基于原位测量和补偿的复杂轮廓曲线数字化磨削加工原理和方法的研究

Research on the principle and methodology of in situ measurement and compensation based digitized complex profile grinding: ①Propose a new principle of digitized intelligence grinding of complex profile. Based on the analysis and design of profile grinding kinematics and dynamic measurement system, a digitized profile grinding process is realized featured with in situ measurement of fabrication parameters and error compensation. ②Study a machine vision based in situ measurement method in the process of profile grinding, including the key issues of high quality dynamic acquisition of complex profile image and the quick sub-pixel extraction of profile edge. ③Build the representation model of profile machining error. Analyze the uncertainty of in situ measurement of profile error and its influence factors. Study the visual servo based close loop intelligence control of profile grinding precision and error compensation algorithm. ④Propose a in situ measurement principle to measure the profile accuracy of grinding wheel. Study the quantized evaluation method of wheel profile error to direct precision wheel dressing. ⑤Quantization of abrasive wheel states including wheel profile accuracy, wheel wear. Interpret the effect of wheel states on profile grinding accuracy. The key problems above will be theoretically and experimentally investigated based on the self-developed digitized profile grinder, to establish the applied theory basis for improving the profile grinding precision and efficiency.

研究基于原位测量和补偿的复杂轮廓曲线数字化磨削加工的原理和方法：①提出一种复杂轮廓曲线精密磨削加工新原理，以制造参数高精度原位测量与补偿为特征，为数字化曲线磨削加工提供理论支撑。②研究一种基于机器视觉的复杂轮廓曲线边缘的高精度原位动态视觉检测方法，解决轮廓图像的高质量动态获取和曲线边缘亚像素快速提取问题。③构建轮廓加工误差表征模型，分析曲线轮廓误差原位测量不确定度及其影响因素，研究基于视觉伺服的曲线加工误差全闭环智能动态补偿方法。④提出一种曲线磨削砂轮廓形精度的快速原位测量原理，研究砂轮廓形误差量化评定方法。⑤建立曲线磨削加工精度评价指标，研究砂轮廓形精度、砂轮磨损的量化表征，探究其对轮廓加工精度的影响规律。依托自主开发数字化曲线磨床对上述关键问题进行理论和实验研究，为创新复杂轮廓曲线加工方式，提高曲线磨削精度和磨削效率提供应用理论基础。

项目主要研究了基于原位测量和补偿的复杂轮廓曲线数字化磨削加工的原理和方法。首先针对复杂轮廓曲线磨削特点，提出了以制造参数高精度原位测量与补偿为特征的数字化曲线磨削加工新原理，研究了基于曲线轮廓加工误差原位测量的多种加工方法，并完成了仿真实验研究，为数字化曲线磨削加工方式创新提供理论指导。其次，研究了一种基于机器视觉的复杂轮廓曲线边缘的高精度原位动态视觉检测方法，解决了轮廓图像的高质量动态获取和曲线边缘亚像素快速定位和提取问题。第三，构建了多种轮廓加工误差表征模型，分析曲线轮廓误差的来源及其影响因素，开发了基于视觉伺服的曲线加工误差全闭环智能动态补偿方法，完成了基于工件全局轮廓和基于工件局部轮廓的加工误差动态检测和补偿算法研究，经实验验证，能有效应用于新一代数字化曲线磨削加工试验平台。第四，提出了一种曲线磨削砂轮廓形精度的快速原位测量原理，研究了砂轮廓形误差和砂轮磨损的量化表征技术，完成了砂轮廓形误差量化评定方法，并进一步探究了砂轮廓形精度对工件轮廓加工精度的影响规律。最后，建立了曲线磨削的轮廓加工精度评价方法和评价指标，提出了一种基于边缘匹配的工件复杂廓形精度的评价算法完成对廓形精度的评价。项目依托自主开发数字化曲线磨床对上述关键问题进行了理论和实验研究，为创新复杂轮廓曲线加工方式，提高曲线磨削精度和磨削效率提供应用理论基础。