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
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
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
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
3D solid models for parts with regular-form surfaces (PRFSs) are effectively generated using traditional parametric design techniques. A new model is obtained by changing some parameters defining the model. The parts ...3D solid models for parts with regular-form surfaces (PRFSs) are effectively generated using traditional parametric design techniques. A new model is obtained by changing some parameters defining the model. The parts with free-form surfaces (PFFSs), however, cannot be defined by several parameters. Usually they are defined by some geometric elements like profile curves. The traditional parametric design approaches have not easily dealt with the PFFSs. A method for generating a solid model and an engineering drawing for PFFSs is proposed in this paper: First, the new profiles are generated from input point data. Second, the profile information is extracted from the existing model. Last, the old profiles are replaced with the new profiles. This method can preserve the associative information of the existing model and automatically generate the drawing including views, dimen- sions, and annotations. The proposed method has been implemented using a commercial CAD/CAM system, Unigraphics, and API functions written in C-language, and were applied to the blades of a turbine generator. Some illustrative examples are pro- vided in order to show the effectiveness of the proposed method.展开更多
With an elastic negative pole being driven by ultra so nic vibration and being moved along the surface of work-piece compliantly by ro bot, a new kind of effective EDM, the compliant EDM, cuts the electrically condu c...With an elastic negative pole being driven by ultra so nic vibration and being moved along the surface of work-piece compliantly by ro bot, a new kind of effective EDM, the compliant EDM, cuts the electrically condu ctive materials away and polishes work-piece of free-form surface. The study o f the contact force between the end of polishing tool and the surface of work-p iece is the key for the compliant EDM to study its cutting mechanism and to make better use of it. This paper makes a model for the contact force and verifies i t by experiments and simulation based on the theory of elastic body kinetics and dynamic stress concentration. The research work shows that this contact force i s caused by both the electrical impulsion of EDM and the mechanical force of ult rasonic vibration, the discharge frequency of compliant EDM has a much more clos er connection with the vibration frequency of polishing tool rather than the fre quency of ultrasonic vibration.展开更多
Current measurement method for unknown free-form surface has low efficiency.To acquire given precision, a lot of null points are measured. Based on change surface curvature, anew measurement planning is put forward. S...Current measurement method for unknown free-form surface has low efficiency.To acquire given precision, a lot of null points are measured. Based on change surface curvature, anew measurement planning is put forward. Sample step is evaluated from the change curvature and thelocally-bounded character of extrapolating curve. Two coefficients, maximum error coefficient andlocal camber coefficient, are used to optimize sampling step. The first coefficient is computed toavoid sampling-point exceeding the measurement range and the second control sampling precision.Compared with the other methods, the proposed planning method can reduce the number of themeasuring-point efficiently for the given precision. Measuring point distributes adaptively by thechange surface curvature. The method can be applied to improve measurement efficiency and accuracy.展开更多
A new method is put forward combining computer vision with computer aidedgeometric design (CAGD) to resolve the problem of free-form surface reconstruction. The surface isfirst subdivided into N-sided Gregory patches,...A new method is put forward combining computer vision with computer aidedgeometric design (CAGD) to resolve the problem of free-form surface reconstruction. The surface isfirst subdivided into N-sided Gregory patches, and a stereo algorithm is used to reconstruct theboundary curves. Then, the cross boundary tangent vectors are computed through reflectance analysis.At last, the whole surface can be reconstructed jointing these patches with G^1 continuity(tangentcontinuity). Examples on synthetic images are given.展开更多
Inspired by the three-dimensional design of flow passages in turbomachinery,this study proposes the concept of integrated passage design.The capability of adjoint method for efficient optimization and the flexibility ...Inspired by the three-dimensional design of flow passages in turbomachinery,this study proposes the concept of integrated passage design.The capability of adjoint method for efficient optimization and the flexibility of the parameterization method based on extended free-form defor-mation have been considered to develop a feasible approach to design an integrated passage.This concept was applied to redesign a typical transonic fan,Rotor 67,and the results were analyzed by CFX.It is shown that the passage was adequately adjusted in all three dimensions and reduced the strength of shock wave and wake-induced flow.In particular,the secondary flow was appropriately reorganized and the corner separation was well controlled in the end wall region,leading to signif-icant improvements in adiabatic efficiency and diffusion.展开更多
A new coarse-to-fine strategy was proposed for nonrigid registration of computed tomography(CT) and magnetic resonance(MR) images of a liver.This hierarchical framework consisted of an affine transformation and a B-sp...A new coarse-to-fine strategy was proposed for nonrigid registration of computed tomography(CT) and magnetic resonance(MR) images of a liver.This hierarchical framework consisted of an affine transformation and a B-splines free-form deformation(FFD).The affine transformation performed a rough registration targeting the mismatch between the CT and MR images.The B-splines FFD transformation performed a finer registration by correcting local motion deformation.In the registration algorithm,the normalized mutual information(NMI) was used as similarity measure,and the limited memory Broyden-Fletcher- Goldfarb-Shannon(L-BFGS) optimization method was applied for optimization process.The algorithm was applied to the fully automated registration of liver CT and MR images in three subjects.The results demonstrate that the proposed method not only significantly improves the registration accuracy but also reduces the running time,which is effective and efficient for nonrigid registration.展开更多
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.
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.
文摘3D solid models for parts with regular-form surfaces (PRFSs) are effectively generated using traditional parametric design techniques. A new model is obtained by changing some parameters defining the model. The parts with free-form surfaces (PFFSs), however, cannot be defined by several parameters. Usually they are defined by some geometric elements like profile curves. The traditional parametric design approaches have not easily dealt with the PFFSs. A method for generating a solid model and an engineering drawing for PFFSs is proposed in this paper: First, the new profiles are generated from input point data. Second, the profile information is extracted from the existing model. Last, the old profiles are replaced with the new profiles. This method can preserve the associative information of the existing model and automatically generate the drawing including views, dimen- sions, and annotations. The proposed method has been implemented using a commercial CAD/CAM system, Unigraphics, and API functions written in C-language, and were applied to the blades of a turbine generator. Some illustrative examples are pro- vided in order to show the effectiveness of the proposed method.
文摘With an elastic negative pole being driven by ultra so nic vibration and being moved along the surface of work-piece compliantly by ro bot, a new kind of effective EDM, the compliant EDM, cuts the electrically condu ctive materials away and polishes work-piece of free-form surface. The study o f the contact force between the end of polishing tool and the surface of work-p iece is the key for the compliant EDM to study its cutting mechanism and to make better use of it. This paper makes a model for the contact force and verifies i t by experiments and simulation based on the theory of elastic body kinetics and dynamic stress concentration. The research work shows that this contact force i s caused by both the electrical impulsion of EDM and the mechanical force of ult rasonic vibration, the discharge frequency of compliant EDM has a much more clos er connection with the vibration frequency of polishing tool rather than the fre quency of ultrasonic vibration.
基金This project is supported by Provincial Key Project of Science and Technology of Zhejiang (No.2003C21031).
文摘Current measurement method for unknown free-form surface has low efficiency.To acquire given precision, a lot of null points are measured. Based on change surface curvature, anew measurement planning is put forward. Sample step is evaluated from the change curvature and thelocally-bounded character of extrapolating curve. Two coefficients, maximum error coefficient andlocal camber coefficient, are used to optimize sampling step. The first coefficient is computed toavoid sampling-point exceeding the measurement range and the second control sampling precision.Compared with the other methods, the proposed planning method can reduce the number of themeasuring-point efficiently for the given precision. Measuring point distributes adaptively by thechange surface curvature. The method can be applied to improve measurement efficiency and accuracy.
基金National Natural Science Foundation of China(No.59975057).
文摘A new method is put forward combining computer vision with computer aidedgeometric design (CAGD) to resolve the problem of free-form surface reconstruction. The surface isfirst subdivided into N-sided Gregory patches, and a stereo algorithm is used to reconstruct theboundary curves. Then, the cross boundary tangent vectors are computed through reflectance analysis.At last, the whole surface can be reconstructed jointing these patches with G^1 continuity(tangentcontinuity). Examples on synthetic images are given.
基金supported by the National Science and Technology Major Project of China(Nos.2017-II-0006-0020,J2019-II-0003-0023).
文摘Inspired by the three-dimensional design of flow passages in turbomachinery,this study proposes the concept of integrated passage design.The capability of adjoint method for efficient optimization and the flexibility of the parameterization method based on extended free-form defor-mation have been considered to develop a feasible approach to design an integrated passage.This concept was applied to redesign a typical transonic fan,Rotor 67,and the results were analyzed by CFX.It is shown that the passage was adequately adjusted in all three dimensions and reduced the strength of shock wave and wake-induced flow.In particular,the secondary flow was appropriately reorganized and the corner separation was well controlled in the end wall region,leading to signif-icant improvements in adiabatic efficiency and diffusion.
基金Project(61240010)supported by the National Natural Science Foundation of ChinaProject(20070007070)supported by Specialized Research Fund for the Doctoral Program of Higher Education of China
文摘A new coarse-to-fine strategy was proposed for nonrigid registration of computed tomography(CT) and magnetic resonance(MR) images of a liver.This hierarchical framework consisted of an affine transformation and a B-splines free-form deformation(FFD).The affine transformation performed a rough registration targeting the mismatch between the CT and MR images.The B-splines FFD transformation performed a finer registration by correcting local motion deformation.In the registration algorithm,the normalized mutual information(NMI) was used as similarity measure,and the limited memory Broyden-Fletcher- Goldfarb-Shannon(L-BFGS) optimization method was applied for optimization process.The algorithm was applied to the fully automated registration of liver CT and MR images in three subjects.The results demonstrate that the proposed method not only significantly improves the registration accuracy but also reduces the running time,which is effective and efficient for nonrigid registration.
