CN115146405A - Thin-wall part model reconstruction method based on non-rigid registration deformation - Google Patents
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Abstract
The invention discloses a thin-wall part model reconstruction method based on non-rigid registration deformation, which comprises the following steps: 1) Carrying out data point sampling on the surface of the part blank, and carrying out preprocessing operations such as denoising, sequencing and the like on sampling points; 2) The set of sampling points is taken as a matching target, carrying out rigid registration on the theoretical CAD model of the part and the preprocessed sampling points; 3) And acquiring section lines at different positions of the post-registration theoretical CAD model by adopting an equal section method and intersection operation, and dispersing the section lines into a point set by adopting an equal parameter method. Taking the sampling point set as a deformation target, carrying out non-rigid registration deformation on the discrete point set of the theoretical section line, and generating the section line by NURBS curve interpolation on the deformed discrete point set; 4) And generating a CAD model suitable for the machining process of the current part by a lofting section line method. The problem of insufficient machining allowance caused by the fact that the actual blank geometric shape cannot envelop a theoretical CAD model due to thermal forming deformation of a thin-wall part is solved.
Description
Technical Field
The invention belongs to the field of mechanical manufacturing and reverse engineering, particularly relates to a model reconstruction method based on non-rigid registration deformation, and belongs to an auxiliary method for improving the accuracy of reverse modeling and the machining precision.
Background
The thin-wall part has the advantages of light weight and less material consumption, and is widely applied to the manufacturing of structural members in the field of aviation. However, the material has lower rigidity and is easy to deform, and the processing precision is difficult to ensure. In order to realize the efficient and high-quality manufacturing of aviation parts, the combined machining of hot forming manufacturing and numerical control milling is the main manufacturing mode of the existing thin-wall parts. Traditional thin-walled parts are formed from an integral blank to a final part, the blank needs to be subjected to numerical control material reduction processing for many times, the production period of the part is long, and the material removal rate is high. In the structural member in the aviation field, a material which is difficult to machine and represented by titanium alloy is often selected, so that the price is high, and the structural member in the aviation field is high in cost.
At present, a thin-wall part is usually formed by near-net forming, only a small amount of machining allowance is left after the part is formed, and the allowance is removed by machining methods such as numerical control milling, grinding and the like, so that the manufacturing period of the thin-wall part is greatly shortened, and the material cost is reduced. However, in the near-net forming process, due to the influence of factors such as temperature fluctuation, die abrasion and thermal deformation, the outline of the thin-wall part subjected to hot forming is deviated from the theoretical shape, so that the distribution of the machining allowance is uneven or even insufficient, partial area under-cut or profile degree and thickness over-difference occur in the milling process, and the manufacturing precision of aviation parts is directly influenced or even scrapped.
At present, the machining precision of parts is improved mainly through operations such as manual correction and grinding, the operation skill and experience of workers are seriously depended, and the production period of the parts is longer and the quality consistency is poor.
Disclosure of Invention
Aiming at the defects of the prior art, the invention provides a model reconstruction method based on non-rigid registration deformation. Aiming at the easily deformed thin-wall part, the problem that the actual blank geometric shape of the thin-wall part cannot envelop the theoretical model CAD model due to the thermal forming deformation is solved by adopting a non-rigid registration deformation means for the theoretical digital model, so that the deformed theoretical digital model can be surrounded by the actual blank shape, and the personalized customization of the thin-wall part processing technology digital model is realized.
A model reconstruction method based on non-rigid registration deformation comprises the following steps:
the method comprises the following steps that firstly, data points of the surface of a thin-wall part blank are sampled through a contact probe or a non-contact point laser displacement sensor, and denoising and sorting operations are carried out on sampling points; the part is a thin-wall part easy to deform, and particularly is a thin-wall skin part.
Step two, rigidly registering the part theoretical CAD model and the preprocessed sampling points;
acquiring section lines with different heights of the registered theoretical CAD model of the part by adopting an equal-height section method, and dispersing the section lines into a point set by adopting an equal-parameter method; then, taking the sampling point set as a deformation target to perform non-rigid registration deformation on the discrete point set and the sampling point set of the theoretical section line, and generating the section line by adopting NURBS curve interpolation on the deformed discrete point set;
and step four, generating a machining process CAD model suitable for the current part by a method of lofting section lines.
In order to optimize the technical scheme, the specific measures adopted further comprise:
the step one, carrying out data point sampling on the surface of the part, namely, carrying out data point sampling planning on the surface of a CAD model of the part by adopting a chord height difference method, fitting a point set of a planned sampling area into a curve, carrying out deviation comparison on the curve and the CAD model of the part, selecting the precision required by the processing of the line profile of the part as a chord tolerance as a sampling point number optimization constraint condition, distributing more sampling points at the curvature mutation parts of the part, having fewer smooth parts and reflecting the change of the appearance characteristics of the part.
In the first step, "denoising and sequencing sampling points" is that the reflection characteristic of the metal surface and the surface cleanliness of parts all affect the point laser displacement sensor, so that noise points, namely unreasonable outliers, are sometimes doped in the sampled data points. Therefore, redundant and abnormal points need to be removed by carrying out denoising operation on the sampling points, so that the data of the sampling points are simplified, and the operation rate is improved; the sampled data points are then sorted to prevent self-intersection of curves when subsequent data points are fitted.
In the second step, the rigid registration takes the sampling point set as a matching target, adopts a closest point iterative algorithm, and shortens the distance between the point pairs by rotating and translating the optimized sampling point and the part theoretical CAD model, so that the references of the two models are overlapped as much as possible, and the rigid registration between the optimized sampling point and the part theoretical CAD model is realized.
And step three, acquiring section lines with different heights of the registered theoretical CAD model of the part by adopting a contour section method, namely setting contour reference planes according to the distribution of sampling points on the basis of the rigidly registered theoretical CAD model, and acquiring corresponding section lines by respectively intersecting different sections with the theoretical CAD model.
The intersection line set taken in the theoretical CAD model is NURBS line segments, wherein the mathematical expression of the NURBS line segments is shown in formula (1):
wherein p is i For controlling the vertex, ω i As a weighting factor, N i,k And (u) is a k-th order B-spline basis function. The value range of the parameter u is [0,1 ]]The isoparametric method equally divides the parameter u into n parts according to the number of the required cross-sectional points, and obtains the coordinate value of the corresponding point according to the coordinate value corresponding to each point and the formula (1).
The third step is that the sampling point set is used as a deformation target to perform non-rigid registration deformation on the discrete point set and the sampling point set of the theoretical section line, the sampling point set is used as a deformation target to establish the corresponding relation between the point pairs, and the relative distance between the section point set and the sampling point set is obtained according to the formula (2)
Then through optimization iteration, solving
The transformation matrix P corresponding to the minimum value of the cross-section point set and the transformed cross-section point set, so as to realize the non-rigid registration deformation between the cross-section point set and the sampling point set, and the formula is as follows:
wherein SD (L(s) i ) τ) represents the sum of the squares of the projection distances from the set of cross-sectional points to the set of sample points along the tangential direction and the normal direction; t (P) is a deformation quantity of the cross-section point set to the sampling point set for free deformation; λ is the deformation coefficient, and a larger value of λ represents a stronger deformation.
The method for lofting the section lines in the fourth step is to import the obtained deformed section point set into the three-dimensional modeling software CATIA. And fitting the point set into a smooth curve by a data point fitting method in the CATIA, and fitting a three-dimensional sheet body by a lofting method so as to reconstruct the model.
The invention has the beneficial effects that:
the invention provides a model reverse modeling method for finish machining of thin-wall parts, solves the problem that the machining allowance of the theoretical CAD model cannot be surrounded by the actual geometric shape of the thin-wall parts due to the near-net forming thermal process is insufficient, reduces the high rejection rate of the thin-wall parts due to under-cut and over-cut, and effectively improves the machining precision and efficiency of the thin-wall parts.
Drawings
FIG. 1 is a flow chart of a non-rigid registration deformation based model reconstruction method of the present invention;
FIG. 2 is a schematic view of the chordal height difference method of the present invention;
FIG. 3 is a schematic diagram of the rigid registration of the present invention;
FIG. 4 is a schematic diagram of an isoparametric method of the present invention;
FIG. 5 is a schematic diagram of the effect of non-rigid deformation of the present invention;
FIG. 6 is a schematic view of the "point-line-plane" configuration of the present invention.
Detailed Description
The present invention will be described in detail with reference to specific examples.
Example 1
Fig. 1 shows a flowchart of a model reconstruction method based on non-rigid registration deformation, which relates to a three-dimensional modeling technique, a digital measurement technique, a computer graphics technique, and the like.
A model reconstruction method based on non-rigid registration deformation aims at a deformable thin-wall part in the embodiment and is a skin part.
The method mainly comprises five steps: data preparation, rigid model registration, section point set acquisition, non-rigid registration deformation and model reconstruction.
The specific process of the data preparation in the step (1) is as follows:
(1) A chord height difference method (shown in figure 2) is adopted to carry out data point sampling planning on the surface of a skin theoretical CAD model, a point set of a planned sampling area is fitted into a curve, the curve is subjected to deviation comparison with the theoretical CAD model, the required precision of part line profile machining is selected as a chord tolerance and is used as a sampling point number optimization constraint condition, the number of sampling points is more at the part curvature abrupt change part, the smooth part is less, and the change of part appearance characteristics is reflected.
(2) And processing the sampling point data into a numerical control measuring program which can be identified by a machine tool through a configured post-processing program, and starting to measure the appearance of the blank of the skin.
(3) After the measurement is finished, the measurement point data is checked, noise points which obviously deviate from the curved surface outline are eliminated, and the surface of the measurement point is smooth and reflects the curved surface characteristics.
(4) And sequencing the denoised measuring points according to the principle that the sequence of the sequenced measuring points is the same as the numerical control measuring sequence, and the curve self-intersection cannot occur in subsequent fitting.
The specific process of model registration in the step (2) is as follows:
(1) And establishing a local coordinate system for the skin theoretical CAD model in three-dimensional modeling software CATIA. The coordinate system selection needs to fully consider the structural characteristics of the parts, and the selection of the section lines is guaranteed to be representative and convenient.
(2) Data is imported and rigidly registered by performing operations such as rotation and translation (see fig. 3), so that the measured data points and the theoretical model are as coincident as possible to find a consistent reference to prepare for taking a section.
The specific process of acquiring the cross-section point set is as follows: and establishing a reference plane at the same plane with the sampling point through the CATIA, and intersecting the reference plane and the theoretical CAD model to obtain a section line.
Taking a section line as an example, taking an intersection line in a theoretical CAD model as a NURBS line segment, creating a point set on the NURBS section line, and distributing points on a boundary line according to an isoparametric method (see fig. 4), wherein the mathematical expression of the NURBS line segment is shown in formula (1):
wherein p is i For controlling the vertex, ω i As a weighting factor, N i,k And (u) is a k-th order B-spline basis function. The value range of the parameter u is [0,1 ]]The isoparametric method equally divides the parameter u into n parts according to the number of the required cross-sectional points, and obtains the coordinate value of the corresponding point according to the coordinate value corresponding to each point and the formula (1).
The non-rigid deformation in the step (3) comprises the following specific processes:
taking a section as an example, taking a data point set (hereinafter referred to as a sampling point set) obtained by measurement and a section point set (hereinafter referred to as a section point set) obtained by a theoretical CAD model as input, taking the sampling point set as a deformation target, establishing a corresponding relation between point pairs, and obtaining a relative distance between the section point set and the sampling point set according to a formula (2)
Then through optimization iteration, solving
And the transformed cross-sectional point set, thereby implementing non-rigid registration deformation between the cross-sectional point set and the sampling point set (as shown in fig. 5), which is expressed by the following formula:
wherein SD (L(s) i ) τ) represents the sum of the squares of the projection distances from the set of cross-sectional points to the set of sample points along the tangential direction and the normal direction; t (P) is a deformation quantity of the cross-section point set to the sampling point set for free deformation; λ is the deformation coefficient, and a larger value of λ represents a more severe deformation.
The concrete process of model reconstruction in the step (4) is as follows: in the three-dimensional design software CATIA, the obtained deformed section line point set is first imported. The deformed cross-section line point set cannot be used for lofting, and the deformed cross-section line point set needs to be fitted into a Curve by using a Curve from Scan command. It should be noted that the tolerance value of the fitted curve should be less than one third of the machining tolerance of the part, the order of the curve is not larger, the curve is better, the curve is overfitted due to an excessively large order, and the order is usually 3 to meet the requirement of continuous smoothness of the fitted curve. After the curve is fitted, corresponding section curves and directions are selected through a multi-section Surface Definition (Muti-sections Surface Definition) function in the CATIA rapid Surface reconstruction module, and then lofting of the characteristic wire frame can be completed (see figure 6).
The curve fitted by the deformed section line points and the curved surface formed by sample placing can be used as a processing technology digifax, the processing requirements of skin part blanks are met, namely the condition that the processing allowance is insufficient does not exist, and the processed curved surface meets the requirements of the contour tolerance band.
The above are only preferred embodiments of the present invention, and the scope of the present invention is not limited to the above examples, and all technical solutions under the inventive concept fall within the scope of the present invention. It will be appreciated by those skilled in the art that changes and modifications may be made thereto without departing from the principles of the invention, the scope of which is defined in the appended claims.
Claims (7)
1. A thin-wall part model reconstruction method based on non-rigid registration deformation is characterized by comprising the following steps:
firstly, carrying out data point sampling on the surface of a part blank and preprocessing a sampling point by using a contact probe or a non-contact point laser displacement sensor, wherein the preprocessing comprises denoising and sequencing operations;
step two, rigidly registering the part theoretical CAD model and the preprocessed sampling points;
acquiring section lines at different positions of the registered part theoretical CAD model by adopting an equal-height section method and intersection operation, and dispersing the section lines into a point set by adopting an equal-parameter method; taking the sampling point set as a deformation target, carrying out non-rigid registration deformation on the discrete point set and the sampling point set, and generating section lines by adopting NURBS curve interpolation on the deformed discrete point set;
and step four, generating a machining process CAD model suitable for the current part blank by a section line lofting method.
2. The thin-wall part model reconstruction method based on the non-rigid registration deformation as claimed in claim 1, characterized in that: in the first step, a data point sampling plan is carried out on the surface of a theoretical CAD model of the part by adopting a chord height difference method; the effects to be exhibited are: sampling points are distributed in the same section, more sampling points are distributed at the position where the curvature of the part is suddenly changed, and the smooth position is less, so that the appearance characteristic change of the part can be reflected.
3. The thin-wall part model reconstruction method based on the non-rigid registration deformation as claimed in claim 1, characterized in that: in the first step, the measurement abnormal points are removed by carrying out denoising processing on the sampling points, so that data points are simplified, and the operation rate and the robustness of the algorithm are improved; by sequencing the sampling points, the self-intersection phenomenon of the curve is prevented when the subsequent data points are fitted.
4. The thin-wall part model reconstruction method based on the non-rigid registration deformation as claimed in claim 1, characterized in that: and step two, the rigid registration is performed by rotating and translating the part theoretical CAD model by taking the sampling point set as a matching target, so that the sampling points and the part theoretical CAD model are overlapped as much as possible.
5. The method for reconstructing the thin-wall part model based on the non-rigid registration deformation as claimed in claim 1, wherein: acquiring section lines with different heights of the registered part theoretical CAD model by adopting an equal-height section method, namely performing intersection operation on the part theoretical CAD model and a reference plane at the position of the same plane as a sampling point to acquire intersection lines, wherein the intersection lines are stored in a NURBS line segment form, and then dispersing the intersection lines into a point set by adopting an equal-parameter method;
the intersection line is NURBS line segment, and its mathematical expression is shown in formula (1)
Wherein,
。
6. the thin-wall part model reconstruction method based on the non-rigid registration deformation as claimed in claim 1, characterized in that: step three, the sampling point set is used as a deformation target to carry out non-rigid registration deformation on the discrete point set and the sampling point set of the theoretical section line, the sampling point set is used as a deformation target to establish the corresponding relation between the point pairs, and a free-form surface deformation algorithm based on projection distance square sum is adopted to carry out non-rigid registration deformation on the discrete point set and the sampling point set, and the mathematical expression is shown in formula (2):
wherein,
the term represents the square sum of the projection distances from the cross-section point set to the sampling point set along the tangential direction and the normal direction;
the deformation quantity is the deformation quantity of the free deformation from the cross section point set to the sampling point set;
7. The thin-wall part model reconstruction method based on the non-rigid registration deformation as claimed in claim 1, characterized in that: the method for lofting the section lines in the fourth step is to introduce the obtained deformed section point set into three-dimensional modeling software CATIA; and fitting the point set into a smooth curve by a data point fitting method in the CATIA, and fitting into a three-dimensional sheet body by a lofting method, thereby realizing the reconstruction of the CAD model of the machining process suitable for the current part blank.
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