algorithm. For example, a method for calculating the complex curved surface contour error by combining a segmentation approximation method and a normalized real-value coding genetic algorithm is proposed in a non-patent document 'accurately calculating the complex curved surface contour error based on the genetic algorithm and the segmentation approximation method'; the non-patent document 'evaluation of complex curved surface profile error based on segmentation spherical approximation and differential evolution' proposes to optimize a measurement path by using a differential evolution algorithm and calculate the complex curved surface profile error based on a segmentation spherical approximation method; in the non-patent document 'complex surface contour error calculation based on particle swarm optimization' the particle swarm optimization is used to search the points on the design surface closest to the measuring points to obtain the contour error; in the non-patent document 'free-form surface contour error evaluation based on STL model', the STL model and a particle swarm algorithm with contraction factors are used for evaluating the contour error of the free-form surface; non-patent document "free-form surface positioning and contour error assessment based on CAD model guided measurement" proposes to combine particle swarm optimization algorithm and quasi-random sequence method to calculate contour error of free-form surface.
Although the error of the profile calculated based on the coordinate measuring machine measurement is accurate, the following problems still exist in the practical engineering application:
(1) the measurement and calculation of the coordinate measuring machine are time-consuming, the measurement and calculation of the contour errors of all parts are difficult, random sampling inspection can be performed only, or only inspection of the first part is performed, and the evaluation of the contour errors of other undetected parts depends on the machining consistency of a machine tool. However, in the actual machining process, even if the same part is machined, the machining effect of the numerical control machine tool may be inconsistent. Therefore, the contour error of the first part is qualified (unqualified) and the contour error of other parts is not qualified (unqualified);
(2) the contour error is an important index for evaluating the surface quality of a part, the excessive contour error at a certain part of the part indicates that the part has a quality defect at the position, the measurement and calculation of the curved surface contour error not only is a means for inspecting the surface quality of the part, but also provides a method for tracing the source of the quality defect reason, if the defect reason is to be traced, the position of the excessive contour error in a processing path needs to be accurately positioned, and a control instruction (speed and acceleration), processing process parameters (spindle rotating speed and cutting amount), processing path characteristics and the like when the position is processed are traced, so as to probe the cause of the surface defect, however, the tracing of the defect reason is difficult to complete in a contour error measurement and calculation mode based on a coordinate measuring machine because a corresponding relationship does not exist between the measurement path of the coordinate measuring machine and the processing path of a numerical control machine.
In summary, it is difficult to measure and calculate the profile errors of all parts and trace the source of the defect in the profile error measurement and calculation method based on the coordinate measuring machine.
Disclosure of Invention
Aiming at the defects or improvement requirements in the prior art, the invention provides an approximate evaluation method for surface contour errors of curved surface processing parts, which is characterized in that a triangular mesh of instruction interpolation points is constructed, then the shortest distance from each feedback point to the triangular mesh is calculated, finally a calibration coefficient is calculated, and the calibrated shortest distance is utilized to approximate the evaluation contour error.
To achieve the above object, according to the present invention, there is provided a method for approximate evaluation of surface profile error of a curved surface-machined part, comprising the steps of:
(a) aiming at the curved surface machining process, respectively recording an instruction interpolation point and a feedback tool position point in each period by taking an interpolation period as a unit, respectively forming a set of the instruction interpolation point and the feedback tool position point, and connecting all adjacent instruction interpolation points in the instruction interpolation point set to form a triangular mesh curved surface consisting of the instruction interpolation points;
(b) calculating the shortest distance from each feedback tool position point in the feedback tool position point set to the triangular mesh curved surface, and storing the shortest distance corresponding to each feedback tool position point;
(c) selecting a plurality of feedback tool positions from the feedback tool position set as tool positions to be measured, actually measuring the actual contour error of each tool position to be measured, setting a calibration coefficient according to the actual contour error corresponding to each tool position to be measured and the shortest distance, and constructing a contour error calculation expression of each feedback tool position by using the calibration coefficient and the shortest distance corresponding to each feedback tool position obtained in the step (b), so as to obtain the contour error of each feedback tool position.
Further preferably, in the step (b), the shortest distance from each feedback tool position point in the feedback tool position set to the surface of the triangular mesh is calculated, and the following steps are preferably performed:
(b1) aiming at any one feedback tool position qiAcquiring an instruction interpolation point corresponding to the feedback tool location point in an interpolation period;
(b2) searching and acquiring all triangles with the instruction interpolation points acquired in the step (b1) as vertexes in the triangular mesh, and respectively calculating the feedback tool location point qiObtaining a plurality of distance values by the distance between each triangle, and recording the minimum value in the plurality of distance values and the triangle corresponding to the minimum value;
(b3) repeating the step (b2) for the other two command interpolation points except the starting point in the triangle corresponding to the minimum value until the obtained minimum value is not reduced any more, thereby obtaining the feedback tool location qiA shortest distance to the triangular mesh.
Further preferably, in step (c), the calibration coefficients are set in the following manner:
wherein m is the number of the randomly selected feedback tool positions and is not more than the total number of the feedback tool positions, DiIs the profile error at the actual measured feedback tool location, diThe shortest distance from the feedback tool location point to the triangular grid is obtained, and K is a calibration coefficient.
Further preferably, in the step (c), the profile error calculation expression for each feedback tool location is preferably performed according to the following expression:
Tolj＝K×dj
wherein, ToljIs the profile error, j is any jth feedback tool position point, j is an element (1,2, …, n), n is the total number of feedback tool positions and is any positive integer.
Further preferably, in step (c), the actual measurement is preferably measured using a three-coordinate measuring machine.
In general, compared with the prior art, the above technical solution contemplated by the present invention can achieve the following beneficial effects:
1. according to the contour error acquisition method provided by the invention, the method is integrated in a numerical control system, the part contour error of a part can be synchronously calculated and obtained when the part is machined, the one-hundred-percent detection of the machined part is realized, and the contour error is accurately estimated by matching the calculation result with a coordinate measuring machine;
2. the method realizes tracing to the cause of the surface quality defect of the part, and specifically, approximately evaluates the contour error of the curved surface by taking the deviation between the feedback cutter position and the triangular mesh curved surface of the instruction interpolation point as an index, so that the position where the contour error is overlarge in the processing path can be automatically positioned, and then the control instruction (speed and acceleration), the processing process parameters (main shaft rotating speed and cutting amount), the characteristics of the programming path and the like when the position is processed are traced back, the cause of the surface defect is explored, and the tracing to the processing defect is completed.
Drawings
FIG. 1 is a flow chart of a method for surface contour error estimation constructed in accordance with a preferred embodiment of the present invention;
FIG. 2 is a schematic illustration of surface profile errors constructed in accordance with a preferred embodiment of the present invention;
FIG. 3 is a schematic diagram of an instruction interpolation point triangular mesh surface constructed in accordance with a preferred embodiment of the present invention;
FIG. 4 is a schematic diagram of the shortest distance between the feedback tool location point and the instruction interpolation point surface model constructed according to the preferred embodiment of the present invention;
FIG. 5 is a schematic diagram illustrating a principle of calculating a shortest distance from a feedback tool location point to a surface of a triangular mesh according to a preferred embodiment of the present invention;
FIG. 6 is a two-dimensional schematic diagram of the principle of approximate evaluation of surface contour errors constructed in accordance with a preferred embodiment of the present invention;
FIG. 7 is a three-dimensional schematic representation of the principles of approximate evaluation of surface contour errors constructed in accordance with a preferred embodiment of the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention. In addition, the technical features involved in the embodiments of the present invention described below may be combined with each other as long as they do not conflict with each other.
Fig. 1 is a flow chart of a method for evaluating a surface profile error constructed according to a preferred embodiment of the present invention, fig. 2 is a schematic diagram of a surface profile error constructed according to a preferred embodiment of the present invention, and as shown in fig. 1 and 2, a method for quickly approximating a surface profile error of a curved surface part includes the following steps:
(1) reconstructing the instruction interpolation points into a triangular mesh surface
And building a PCL (point closed library) working environment in VS, calling a PCL library function, setting a proper parameter, and reconstructing the instruction interpolation point into a triangular mesh curved surface. Fig. 3 is a schematic diagram of an instruction interpolation point triangular mesh surface constructed according to a preferred embodiment of the present invention, and as shown in fig. 3, is a schematic diagram of a reconstructed instruction interpolation point triangular mesh surface, where each vertex of a triangle is an instruction interpolation point, and all vertices of a triangular mesh surface are an instruction interpolation point set.
From the fact that each triangle consists of three instruction interpolation points, the relationship can be derived, as follows,
Tj{(pi,pj,pk)}
wherein,Tjis any triangle in the triangular mesh curved surface; (p)i,pj,pk) Three vertexes of the triangle;
as further seen in FIG. 3, each instruction interpolation point is associated with a plurality of triangles, such as piTriangles 1-6 are related. The following relation p can be established by counting the triangles associated with each instruction interpolation pointi{Ti......Tj... }, wherein p isiInserting any point in the point set for the instruction; { Ti......Tj... } is a set of triangles that are vertices.
(2) Calculating the deviation between the feedback tool position and the instruction interpolation point surface model
The invention calculates the deviation between the feedback cutter point and the instruction interpolation point triangular mesh curved surface by calculating the shortest distance from each feedback cutter point to the instruction interpolation point triangular mesh curved surface.
Because the instruction interpolation point and the feedback cutter point are recorded in the whole machining process by taking the interpolation period as a unit, the instruction interpolation point and the feedback cutter point have a one-to-one correspondence relationship. Fig. 4 is a schematic diagram of the shortest distance between the feedback tool location point and the instruction interpolation point curved surface model constructed according to the preferred embodiment of the present invention, as shown in fig. 4, a is any point in the mass feedback tool location points, B is the instruction interpolation point corresponding thereto, C is the projection of a on the instruction interpolation point curved surface, and d is the shortest distance between the feedback tool location point and the instruction interpolation point curved surface model, that is, the deviation between the feedback tool location point a and the instruction interpolation point curved surface model. As can be seen from the figure: the projection of the feedback cutter location point on the curved surface of the instruction interpolation point is near the instruction interpolation point corresponding to the feedback cutter location point. Therefore, the calculation of the shortest distance from each feedback tool location point to the triangular mesh curved surface of the instruction interpolation point can be converted into the calculation of the shortest distance from each feedback tool location point to a triangle near the corresponding instruction interpolation point.
And (3) calculating the shortest distance by executing the following steps on each feedback tool position:
(2-1) any feedback tool position qiThe corresponding instruction interpolation point is piCalculating q according to the relation provided in step (1)iTo by piRecording the shortest distance d and the triangle T with the shortest distance for the distances of all the triangles at the vertex;
FIG. 5 is a schematic diagram illustrating the principle of calculating the shortest distance from the feedback tool point to the surface of the triangular mesh according to the preferred embodiment of the present invention, such as calculating q in FIG. 5iThe distance to triangle 1-6 shows that the triangle 1 is closest, and is recorded as distance d and triangle T is 1;
(2-2) calculation of qiThe shortest distance d1 and the triangle T1 having the shortest distance are recorded as the distances to other triangles having the remaining vertices of the triangle T. D1 is compared with d, if d1 is larger than or equal to d, the calculation is stopped, and d is the shortest distance from the feedback cutter point to the triangular mesh curved surface; if d1 is less than d, making d equal to d1 and T equal to T1, and continuing to execute (2-2);
as shown in FIG. 5, the other triangles having the other two vertices of the triangle T (1) as vertices are triangles 7-13, and q is calculatediDistance to No. 7-13, the result shows that the distance to No. 7 is the shortest, which is recorded as d1 and triangle T1-7, because d1 < d, let d-d 1, T-T1-7; continuing to calculate, taking the other triangles taking the other vertexes of the T-shaped triangle (No. 7) as vertexes as triangles No. 14-16, and calculating qiThe distance to No. 14-16 shows that the distance to No. 14 is the shortest, which is recorded as d1, but d1 ≧ d, so the calculation is stopped. d is the shortest distance from the feedback tool position point to the instruction interpolation point triangular mesh curved surface, namely the deviation between the feedback tool position point and the instruction interpolation point curved surface.
The final calculation result of this step is:
{d1，d2,…,dj,…,dn}
and n is the total number of the feedback tool location points of the part.
(3) Calculating a calibration coefficient
The method uses the deviation between the feedback cutter position point and the command interpolation point curved surface as an index to approximately evaluate the curved surface contour error (the deviation between the designed curved surface and the actual processing surface of the part), and the index needs to be calibrated for more accurately evaluating the curved surface contour error.
Therefore, if the method is adopted for approximately evaluating the contour error for the first time or processing parameters, processed parts and the like are changed, a calibration coefficient needs to be calculated firstly; otherwise, skipping the step and directly executing the step (4);
selecting any m (generally 3-5) feedback tool positions from the massive feedback tool positions, firstly calculating the deviation between the selected feedback tool positions and the triangular mesh curved surface of the instruction interpolation point according to the methods provided in the step (1) and the step (2), and recording the result as dii∈[1,m](ii) a Then, a coordinate measuring machine is used for measuring and calculating the profile error at the position corresponding to each feedback cutter point, and the result is recorded as Dii∈[1,m]。diAnd DiHas the following relationship:
Di＝K×di
calculating a calibration coefficient K according to the following formula:
(4) approximate evaluation of contour error
And (3) multiplying each deviation value obtained by calculation in the step (2) by a calibration coefficient K in sequence to obtain:
{K×d1，K×d2,…,K×dj,…,K×dn}
the set is the final index of the approximate evaluation contour error of the invention, and the size of the part contour error is approximately evaluated according to the size of the index.
The method provided by the invention is integrated as a function of a numerical control system, the approximate evaluation result of the profile error can be calculated at the same time when a part is machined, the part with larger profile error is screened out by using the evaluation result, and the coordinate measuring machine is used for purposeful detection, specifically, when the approximate evaluation result obtained by the method is too large, the profile error of the part is very large, and the coordinate measuring machine is not required to be used for measuring again; when the approximate evaluation result is very small, the part contour error is small, and the part contour error does not need to be measured by a coordinate measuring machine; when the approximate evaluation index is not large or small, the coordinate measuring machine is required to be adopted to actually measure the actual contour error again, and the following mode can be referred to for specific operation;
according to the approximate evaluation result and the maximum profile error D allowed by qualified partsmaxThe parts are divided into three categories:
(1) the approximate evaluation index of the curved surface contour error is less than K1 multiplied by DmaxThe profile error is very small, the quality of the part is qualified, and further measurement is not needed;
(2) the approximate evaluation index of the curve contour error is more than K2 multiplied by DmaxThe profile error is large, the quality of the part is unqualified, and further measurement is not needed;
(3) the approximate evaluation index of the curved surface contour error is less than K2 multiplied by DmaxAnd is greater than K1 XDmaxAnd the part quality is evaluated to be qualified by further purposefully measuring and calculating the profile error by using a coordinate measuring machine, and the part can be detected in one hundred percent by combining the approximate evaluation result of the invention and the measurement and calculation result of the coordinate measuring machine (coefficients K1 and K2 are determined according to actual processing experience).
In a specific embodiment, the invention is integrated in a numerical control system, the calculation time is about 1 second, and in the prior art, the steps of measuring the contour error by using a coordinate measuring machine are as follows: the method has the advantages that the measurement process is complex, the measurement is difficult to be performed in percent, the process is long and only can be performed by sampling, and the contour error of other undetected parts can only be evaluated by the result of sampling, namely no measurement is performed.
In addition, because the feedback tool positions correspond to interpolation periods one by one in the method provided by the invention, (each interpolation period is that each interpolation point has an approximate evaluation index), the coordinates of the interpolation points and the program line number of the position with larger profile error can be determined, and the reasons for surface defects can be researched by backtracking control instructions (speed and acceleration), processing process parameters (spindle rotating speed and cutting amount), processing path characteristics and the like when the program line number is processed.
It will be understood by those skilled in the art that the foregoing is only a preferred embodiment of the present invention, and is not intended to limit the invention, and that any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the scope of the present invention.
Claims (2)
1. An approximate evaluation method for surface profile errors of curved surface processing parts is characterized by comprising the following steps:
(a) aiming at the curved surface machining process, respectively recording an instruction interpolation point and a feedback tool position point in each period by taking an interpolation period as a unit, respectively forming a set of the instruction interpolation point and the feedback tool position point, and connecting all adjacent instruction interpolation points in the instruction interpolation point set to form a triangular mesh curved surface consisting of the instruction interpolation points;
(b) calculating the shortest distance from each feedback tool position point in the feedback tool position point set to the triangular mesh curved surface, and storing the shortest distance corresponding to each feedback tool position point;
(c) selecting a plurality of feedback tool positions from the feedback tool position set as tool positions to be measured, actually measuring the actual contour error of each tool position to be measured, setting a calibration coefficient according to the actual contour error corresponding to each tool position to be measured and the shortest distance, and constructing a contour error calculation expression of each feedback tool position by using the calibration coefficient and the shortest distance corresponding to each feedback tool position obtained in the step (b), so as to obtain the contour error of each feedback tool position;
in the step (b), the shortest distance from each feedback tool position point in the feedback tool position point set to the triangular mesh curved surface is calculated, and the method comprises the following steps:
(b1) aiming at any one feedback tool position qiAcquiring an instruction interpolation point corresponding to the feedback tool location point in an interpolation period;
(b2) finding and retrieving vertices in the triangular mesh that are the instruction interpolation points obtained in step (b1)Having a triangle shape, respectively calculating the feedback tool location point qiObtaining a plurality of distance values by the distance between each triangle, and recording the minimum value in the plurality of distance values and the triangle corresponding to the minimum value;
(b3) repeating the step (b2) one by one on the other two vertexes except the command interpolation point in the triangle corresponding to the minimum value until the obtained minimum value is not reduced any more, thereby obtaining the feedback tool location point qiA shortest distance to the triangular mesh;
in step (c), the calibration coefficients are set in the following manner:
wherein m is the number of the randomly selected feedback tool positions and is not more than the total number of the feedback tool positions, DiIs the profile error at the actual measured feedback tool location, diThe shortest distance from the feedback tool location point to the triangular grid is provided, and K is a calibration coefficient;
in the step (c), the profile error calculation expression of each feedback tool position is performed according to the following expression:
Tolj＝K×dj
wherein, ToljIs the profile error, j is any jth feedback tool position point, j is an element (1,2, …, n), n is the total number of feedback tool positions and is any positive integer.
2. The method for approximate evaluation of surface profile error of a curved surface machined part of claim 1, wherein in step (c) said actual measurement is measured using a three-coordinate measuring machine.
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