CN115146405B - 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) Sampling data points on the surface of the part blank, and carrying out pretreatment operations such as denoising, sequencing and the like on the sampling points; 2) Taking the sampling point set as a matching target, and carrying out rigid registration on the theoretical CAD model of the part and the preprocessed sampling points; 3) And acquiring cross section lines of different positions of the registered theoretical CAD model by adopting an isocross section method and intersecting operation, and dispersing the cross section lines into point sets by adopting an isoparametric method. Taking the sampling point set as a deformation target, performing non-rigid registration deformation on the discrete point set of the theoretical section line, and generating the section line by adopting NURBS curve interpolation on the deformed discrete point set; 4) And generating a CAD model adapting to the processing technology of the current part by a lofting section line method. The problem of the thin wall part because of the actual blank geometry that thermoforming warp causes can't envelope theoretical CAD model and lead to the fact the processing allowance not enough is solved.
Description
Technical Field
The invention belongs to the field of machine manufacturing and reverse engineering, and particularly relates to a model reconstruction method based on non-rigid registration deformation, which belongs to an auxiliary method for improving reverse modeling accuracy and machining precision.
Background
The thin-wall part has the advantages of light weight and less material consumption, and is widely applied to the manufacture of structural parts in the aviation field. But the rigidity of the material is lower, the material is easy to deform, and the processing precision is difficult to ensure. In order to realize high-efficiency and high-quality manufacture of aviation parts, the combined machining of the hot forming manufacture and the numerical control milling is the main manufacturing mode of the current thin-wall parts. The traditional thin-wall part is formed from an integral blank to a final part, numerical control material reduction processing is needed to be carried out on the blank for many times, the production period of the part is long, and the material removal rate is high. In the structural part in the aviation field, materials are often difficult to process, which are represented by titanium alloy, and the materials are high in price, so that the structural part in the aviation field has high cost.
At present, the thin-wall part is often formed in a near-net shape, only a small amount of machining allowance is reserved after the part is formed, and the allowance is removed through machining methods such as numerical control milling and grinding, so that the manufacturing period of the thin-wall part is greatly shortened, and the material cost is reduced. However, due to the influence of factors such as temperature fluctuation, die abrasion, thermal deformation and the like in the near net forming process, the appearance of the thin-wall part after thermal forming has deviation from the theoretical shape, so that the machining allowance distribution is uneven or even insufficient, partial region undercut or out-of-tolerance in profile degree and thickness 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, polishing and the like, and the parts are longer in production period and poor in quality consistency due to severe dependence on the operation skills and experiences of workers.
Disclosure of Invention
The invention provides a model reconstruction method based on non-rigid registration deformation aiming at the defects of the prior art. Aiming at the thin-wall part easy to deform, the problem that the geometric shape of an actual blank of the thin-wall part caused by thermoforming deformation cannot envelope a CAD model of the theoretical model 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 personalized customization of the digital model of the thin-wall part processing technology is realized.
A method of model reconstruction based on non-rigid registration deformation, comprising the steps of:
step one, sampling data points on the surface of a blank of a thin-wall part through a contact probe or a non-contact point laser displacement sensor, and denoising and sequencing the sampling points; the part is a thin-wall part which is easy to deform, in particular to a thin-wall skin part.
Step two, carrying out rigid registration on the part theoretical CAD model and the preprocessed sampling points;
step three, acquiring section lines of different heights of the registered part theoretical CAD model by adopting a contour cross-section method, and dispersing the section lines into point sets by adopting an isoparametric 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 adapting to the current part by a lofting section line method.
In order to optimize the technical scheme, the specific measures adopted further comprise:
and in the step one, the data point sampling is carried out on the surface of the part, namely, the data point sampling planning is carried out on the surface of the CAD model of the part by adopting a chord height difference method, the point set of the planned sampling area is fitted into a curve, the curve is compared with the CAD model of the part, the precision required by the contour degree processing of the part line is selected as chord tolerance, the sampling point is used as the optimization constraint condition of the sampling point, the sampling point is distributed more at the curvature abrupt change of the part, the smooth part is less, and the change of the appearance characteristic of the part is reflected.
In the first step, the sampling points are denoised and sequenced, and due to the reflection characteristic of the metal surface and the cleanliness of the part surface, the point laser displacement sensor is affected, so that noise points, namely unreasonable outliers, are sometimes doped in the sampled data points. Therefore, redundant and abnormal points are removed by denoising 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 ordered to prevent self-intersection of the curve during subsequent data point fitting.
In the second step, the rigid registration is to use a sampling point set as a matching target, adopt a nearest point iterative algorithm, and shorten 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 realize the rigid registration between the optimized sampling point and the part theoretical CAD model.
And step three, acquiring section lines of different heights of the registered part theoretical CAD model by adopting a contour section method, wherein the section lines are based on the rigidly registered theoretical CAD model, the contour reference plane is set according to the distribution of sampling points, and the section lines are respectively intersected with the theoretical CAD model through different sections to obtain the corresponding section lines.
The intersection line set taken in the theoretical CAD model is NURBS line segment, wherein the mathematical expression of the NURBS line segment is shown as (1):
wherein p is i To control the vertex, ω i As a weight factor, N i,k (u) is a k-th order B-spline basis function. The value range of the parameter u is [0,1 ]]The constant parameter method is to divide the parameter u into n parts according to the number of the required section points, and obtain the coordinate value of the corresponding point according to the coordinate value of each point and the formula (1).
In the third step, the 'non-rigid registration deformation of discrete point sets and sampling point sets of theoretical section lines by taking the sampling point sets as deformation targets' is that the sampling point sets are taken as deformation targets, the corresponding relation between the point pairs is established, and the relative distance between the section point sets and the sampling point sets is obtained according to the formula (2)Next, by optimizing the iteration, solve +.>The transformation matrix P corresponding to the minimum value of the (2) and the transformed cross-section point set, thereby realizing 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 squares of the projection distances of the cross-sectional point set to the sample point set in tangential and normal directions; t (P) is the deformation amount of the free deformation of the cross-section point set to the sampling point set; λ is a deformation coefficient, and a larger value of λ represents a stronger deformation.
And step four, the method of lofting the section line is that the obtained deformed section point set is imported into three-dimensional modeling software CATIA. Fitting the point set into a smooth curve by a data point fitting method in CATIA, and fitting a three-dimensional sheet body by a lofting method, thereby realizing the reconstruction of the model.
The invention has the beneficial effects that:
the invention provides a model reverse modeling method for the finish machining of the thin-wall part, solves the problem that the actual geometric shape of the thin-wall part cannot surround the machining allowance of a theoretical CAD model due to the near-net forming thermal process, reduces the high rejection rate of the thin-wall part caused by undercutting and overcutting, and effectively improves the machining precision and efficiency of the thin-wall part.
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 diagram of the chordal height difference method of the present invention;
FIG. 3 is a schematic diagram of rigid registration of the present invention;
FIG. 4 is a schematic diagram of the isoparametric method of the present invention;
FIG. 5 is a schematic illustration of the non-rigid deformation effect of the present invention;
fig. 6 is a schematic view of a "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
The flow chart of a model reconstruction method based on non-rigid registration deformation as shown in fig. 1 relates to a three-dimensional modeling technology, a digital measurement technology, a computer graphics technology and the like.
A model reconstruction method based on non-rigid registration deformation refers to a covering part, wherein the 'easily deformable thin-wall part' in the embodiment is aimed at.
Mainly comprises five steps: data preparation, model rigid registration, cross-section point set acquisition, non-rigid registration deformation and model reconstruction.
The specific process of data preparation in the step (1) is as follows:
(1) And (3) carrying out data point sampling planning on the surface of the theoretical CAD model of the skin by adopting a chord height difference method (see figure 2), fitting a point set of a planned sampling area into a curve, comparing the curve with the theoretical CAD model, selecting the contour degree processing required precision of the part line as chord tolerance, taking the chord tolerance as a sampling point optimization constraint condition, distributing more sampling points at the curvature abrupt change of the part, and reacting less smooth parts to the shape characteristic change of the part.
(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 skinned blank.
(3) After the measurement is finished, the data of the measurement points are checked, noise points which obviously deviate from the curve profile are eliminated, and the surface of the measurement points reflects the curve characteristics smoothly.
(4) The denoised measurement points are sequenced, and the sequencing principle is that the sequence among the sequenced measurement points is the same as the numerical control measurement sequence, and the self-intersection of the curves cannot occur in the subsequent fitting.
The specific process of model registration in the step (2) is as follows:
(1) And establishing a local coordinate system for the theoretical CAD model of the skin in three-dimensional modeling software CATIA. The structural characteristics of the parts are fully considered in the selection of the coordinate system, and the representativeness and convenience of the selection of the section line are ensured.
(2) Data is imported, and rigid registration is carried out by carrying out operations such as rotation, translation and the like (see fig. 3), so that measured data points and a theoretical model are overlapped as much as possible, and a consistent reference is found to prepare for taking a section.
The specific process for acquiring the cross-section point set is as follows: and establishing a reference plane at the same plane with the sampling point through CATIA, and intersecting the reference plane with a theoretical CAD model to obtain a section line.
Taking a cross-sectional line as an example, the intersecting line taken in the theoretical CAD model is a NURBS line segment, a point set needs to be created on the NURBS cross-sectional line, and points are distributed 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 To control the vertex, ω i As a weight factor, N i,k (u) is a k-th order B-spline basis function. The value range of the parameter u is [0,1 ]]The constant parameter method is to divide the parameter u into n parts according to the number of the required section points, and obtain the coordinate value of the corresponding point according to the coordinate value of each point and the formula (1).
The specific process of the non-rigid deformation in the step (3) is as follows:
taking a section as an example, taking a data point set obtained by measurement (hereinafter referred to as a sampling point set for short) and a section point set obtained by a theoretical CAD model (hereinafter referred to as a section point set for short) as inputs, taking the sampling point set as a deformation target, establishing a corresponding relation between point pairs, and obtaining the relative distance between the section point set and the sampling point set according to a formula (2)Next, by optimizing the iteration, solve +.>The transformation matrix P corresponding to the minimum value of (a) and the transformed cross-sectional point set, thereby realizing non-rigid registration deformation (as shown in fig. 5) between the cross-sectional point set and the sampling point set, and the formula is as follows:
wherein SD (L(s) i ) τ) represents the sum of squares of the projection distances of the cross-sectional point set to the sample point set in tangential and normal directions; t (P) is the deformation amount of the free deformation of the cross-section point set to the sampling point set; λ is the deformation coefficient, and a larger value of λ represents a stronger deformation.
The specific process of the model reconstruction in the step (4) is as follows: in the three-dimensional design software CATIA, the obtained deformed cross-sectional line point set is first imported. The deformed set of cross-sectional line points cannot be used for lofting, and the deformed set of cross-sectional points 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, and the order of the curve is not larger and better, the excessive order can cause the curve to be over-fitted, and the requirement of continuous fairing of the fitted curve can be met by taking 3 from the order. After the curve is fitted, the lofting of the characteristic line frame can be completed by selecting corresponding section curves and directions through the multi-section curved surface definition (Muti-sections Surface Definition) function in the CATIA rapid curved surface reconstruction module (see figure 6).
The curve fitted by the deformed section line point set can be used as a processing technology digital model by the curved surface formed by lofting, the processing requirement of the skin part blank is met, namely, the condition of insufficient processing allowance is avoided, and the processed surface meets the requirement of a contour tolerance zone.
The above is only a preferred embodiment of the present invention, and the protection scope of the present invention is not limited to the above examples, and the technical solutions under the inventive concept of the present invention all belong to the protection scope of the present invention. It should be noted that modifications and variations can be made by persons skilled in the art in light of the above teachings without departing from the spirit and scope of the invention as defined by the appended claims.
Claims (7)
1. A reconstruction method of a CAD model of a thin-wall part based on non-rigid registration deformation is characterized by comprising the following steps:
step one, carrying out data point sampling on the surface of a part blank through a contact probe or a non-contact point laser displacement sensor and preprocessing sampling points, wherein the preprocessing is denoising and sequencing operation;
step two, carrying out rigid registration on the part theoretical CAD model and the preprocessed sampling points;
step three, acquiring cross section lines of different positions of the registered part theoretical CAD model by adopting a contour cross section method and intersecting operation, and dispersing the cross section lines into point sets by adopting an isoparametric 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 a section line on the deformed discrete point set by adopting NURBS curve interpolation;
and step four, generating a machining process CAD model adapting to the current part blank by a section line lofting method.
2. The non-rigid registration deformation-based thin-wall part CAD model reconstruction method according to claim 1, wherein the method comprises the following steps: in the first step, a chord height difference method is adopted to conduct data point sampling planning on the surface of a part theoretical CAD model; the effects to be exhibited are as follows: the sampling points are distributed in the same section, the sampling points are distributed more at the abrupt change of the curvature of the part, and the smooth parts are fewer, so that the change of the appearance characteristics of the part can be reflected.
3. The non-rigid registration deformation-based thin-wall part CAD model reconstruction method according to claim 1, wherein the method comprises the following steps: in the first step, the sampling points are subjected to denoising treatment, so that abnormal points are removed, data points are simplified, and the operation rate and the robustness of an algorithm are improved; by sequencing the sampling points, the self-intersecting phenomenon of the curves during the fitting of the subsequent data points is prevented.
4. The non-rigid registration deformation-based thin-wall part CAD model reconstruction method according to claim 1, wherein the method comprises the following steps: and secondly, carrying out rigid registration on the part theoretical CAD model by taking the sampling point set as a matching target and carrying out rotation and translation operation, so that the sampling point and the part theoretical CAD model are overlapped as much as possible.
5. The non-rigid registration deformation-based thin-wall part CAD model reconstruction method according to claim 1, wherein the method comprises the following steps: acquiring cross section lines of different heights of the registered part theoretical CAD model by adopting a contour cross section method, namely acquiring intersecting lines by adopting a reference plane and the part theoretical CAD model at the same plane position as the sampling point, wherein the storage form of the intersecting lines is NURBS line segments, and dispersing the intersecting lines into point sets by adopting an isoparameter method;
the intersecting line is NURBS line segment, and the mathematical expression is shown in formula (1)
Wherein p is i To control the vertex, w i As a weight factor, N i,k (u) is a k-th order B-spline basis function.
6. The non-rigid registration deformation-based thin-wall part CAD model reconstruction method according to claim 1, wherein the method comprises the following steps: and step three, performing non-rigid registration deformation on the discrete point set and the sampling point set of the theoretical section line by taking the sampling point set as a deformation target, wherein the sampling point set is taken as the deformation target, a corresponding relation between point pairs is established, a free-form surface deformation algorithm based on the projection distance square sum is adopted to perform non-rigid registration deformation on the discrete point set and the sampling point set, and the mathematical expression is shown in the formula (2):
wherein SD (L(s) i ) τ) represents the sum of squares of the projection distances of the cross-sectional point set to the sample point set in tangential and normal directions;
t (P) is the deformation amount of the free deformation of the cross-section point set to the sampling point set; λ is the deformation coefficient, and a larger value of λ represents a stronger deformation.
7. The non-rigid registration deformation-based thin-wall part CAD model reconstruction method according to claim 1, wherein the method comprises the following steps: the method of lofting through section lines is that the obtained deformed section point set is imported into three-dimensional modeling software CATIA; fitting the point set into a smooth curve by a data point fitting method in CATIA, and fitting into a three-dimensional sheet body by a lofting method, thereby realizing reconstruction of a CAD model adapting to the processing technology of the current part blank.
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