基于复合在机测量的双公差约束下负余量曲面的适应性加工  

Tolerance-constrained adaptive machining of negative allowance surface based on composite on-machine measurement

作　　者：丁大伟 傅玉灿[2] 徐韬锐[2] 徐丰羽 DING DaWei;FU YuCan;XU TaoRui;XU FengYu(College of Automation&College of Artificial Intelligence,Nanjing University of Posts and Telecommunications,Nanjing 210023,China;College of Mechanical&Electrical Engineering,Nanjing University of Aeronautics and Astronautics,Nanjing 210016,China)

机构地区：[1]南京邮电大学自动化学院、人工智能学院,南京210023 [2]南京航空航天大学机电学院,南京210016

出　　处：《中国科学：技术科学》2024年第1期91-106,共16页Scientia Sinica(Technologica)

基　　金：国家自然科学基金青年项目(批准号:52205568)和国家自然科学基金面上项目(批准号:52175100)资助。

摘　　要：针对复杂舱体进气道曲面热成形铸造毛坯尺寸一致性差、轮廓度和壁厚成形精度低等问题,本文提出基于复合在机测量的双公差约束下负余量曲面适应性加工方法.首先搭建复合在机测量平台,为减少数据迟滞,开发同步数据采集系统,提出激光传感器位姿迭代标定方法并分析测量误差;随后在曲面轮廓测量数据指导下,通过精确法矢解算实现壁厚的高精度超声在机测量.面向负余量曲面加工,建立轮廓度公差和壁厚公差双重约束下的数学模型,以公差占用度、不均匀度以及一致度为优化目标,在不同权重参数下实现数据驱动的新曲面重建;随后,针对复杂舱体进气道曲面制定了复合在机测量与适应性加工策略,并进行有效性验证.结果表明,轮廓度测量最大正负误差分别为+0.0083和-0.0073 mm,壁厚测量误差均在0.03 mm以内,表明在机测量系统有效.此外,该舱体进气道曲面存在负余量为-0.0524 mm区域,适应性加工后轮廓度最大正偏差和最小负偏差分别为+0.0538和-0.3655 mm,壁厚偏差最大值和最小值分别为+0.16和-0.22 mm,满足公差要求(轮廓度:-0.5~+1 mm,壁厚:-0.4~+0.2 mm)且可实现全曲面高精高效适应性加工.Aiming at the issues of poor dimensional consistency, low profile, and wall thickness forming accuracy of the complex cabin intake port surface, a tolerance-constrained adaptive machining approach for negative allowance surface based on the composite on-machine measurement is proposed. A composite on-machine measurement platform is constructed with the hysteresis effect clarified, and a synchronous data acquisition system is developed. The measurement error is then examined along with a proposed iterative calibration method for laser sensors. Under the guidance of measured profile data, the high-precision ultrasonic on-machine measurement of wall thickness is achieved by accurately solving normal vectors. For machining surfaces with negative allowance, a mathematical model is developed under double constraints of profile and thickness. Additionally, occupancy, non-uniformity, and consistency are defined, and under various weights, a data-driven surface reconstruction is realized. Experiments are used to develop and validate an on-machine measurement and adaptive machining strategy for the intricate cabin inlet surface. The results demonstrate that the positive and negative errors of the measured profile are +0.0083 and-0.0073 mm, respectively, and the errors of wall thickness are within 0.03 mm. When the surface has a negative allowance of-0.0524 mm, the profile's maximum positive and minimum negative deviations after adaptive machining are +0.0538 and-0.3655 mm, respectively. And the maximum and minimum values of the wall thickness deviation are +0.16 and-0.22 mm, respectively, which satisfy the tolerance requirements and achieve accurate and effective machining of the whole surface.

关 键 词：复合在机测量 公差约束 负余量曲面 适应性加工 

分 类 号：TG806[金属学及工艺—公差测量技术] V46[航空宇航科学与技术—航空宇航制造工程]