基于高密度点云测量数据的复杂多腔体零件制造误差建模理论与控制方法

The workpieces with multiple chambers are widely applied in aviation, aerospace, energy and automobile industries, etc., and their manufacturing errors affect greatly the service functions of the final product. This project takes manufacturing errors of the workpieces with multiple chambers as subject investigated, develops datum transformation based on the high-density point cloud and reconstruction algorithm of irregular surfaces of the chambers, and realizes the irregular surface configuration, boundary extraction and accurate volume calculation. Based on revealing the formation mechanism, joint variation and performance evolution of the manufacturing errors (features of chambers, plane, etc) extending in the time-domain and space-domain along the process, a combined time-space forecasting model for manufacturing errors of multi-chamber parts is proposed, and quantitative calculation of manufacturing errors in multi-stage manufacturing process of the multi-chamber parts is achieved. New control charts suitable for the sample size, data structure and error fluctuation rule of multi-chamber parts with high density point cloud data are developed to realize the time and space-based on-line monitoring of high dimensional nonlinear point cloud data. A multi-objective algorithm and feasible engineering solutions for volume consistency control of multiple chambers based on high-density point cloud data are constructed, and new methods of process optimization and tool monitoring are developed to realize on-line manufacturing feedback compensation and process optimization under mass production conditions. This project will create a new scientific basis and practical tool for modeling, monitoring and on-line robust control of manufacturing errors of complicated multi-chamber workpieces.

多腔体零件广泛应用于航空、航天、能源、汽车等领域，其制造误差对最终产品的服役性能具有重要影响。本项目以复杂多腔体零件制造误差为研究对象，建立高密度点云数据基准转换和内腔不规则曲面重构算法，实现不规则曲面构形、边界提取与容积精确计算。在揭示内腔、平面等特征制造误差随着工序延展在时间域和空间域的形成机理和联合变化规律基础上，提出多腔体零件制造误差时间-空间联合预测模型，实现对多腔体零件多工序制造过程制造误差的定量计算。开发新的适合多腔体零件高密度点云数据样本量、数据结构和误差波动规律的控制图，实现高维度非线性点云数据的时间-空间联合在线监控。基于高密度点云数据构建内腔一致性控制多目标算法与可行工程解，开发新的工艺优化和刀具监控方法，实现大批量生产条件下的制造误差在线补偿反馈和工艺优化。本项目将为复杂多腔体零件制造误差建模、监控与在线健壮控制产生一个新的科学基础与实践工具。

零件的制造误差是机械加工的重要控制对象。复杂多腔体零件通常具有壁薄、内腔形状复杂等特点，其制造误差的测量和控制一直是研究重点和难点。本项目依据高精度高密度的点云测量数据，整体反映复杂腔体零件的三维信息，从而能够揭示复杂多腔体零件制造误差的形成规律，变革传统误差控制模式。.本研究提出了复杂多腔体零件制造误差的建模理论与控制方法，围绕高密度点云数据，解决了多腔体零件不规则曲面构形、边界提取与容积精确计算的问题，提出了多腔体零件制造误差时间-空间联合预测模型，开发了高维轮廓控制图，准确揭示了多工序制造过程制造误差的传递和控制规律，实现了高维度非线性点云数据的在线监控和制造过程闭环在线健壮反馈控制。针对多腔体容积一致性问题建立容积波动与铣削深度关系模型和工程可行解，提出基于批次的腔体曲面容积波动控制方法。对多腔体零件制造误差工艺参数优化建模，开发新的工艺优化和刀具监控方法，实现大批量生产条件下的制造误差在线补偿反馈和工艺优化。为复杂多腔体零件多工序加工过程中的质量提升提供了新的科学基础与实践工具。