考虑表面/亚表面微缺陷的复杂产品配合性能预测与定制选配方法及应用

Part fitting performance analysis is a key technology of assembly design of complex product. In order to describe the surface / sub-surface microdefect characteristic of part fitting surface more accurately, the theory and method of composite dimensional modeling of complex part based on three “dimension” (integral dimension, fractal dimension and high dimension) and three “appearance” (shape, topography and pattern) fusion are proposed. Firstly, the model of part microdefect surface / sub-surface appearance is established, which can express the integral dimensional shape of part surface in macro level, the fractal dimensional detail topography in micro level, and high dimensional pattern of local microdefect in mesoscopic scale. Then, the evaluation method of the part usability considering the surface / sub-surface microdefect under the enhanced geometry characteristic is proposed. The composite evaluation on the surface usability of complex parts is realized based on the influence range of surface shape on microdefect quantity, and the impact intensity of surface topography on microdefect pattern. Moreover, the assembly accuracy prediction and the customized matching technologies based on the contact cluster constraint are proposed, and geometric deviation and performance prediction combined complex parts customized matching is realized under working load. Finally, the fitting performance prediction and customized matching system for complex product is developed, which is applied to the matching analysis of the industrial steam turbine, and improves the assembly accuracy and assembly success rate of complex product.

零件配合性能分析是复杂产品装配设计中的关键技术，零件表面信息的完整性是影响产品配合性能预测准确性的重要因素。针对如何客观、准确地描述考虑表面/亚表面微缺陷的零件配合面特性这一问题，提出三“维”（整数维、分数维、高维）三“形”（形状、形貌、形态）融合的表面特征建模理论，在整体上表达零件表面宏观形状信息的同时，很好地表达了零件表面的分数维形貌细节以及局部微缺陷的高维形态；提出考虑表面/亚表面微缺陷增强几何特征的零件可用性评价方法，从宏观表面形状对微缺陷数量的影响范围、微观表面形貌对微缺陷形态的作用强度两个角度实现零件可用性复合评价；提出基于接触簇约束的复杂零件装配精度预测与定制选配技术，实现工作载荷下几何偏差和性能预测相结合的复杂零件定制选配。在理论研究的基础上，开发复杂产品配合性能预测与选配系统，应用于工业汽轮机转子叶片等关键零件的选配分析，为提高复杂产品装配精度与装配成功率提供技术支持。

围绕考虑表面/亚表面微缺陷的复杂产品配合性能预测与定制选配方法开展了系统深入的研究，取得的理论和技术突破包括：. 1）提出了增强几何特征融合的含微缺陷零件表面/亚表面模型构建方法，通过三“维”三“形”特征融合，在整体上表达零件表面宏观形状信息的同时，很好地表达了零件表面的分数维形貌细节以及局部微缺陷的高维形态。. 2）提出了考虑表面/亚表面微缺陷增强几何特征的零件可用性评价方法，从宏观表面形状对微缺陷数量的影响范围、微观表面形貌对微缺陷形态的作用强度两个角度实现了零件可用性复合评价。. 3）提出了基于性能预测的含微缺陷复杂零件定制选配技术，获得了配合零件在工作载荷下的装配定位区间和接触性能，实现了工作载荷下几何偏差和性能预测相结合的复杂零件定制选配。. 4）开发了复杂产品配合性能预测与选配系统，应用于工业汽轮机、航天电液伺服阀、导引头位标器关键零部件的性能预测与定制选配，提高了复杂产品装配精度与装配成功率，为复杂产品高精度装配工艺设计与选配方案制定提供技术支持。. 在国内外高水平学术期刊上发表了论文15篇（其中，SCI论文13篇），申请了国家发明专利10项（其中，已授权7项），取得了软件著作权5项，获得了2020年中国产学研合作创新与成果二等奖，参加国际学术会议并作分组报告3次，培养了博士研究生7名、硕士研究生4名。