Although significant progress has been made in precision machining of free-form surfaces recently, inspection of such surfaces remains a difficult problem. In order to solve the problem that no specific standards for ...Although significant progress has been made in precision machining of free-form surfaces recently, inspection of such surfaces remains a difficult problem. In order to solve the problem that no specific standards for the verification of free-form surface profile are available, the profile parameters of free-form surface are proposed by referring to ISO standards regarding form tolerances and considering its complexity and non-rotational symmetry. Non-uniform rational basis spline（NURBS） for describing free-form surface is formulated. Crucial issues in surface inspection and profile error verification are localization between the design coordinate system（DCS） and measurement coordinate system（MCS） for searching the closest points on the design model corresponding to measured points. A quasi particle swarm optimization（QPSO） is proposed to search the transformation parameters to implement localization between DCS and MCS. Surface subdivide method which does the searching in a recursively reduced range of the parameters u and v of the NURBS design model is developed to find the closest points. In order to verify the effectiveness of the proposed methods, the design model is generated by NURBS and the measurement data of simulation example are generated by transforming the design model to arbitrary position and orientation, and the parts are machined based on the design model and are measured on CMM. The profile errors of simulation example and actual parts are calculated by the proposed method. The results verify that the evaluation precision of freeform surface profile error by the proposed method is higher 10%-22% than that by CMM software. The proposed method deals with the hard problem that it has a lower precision in profile error evaluation of free-form surface.展开更多
An essential step for the realization of free-form surface structures is to create an efficient structural gird that satisfies not only the architectural aesthetics,but also the structural performance.Employing the ma...An essential step for the realization of free-form surface structures is to create an efficient structural gird that satisfies not only the architectural aesthetics,but also the structural performance.Employing the main stress trajectories as the representation of force flows on a free-form surface,an automatic grid generation approach is proposed for the architectural design.The algorithm automatically plots the main stress trajectories on a 3D free-form surface,and adopts a modified advancing front meshing technique to generate the structural grid.Based on the proposed algorithm,an automatic grid generator named "St-Surmesh" is developed for the practical architectural design of free-form surface structure.The surface geometry of one of the Sun Valleys in Expo Axis for the Expo Shanghai 2010 is selected as a numerical example for validating the proposed approach.Comparative studies are performed to demonstrate how different structural grids affect the design of a free-form surface structure.展开更多
Nowadays,free-form surfaces have been widely used in various industrial fields.They are usually machined by CNC machine tools,but recently have also begun to be manufactured by industrial robotic arm manipulators,than...Nowadays,free-form surfaces have been widely used in various industrial fields.They are usually machined by CNC machine tools,but recently have also begun to be manufactured by industrial robotic arm manipulators,thanks to low cost,large operation reaching space and high machining flexibility of robot.So far,various methodologies have been proposed to improve efficiency and quality of free-form surface machining,thus this paper aims at providing a state-ofthe-art review on research advances in free-form surface machining.In this review,tool path generation,feedrate scheduling in Cartesian space and trajectory planning in joint space are focused for both CNC machining and robot machining,and their research statues,existing difficulties and key issues are discussed in detail.Finally,the feasible routes,breakthrough points and future development trend are also expounded.展开更多
Titanium hollow blades are characterized with lightweight and high structural strength, which are widely used in advanced aircraft engines nowadays. Superplastic forming/diffusion bonding （SPF/DB） combined with nume...Titanium hollow blades are characterized with lightweight and high structural strength, which are widely used in advanced aircraft engines nowadays. Superplastic forming/diffusion bonding （SPF/DB） combined with numerical control （NC） milling is a major solution for manufacturing titanium hollow blades. Due to the shape deviation caused by multiple heat and pressure cycles in the SPF/DB process, it is hard to manufacture the leading and tailing edges by the milling process. This paper presents a new adaptive machining approach using free-form deformation to solve this problem. The actual SPF/DB shape of a hollow blade was firstly inspected by an on-machine measurement method. The measured point data were matched to the nominal SPF/DB shape with an improved ICP algorithm afterwards, by which the point-pairs between the measurement points and their corresponding points on the nominal SPF/DB shape were established, and the maximum modification amount of the final nominal shape was constrained. Based on the displacements between the point-pairs, an accurate FFD volume was iteratively calculated. By embedding the final nominal shape in the deformation space, a new final shape of the hollow blade was built. Finally, a series of measurement and machining tests was performed, the results of which validated the feasibility of the proposed adaptive machining approach.展开更多
It is of great significance to develop a high-efficiency and low-noise propeller optimization method for new-generation propeller aircraft design.Coupled with free form deformation method,dynamic mesh interpolation te...It is of great significance to develop a high-efficiency and low-noise propeller optimization method for new-generation propeller aircraft design.Coupled with free form deformation method,dynamic mesh interpolation technology,optimization algorithm,surrogate model,aerodynamic calculation and aeroacoustic prediction model module,the integrated aerodynamic and aeroacoustic design method of propeller is built.The optimization design for the six-blade propeller is carried out.The non-reduction in efficiency,thrust coefficient and the minimum of aerodynamic noise is treated as the optimization design objective.The spatial vorticity distribution of the propeller before and after the design is also analyzed by using unsteady computational fluid dynamics method.The results show that the optimized propeller can effectively reduce the aerodynamic noise level.The maximum total sound pressure level can be reduced by 5 dB without reducing its aerodynamic performance.The developed method has good application potential in low-noise optimization design of propeller and other rotating machinery.展开更多
基金supported by National Natural Science Foundation of China(Grant No. 51075198)Jiangsu Provincial Natural Science Foundation of China(Grant No. BK2010479)+1 种基金Jiangsu Provincial Project of 333 Talents Engineering of ChinaJiangsu Provincial Project of Six Talented Peak of China
文摘Although significant progress has been made in precision machining of free-form surfaces recently, inspection of such surfaces remains a difficult problem. In order to solve the problem that no specific standards for the verification of free-form surface profile are available, the profile parameters of free-form surface are proposed by referring to ISO standards regarding form tolerances and considering its complexity and non-rotational symmetry. Non-uniform rational basis spline（NURBS） for describing free-form surface is formulated. Crucial issues in surface inspection and profile error verification are localization between the design coordinate system（DCS） and measurement coordinate system（MCS） for searching the closest points on the design model corresponding to measured points. A quasi particle swarm optimization（QPSO） is proposed to search the transformation parameters to implement localization between DCS and MCS. Surface subdivide method which does the searching in a recursively reduced range of the parameters u and v of the NURBS design model is developed to find the closest points. In order to verify the effectiveness of the proposed methods, the design model is generated by NURBS and the measurement data of simulation example are generated by transforming the design model to arbitrary position and orientation, and the parts are machined based on the design model and are measured on CMM. The profile errors of simulation example and actual parts are calculated by the proposed method. The results verify that the evaluation precision of freeform surface profile error by the proposed method is higher 10%-22% than that by CMM software. The proposed method deals with the hard problem that it has a lower precision in profile error evaluation of free-form surface.
基金Project(51378457)supported by the National Natural Science Foundation of China
文摘An essential step for the realization of free-form surface structures is to create an efficient structural gird that satisfies not only the architectural aesthetics,but also the structural performance.Employing the main stress trajectories as the representation of force flows on a free-form surface,an automatic grid generation approach is proposed for the architectural design.The algorithm automatically plots the main stress trajectories on a 3D free-form surface,and adopts a modified advancing front meshing technique to generate the structural grid.Based on the proposed algorithm,an automatic grid generator named "St-Surmesh" is developed for the practical architectural design of free-form surface structure.The surface geometry of one of the Sun Valleys in Expo Axis for the Expo Shanghai 2010 is selected as a numerical example for validating the proposed approach.Comparative studies are performed to demonstrate how different structural grids affect the design of a free-form surface structure.
基金partially supported by the National Natural Science Foundation of China(Nos.91948203,51975097)the National Key Research and Development Project(No.2020YFA0713702)to Dalian University of Technology。
文摘Nowadays,free-form surfaces have been widely used in various industrial fields.They are usually machined by CNC machine tools,but recently have also begun to be manufactured by industrial robotic arm manipulators,thanks to low cost,large operation reaching space and high machining flexibility of robot.So far,various methodologies have been proposed to improve efficiency and quality of free-form surface machining,thus this paper aims at providing a state-ofthe-art review on research advances in free-form surface machining.In this review,tool path generation,feedrate scheduling in Cartesian space and trajectory planning in joint space are focused for both CNC machining and robot machining,and their research statues,existing difficulties and key issues are discussed in detail.Finally,the feasible routes,breakthrough points and future development trend are also expounded.
基金the financial supports of the National Natural Science Foundation of China(No.51475233)the Fundamental Research Funds for Central Universities(No.NZ2016107)the Jiangsu Innovation Program for Graduate Education(No.CXLX13_139)
文摘Titanium hollow blades are characterized with lightweight and high structural strength, which are widely used in advanced aircraft engines nowadays. Superplastic forming/diffusion bonding （SPF/DB） combined with numerical control （NC） milling is a major solution for manufacturing titanium hollow blades. Due to the shape deviation caused by multiple heat and pressure cycles in the SPF/DB process, it is hard to manufacture the leading and tailing edges by the milling process. This paper presents a new adaptive machining approach using free-form deformation to solve this problem. The actual SPF/DB shape of a hollow blade was firstly inspected by an on-machine measurement method. The measured point data were matched to the nominal SPF/DB shape with an improved ICP algorithm afterwards, by which the point-pairs between the measurement points and their corresponding points on the nominal SPF/DB shape were established, and the maximum modification amount of the final nominal shape was constrained. Based on the displacements between the point-pairs, an accurate FFD volume was iteratively calculated. By embedding the final nominal shape in the deformation space, a new final shape of the hollow blade was built. Finally, a series of measurement and machining tests was performed, the results of which validated the feasibility of the proposed adaptive machining approach.
文摘It is of great significance to develop a high-efficiency and low-noise propeller optimization method for new-generation propeller aircraft design.Coupled with free form deformation method,dynamic mesh interpolation technology,optimization algorithm,surrogate model,aerodynamic calculation and aeroacoustic prediction model module,the integrated aerodynamic and aeroacoustic design method of propeller is built.The optimization design for the six-blade propeller is carried out.The non-reduction in efficiency,thrust coefficient and the minimum of aerodynamic noise is treated as the optimization design objective.The spatial vorticity distribution of the propeller before and after the design is also analyzed by using unsteady computational fluid dynamics method.The results show that the optimized propeller can effectively reduce the aerodynamic noise level.The maximum total sound pressure level can be reduced by 5 dB without reducing its aerodynamic performance.The developed method has good application potential in low-noise optimization design of propeller and other rotating machinery.
