CN111177906B - Method for accurately compensating discrete die profile - Google Patents
Method for accurately compensating discrete die profile Download PDFInfo
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- CN111177906B CN111177906B CN201911318820.4A CN201911318820A CN111177906B CN 111177906 B CN111177906 B CN 111177906B CN 201911318820 A CN201911318820 A CN 201911318820A CN 111177906 B CN111177906 B CN 111177906B
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- G06T17/10—Constructive solid geometry [CSG] using solid primitives, e.g. cylinders, cubes
Abstract
The invention belongs to the field of metal forging and extruding precision forming, and particularly relates to a discretization die profile precision compensation method which is a profile compensation method based on point-to-point operation. According to the invention, according to the principle of profile reverse compensation, point cloud matching between the profile of the mold and the profile of the part is completed by utilizing the closest point pair technical thought, so that all point cloud compensation of the profile of the mold is realized, the influence of mold deformation and part resilience on the forming precision can be effectively reduced, and meanwhile, the technology for directly generating the STL model from the point cloud is provided, the traditional profile point line surface fitting error is avoided, and the compensation precision of the profile of the complex mold is improved. The invention can reasonably control the influence of the deformation of the die and the rebound of the part on the forming precision, is beneficial to the precision design of die products and improves the development efficiency.
Description
Technical Field
The invention belongs to the field of metal forging and extruding precision forming, and particularly relates to a numerical simulation-based die deformation and part springback compensation method.
Background
The information disclosed in this background of the invention is only for enhancement of understanding of the general background of the invention and is not necessarily to be taken as an acknowledgement or any form of suggestion that this information forms the prior art already known to a person skilled in the art.
With the development of the mechanical industry, particularly the continuous development of the modern manufacturing industry, the precision forging and extruding forming technology is widely applied, and by adopting the technology, the part can meet the design requirement without subsequent processing or with a small amount of processing after being formed, so the requirement on the control of the forming precision is very high. In the part forming process, especially in the cold forming process, the die is stressed to generate elastic deformation, and the part can generate certain resilience after being demoulded, both the elastic deformation and the resilience can cause deviation between the shape, the size and the design of the part, so that the part forming precision is directly influenced, and the deformation can not be avoided generally.
The research on the rebound problem at home and abroad mainly focuses on the sheet forming, and in the aspect of volume forming, the plastic deformation of a part is generally considered to be far larger than the elastic deformation, so that the problems of the elastic deformation of a die in the forming process and the rebound of the part after forming are often ignored. Some scholars also study the part resilience and the elastic deformation of the die, and the traditional method compensates the die by adopting a trial-and-error method based on experience, so that the time and the labor are consumed, the part with a simple curved surface can only be subjected to the skill and the experience of an operator, the development period of the die is long, and the development of the die industry is not facilitated.
In recent years, some scholars have proposed a method of compensating the die profile to solve the problem of springback, that is, the die profile is pre-corrected under the premise of considering the springback amount so as to ensure that the shape and size of the part after springback meet the design requirements. However, the inventor finds that most of the research done at present only compensates for the springback of the part after demolding or only compensates for the deformation of the die during the forming process, or completes the simultaneous compensation of the elastic deformation of the die and the springback of the part aiming at a certain section curve, such as the compensation of the involute gear, the compensation of certain sections of the blade, and the like, and the report of a precise compensation method for the space complex section is lacked. The problems that the complex molded surface is difficult to describe by a curved surface equation, the research on a plurality of sections of the curved surface is not accurate enough, time and labor are wasted, the efficiency is low, the shape of the deformed mold and the shape of the part before springback cannot be measured, the point-to-point relation between the molded surface of the mold and the molded surface of the part cannot be determined and the like exist.
Disclosure of Invention
Aiming at the problems, the invention provides a discretization die profile accurate compensation method, which is used for discretizing a die and a part based on numerical simulation, accurately calculating the deformation of the die and the springback of the part after demoulding in the forming process, realizing the accurate compensation of the complex die profile and being beneficial to improving the forming precision of the part.
In order to achieve the purpose, the invention adopts the following technical scheme: the method comprises the steps of compensating a mould profile based on point-to-point operation, completing mould deformation and part springback compensation by using the method, carrying out simulation according to a new mould profile after compensation, repeating the operation and carrying out iterative compensation for many times if the size of a formed part does not meet the tolerance requirement, and thus realizing accurate compensation of mould deformation and part springback in the forming process.
Specifically, the method for accurately compensating the profile of the discretization die comprises the following steps:
(1) drawing a three-dimensional modeling diagram of the blank model and the die model before compensation;
(2) carrying out grid division on the blank model and the die model by a numerical simulation means, then discretizing an entity, finishing simulation calculation of part forming and part demoulding resilience, and obtaining a unit grid model consisting of a plurality of nodes before and after die deformation and before and after part demoulding resilience and grid node data;
(3) screening node data on the surfaces of the die and the part, removing the node data at positions which do not need to be compensated, and reserving profile point cloud data to be compensated which have large influence on forming precision;
(4) carrying out point pair matching on the profile point cloud before and after the mould deformation and the profile point cloud before and after the part deformation, and completing the deformation compensation of each point in the mould profile by applying the mould profile reverse compensation principle to obtain all point cloud data after the profile compensation to be performed;
(5) combining the point clouds which are removed in the step (3) and do not need to be compensated with the point clouds compensated by the compensation molded surface in the step (4) into a group of point clouds, namely the discrete point clouds on all the surfaces of the compensated mold;
(6) performing reverse modeling on the discrete point cloud data on the surface of the compensated mold to obtain a compensated mold entity model;
(7) carrying out simulation again according to the compensated mould solid model obtained in the step (6), calculating the distance error between the size of the formed part and the standard molded surface, and comparing the distance error with the tolerance of the part;
(8) and (4) if the comparison result does not meet the requirement of the dimensional tolerance of the part, repeating the steps (3) to (7), and starting the step (3), wherein the solid model obtained in the step (6) is taken as an object.
Further, in the step (1), a three-dimensional modeling software is adopted to draw the three-dimensional modeling diagram, and optionally, the three-dimensional modeling software includes UG and the like.
Further, in the step (2), the unit mesh used may be a tetrahedral mesh or a hexahedral mesh.
Further, in step (2), the node data includes three-dimensional coordinates and tetrahedral vertex information of all nodes.
Further, in the step (3), the basis for screening the surface node data is as follows: the patches inside the solid are all common units, i.e. they will be shared with another tetrahedron or hexahedron, while the patches on the surface of the solid will not be shared.
Further, in the step (3), the data not requiring compensation includes non-molding surfaces such as a symmetry surface.
Further, in the step (3), the removal of the data of the position which does not need to be compensated can be performed according to the three-dimensional geometric features of the entity.
Further, in the step (4), when the point pair matching is carried out, the closest point from the part molded surface to the point cloud of the molded surface of the mold is taken as the matching point pair.
Further, in the step (4), the principle of the reverse compensation of the mold surface is to add the deformation of the mold and the rebound quantity of the part after demolding to the size of the mold surface reversely, namely D2＝D1+Δ1+Δ2Wherein: d1The size of the mould profile before compensation; d2The size of the mould profile after compensation; delta1The deformation of the molded surface of the mold; delta2The rebound quantity of the part after demolding.
Further, in step (6), the inverse reconstruction of the compensated model may be performed by following the working principle of point-line-plane-body, or by directly completing the conversion from point cloud to STL model data by using programming software.
Further, in the step (7), the distance error between the size of the finally formed part and the standard profile is the average distance between all nodes in the standard profile and the nearest point of the profile of the formed part.
According to the principle of reverse compensation of the mold surface, the invention completes the matching of the point cloud of the mold surface and the point cloud of the part surface by utilizing the technical idea of the nearest point pair, and simultaneously completes the compensation of all the point clouds on the mold surface, thereby effectively reducing the influence of the mold deformation and the part rebound on the final forming size precision. Meanwhile, a technology for directly generating the STL file model by the point cloud is provided, so that errors in the traditional profile point-line-surface fitting process are avoided, and the efficiency and the precision of the profile compensation of the complex mould are improved.
Compared with the prior art, the invention has the following beneficial effects:
(1) the invention provides a method for describing a complex profile by using discretized point cloud, which avoids the limitation of compensating by intercepting part of a section in the traditional complex profile compensation.
(2) The invention can eliminate the influence of the deformation of the die and the rebound of the part on the precision of the finally formed part to the maximum extent in the forming process, simultaneously save the die testing cost, shorten the debugging period and improve the precision and the efficiency of the die development.
(3) The invention provides a model reconstruction method based on point cloud to STL model conversion, which avoids the traditional curved surface reconstruction process causing precision loss and improves the precision and efficiency of model reconstruction.
Drawings
The accompanying drawings, which are incorporated in and constitute a part of this specification, are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification, illustrate exemplary embodiments of the invention and together with the description serve to explain the invention and not to limit the invention.
Fig. 1 is a schematic flow chart of a method for accurately compensating a discretized mold profile according to an embodiment of the present invention.
FIG. 2 is a data graph of a node grid of a male mold surface in an embodiment of the invention.
FIG. 3 is a diagram of part profile node grid data in an embodiment of the present invention.
FIG. 4 is a point cloud of a molded surface to be compensated before deformation of a male die in the embodiment of the invention.
FIG. 5 is a point cloud of a profile to be compensated before a part rebounds in the embodiment of the invention.
Fig. 6 is a schematic diagram of a closest point pair in the embodiment of the present invention.
FIG. 7 is a schematic diagram illustrating a point-to-point operation compensation principle according to an embodiment of the present invention.
FIG. 8 is a convex model of the discrete point cloud converted into an STL file in an embodiment of the present invention.
Detailed Description
It should be noted that the following detailed description is exemplary and is intended to provide further explanation of the disclosure. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs.
It is noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments according to the present application. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, and it should be understood that when the terms "comprises" and/or "comprising" are used in this specification, they specify the presence of stated features, steps, operations, devices, components, and/or combinations thereof, unless the context clearly indicates otherwise.
As described in the background art, for a more complex profile, there are problems that the shape of the die after deformation and the shape of the part before springback cannot be measured, and the point-to-point relationship between the die profile and the part profile cannot be determined. Therefore, the invention provides a method for accurately compensating the profile of the discretization die; the invention will now be further described with reference to the accompanying drawings and detailed description.
Referring to fig. 1, a method for accurately compensating a profile of a discretized mold comprises the following steps:
(1) before compensation is completed, three-dimensional modeling is performed on a blank model and a die model; in the embodiment, the modeling of the required entity is completed by using three-dimensional modeling software UG;
(2) performing finishing forming and springback simulation calculation on the model established in the step (1) by adopting numerical simulation software in a computer at an extrusion speed of 60mm/s according to actual forming conditions, and extracting a grid model with a unit grid and grid node data which are formed by a plurality of nodes before and after the die deformation and the part demolding springback in the finishing process, wherein the grid model comprises three-dimensional coordinate values of all nodes and tetrahedral vertex information; in the present embodiment, the simulation is completed by using the numerical simulation software DEFORM;
(3) screening node data on the surfaces of a die and a part, wherein the node data are male die profile node grid data as shown in figure 2, the node data are part profile node grid data as shown in figure 3, non-forming surfaces such as a symmetrical surface and the like are removed as data which do not need compensation, and profile point clouds to be compensated influencing forming precision are left, wherein the profile point clouds to be compensated are data before deformation of the male die as shown in figure 4, and the profile point clouds to be compensated are data before rebound of the part as shown in figure 5; in this embodiment, the deletion of the point sets is completed based on the MATLAB programming;
(4) the schematic diagram of point-to-point matching between the point cloud of the molded surface before and after the deformation of the mold and the point cloud of the molded surface before and after the deformation of the part and determining the closest point is shown in fig. 6, and for one point P in the point cloud P of the molded surface of the moldiSearching and p in part surface point cloud QiThree points with the shortest Euclidean distance are marked as qj1、qj2、qj3Constructing a triangular patch from the three points, and deriving from piPointing the triangle patch and recording as qjThe foot is taken as point piThe closest point in the point cloud of the part profile, i.e. this point is taken as piMatching points of points.
After obtaining the matching point pairs, more specifically, by oneThe compensation process of the point is illustrated as an example, as shown in FIG. 7, point a1、a2Respectively the position of a certain point before and after the deformation of the male die, b1、b2Respectively corresponding points at the position before and after the part is deformed, assuming the point o as the origin of the coordinate system, and taking a as1Is a standard size reference point, then vector
The deformation amount and vector of the male die
Is the amount of springback of the part. Firstly compensating the deformation of the male die, and obtaining a position c after reverse compensation1Wherein
Then, the part springback compensation is carried out to obtain a position c2Wherein
c2Namely the compensated position of the point. And has the following components:
calculating according to formula (I), formula (II) and formula (III) to obtain the compensated point c2The coordinates of (a). The compensation process of other nodes is the same as that of the nodes, so that all point cloud data after profile compensation can be obtained; in this embodiment, the point pair matching and compensation operations are done based on software MATLAB programming.
(5) Forming a point cloud set by the point cloud at the position of the non-forming surface such as the symmetrical surface removed in the step (3) and the point cloud after medium surface compensation in the step (4), namely point cloud data of the surface of the convex die after compensation;
(6) performing reverse reconstruction on the point cloud data on the surface of the convex mold after compensation in the step (5) to obtain a compensated mold entity model; in this embodiment, the conversion from point cloud to STL model data is accomplished directly using software MATLAB programming, and the result is shown in fig. 8.
(7) Carrying out simulation again by the new mould after profile compensation in the computer, calculating the distance error between the size of the final formed part and the standard profile, and comparing the distance error with the tolerance of the part; in this embodiment, the error in the distance between the dimension of the formed part and the standard profile is the average distance from all nodes of the standard profile to the nearest point of the profile of the formed part, as shown in FIG. 6, assuming that point p is the pointiCompensating any point in the profile for the punch, point qjFor the closest matching point in the profile of the corresponding part, the error distance D is:
in the formula (IV), diIs a point piAnd point qjThe distance between them.
From the above implementation results, it can be seen that: according to the invention, according to the principle of reverse compensation of the mold surface of the mold, the matching of the point cloud of the mold surface and the point cloud of the part surface is completed by utilizing the technical idea of the nearest point pair, and simultaneously, the technology of directly generating the STL file model from the point cloud is adopted, so that the forming error distance of the obtained embodiment is respectively reduced by 0.065mm and 0.04mm compared with the forming error distance which is not compensated and is based on point-line-surface compensation, the influence of the deformation of the mold and the rebound of the part on the final forming size precision is obviously reduced, the error in the traditional process of point-line-surface fitting of the mold surface is avoided, and the efficiency and the precision of the compensation of the complicated mold surface are improved.
The above description is only a preferred embodiment of the present application and is not intended to limit the present application, and various modifications and changes may be made by those skilled in the art. Any modification, equivalent replacement, improvement and the like made within the spirit and principle of the present application shall be included in the protection scope of the present application.
Claims (11)
1. A method for accurately compensating a profile of a discretization die is characterized by comprising the following steps:
(1) drawing a three-dimensional modeling diagram of the blank model and the die model before compensation;
(2) carrying out grid division on the blank model and the die model by a numerical simulation means, then discretizing an entity, finishing simulation calculation of part forming and part demoulding resilience, and obtaining a unit grid model consisting of a plurality of nodes before and after die deformation and before and after part demoulding resilience and grid node data;
(3) screening node data on the surfaces of the die and the part, removing the node data at positions which do not need to be compensated, and reserving profile point cloud data to be compensated which have large influence on forming precision;
(4) carrying out point pair matching on the profile point cloud before and after the mould deformation and the profile point cloud before and after the part deformation, and completing the deformation compensation of each point in the mould profile by applying the mould profile reverse compensation principle to obtain all point cloud data after the profile compensation to be performed; in the step (4), the principle of the reverse compensation of the mold surface is that the deformation of the mold and the rebound quantity of the part after demolding are reversely added to the size of the mold surface, namely D2＝D1+Δ1+Δ2Wherein: d1The size of the mould profile before compensation; d2The size of the mould profile after compensation; delta1The deformation of the molded surface of the mold; delta2The rebound quantity of the part after demolding;
(5) combining the point clouds which are removed in the step (3) and do not need to be compensated with the point clouds compensated by the compensation molded surface in the step (4) into a group of point clouds, namely the discrete point clouds on all the surfaces of the compensated mold;
(6) performing reverse modeling on the discrete point cloud data on the surface of the compensated mold to obtain a compensated mold entity model;
(7) carrying out simulation again according to the compensated mould solid model obtained in the step (6), calculating the distance error between the size of the formed part and the standard molded surface, and comparing the distance error with the tolerance of the part;
(8) and (4) if the comparison result does not meet the requirement of the dimensional tolerance of the part, repeating the steps (3) to (7), and starting the step (3), wherein the solid model obtained in the step (6) is taken as an object.
2. The method for precisely compensating for the mold surface of the discretized mold according to claim 1, wherein, in the step (1), the three-dimensional modeling drawing is drawn by using three-dimensional modeling software.
3. The method for precisely compensating for the profile of the discretized mold according to claim 2, wherein the three-dimensional modeling software is UG.
4. The method for precisely compensating for the profile of the discretized mold according to claim 1, wherein in the step (2), the unit cell used comprises one of a tetrahedral cell and a hexahedral cell.
5. The method for precisely compensating for the profile of the discretized mold according to claim 1, wherein in the step (2), the nodal data comprises all of the nodal three-dimensional coordinates and tetrahedral vertex information.
6. The method for precisely compensating for the profile of the discretized mold according to claim 1, wherein in the step (3), the surface node data is screened based on: the patches inside the solid are all common units, i.e. they will be shared with another tetrahedron or hexahedron, while the patches on the surface of the solid will not be shared.
7. The method for precisely compensating the profile of the discretized mold according to claim 1, wherein in the step (3), the data not requiring compensation includes an unformed surface such as a symmetric surface.
8. The method for precisely compensating the profile of the discretized mold according to claim 1, wherein the removing of the data of the position where the compensation is not required is performed according to a three-dimensional geometric characteristic of the solid body in the step (3).
9. The method for precisely compensating the discretized mold surface according to claim 1, wherein in the step (4), the closest point in the part surface to the point cloud of the mold surface is used as the matching point pair when the point pair matching is performed.
10. The method for precisely compensating the profile of the discretized mold according to claim 1, wherein, in the step (6), the inverse reconstruction of the post-compensation mold model is performed by following the working principle of point-line-plane-body;
or, the inverse reconstruction of the compensated mold model directly completes the conversion from the point cloud to the STL model data by using programming software.
11. The method for precisely compensating the profile of the discretized mold according to claim 1, wherein in the step (7), the distance error between the dimension of the finally formed part and the standard profile is an average distance between all nodes in the standard profile and the nearest point of the profile of the formed part.
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| CN112008436B (en) * | 2020-07-29 | 2022-05-10 | 成都飞机工业（集团）有限责任公司 | Multi-feature thin-wall plate part machining method based on initial residual stress release of blank |
| CN112131734B (en) * | 2020-09-18 | 2022-07-05 | 杭州筑峰科技有限公司 | Die matching method and system applied to curtain wall aluminum profile |
| CN113268832B (en) * | 2021-06-04 | 2023-03-14 | 邵一丹 | Design method of composite material bonding mold |
| CN116638061B (en) * | 2023-06-14 | 2023-11-21 | 广州市型腔模具制造有限公司 | Die casting size deformation control method for new energy automobile |
| CN116689781B (en) * | 2023-06-15 | 2024-02-02 | 常州工学院 | Anti-deformation compensation type additive manufacturing forming precision control method |
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