增材制造设备位置误差建模与补偿策略  

Positioning error modeling and compensation strategy of additive manufacturing equipment

作　　者：刘洁[1] 赵训茶[1] 王文文[1] LIU Jie;ZHAO Xuncha;WANG Wenwen(Department of Intelligent Manufacturing,Shandong Labor Vocational and Technical College,Jinan 250022,China)

机构地区：[1]山东劳动职业技术学院智能制造系,山东济南250022

出　　处：《机电工程》2024年第12期2261-2271,共11页Journal of Mechanical & Electrical Engineering

基　　金：国家自然科学基金资助项目(31801632)。

摘　　要：针对广泛存在的增材制造成型产品几何与尺寸精度缺陷问题,提出了一种基于校准样件增广点实测数据与最小二乘拟合方法的增材制造设备位置误差建模与补偿策略。首先,以广泛应用的熔丝成型设备为原型,搭建了增材制造成型试验台,制造了用于建立增材制造成型设备位置误差的阶梯型金字塔校准试样集群,并采用精密坐标测量仪对试样各级台阶水平面中心点(增广点)位置以及相对竖直面的距离进行了测量;然后,基于实测数据与运动链-误差传递关系,采用低阶多项式对设备位置误差进行了表征,利用最小二乘拟合对误差模型的参数进行了估计,并根据估计参数的显著性水平,对初始误差模型进行了优化;最后,基于优化后的模型对成型件立体光刻文件进行了修正,实现了增材制造设备的位置误差补偿,提出了简要的尺寸补偿方法,并采用了新的校准式样集群与实际零件制造验证了该误差模型和补偿方法的有效性。研究结果表明:相较于未采用误差补偿制造的校准试样集群与实际零件,采用设备位置误差补偿后的成型产品最大位置误差均可控制在300μm以下,采用设备位置和尺寸误差进行补偿后,所制造的实际零件关键特征的最大相对尺寸误差为-2.4%,能够较好地满足实际工程需求,说明了误差模型和补偿方法的有效性。Aiming at the widespread geometric and dimensional accuracy defects of additive manufacturing products,a modeling and compensation strategy for the position error of additive manufacturing machines was proposed based on the measured data of calibration sample augmentation point and the least square fitting method.Firstly,based on the widely used fuse forming equipment,an additive manufacturing test bench was built.Based on the test bench,a step pyramid calibration sample cluster was manufactured to establish the position error of the additive manufacturing equipment.The position of the center point(augmented point)and the distance to the vertical plane of each step were measured by a coordinate measuring machine.Secondly,based on the measured data and the kinematic chain-error transfer relationship,the equipment position error was characterized by low-order polynomial,and the parameters of the error model were estimated by least square fitting.At the same time,the initial error model was optimized according to the significance level of the estimated parameters.Finally,the position error compensation of the additive manufacturing equipment was carried out by using the optimized model combined with the modification of the stereo lithography file of the formed parts,and a brief size compensation method was proposed at the same time.The validity of the proposed error model and compensation method was verified by the forming processes of a new calibration sample cluster and real-world mechanical parts.The research results show that,comparing with the calibration sample cluster and the real-world mechanical parts manufactured without using error compensation,the maximum position error of the formed products after using the equipment position error compensation can be controlled below 300μm,and the maximum relative dimensional error of the key features of the formed real-world mechanical parts is-2.4%after the comprehensive use of the equipment position and size error compensation.It meets the actual engineering needs,

关 键 词：误差补偿 增材制造 增广点最小二乘拟合 几何精度 尺寸补偿 运动链 

分 类 号：TH161.1[机械工程—机械制造及自动化] TH164