CN110134071B - Image processing-based circular cutting tool path generation method under constraint condition of skin mirror milling process - Google Patents
Image processing-based circular cutting tool path generation method under constraint condition of skin mirror milling process Download PDFInfo
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Abstract
A method for generating a circular cutting tool path based on image processing under the constraint condition of a skin mirror milling process comprises the following steps: firstly, extracting the boundary geometric characteristics of a cavity region to be processed on a skin, and converting the boundary geometric characteristics into an image; secondly, extracting a central skeleton of the binary image, and calculating the shortest Euclidean distance between a contour line pixel point and the central skeleton; using the central skeleton as the center to bias outwards to generate an initial circular cutter track; and fourthly, converting the initial tool path into an image, carrying out process constraint verification on the tool path, and carrying out iterative deformation on the tool path image by utilizing a moving least square technology to optimize the tool path until an optimal circular cutting tool path meeting the process constraint is obtained. The method can overcome the defect that the traditional tool path generation method is difficult to be suitable for the skin mirror image milling process constraint, realizes the generation of the tool path under the process constraint, finally obtains the mirror image milling tool path which has no residue during processing, qualified step pitch, smooth track and no tool lifting, and meets the skin mirror image milling processing requirement.
Description
Technical Field
The invention belongs to the technical field of Computer Aided Manufacturing (CAM), in particular to a method for generating and optimizing a circular cutter path, and particularly relates to a method for generating the circular cutter path of skin mirror milling.
Background
The aircraft skin has a plurality of groove characteristics, and due to the characteristics of the aircraft skin, the aircraft skin has large size, complex appearance, high material removal rate and poor rigidity, so that the processing quality of the aircraft skin cannot be well controlled all the time. In order to overcome the defect that deformation is out of tolerance due to insufficient rigidity in the skin milling process, a skin mirror milling system is adopted in the manufacturing industry at present. And a jacking device which follows the mirror image of the cutter is applied to the back surface of the skin, so that the rigidity of the thin-wall skin is increased. The ultrasonic thickness measuring sensor is installed on the top bracing device, so that the skin thickness can be monitored in real time, and the processing quality is further ensured. And due to the existence of the thickness sensor, the cutter path of the skin mirror milling is restricted by the process.
Firstly, in order to ensure the final shape of the skin, no residue is required to be processed along a tool path; secondly, the step distance between the tool paths should be changed within a certain range. If the step distance is too large and exceeds the diameter of the cutter, machining residues can be caused, extra tool paths are needed to be added to remove the local residues, and the machining efficiency is affected; if the step distance is too small to be smaller than the safe use distance reserved by the ultrasonic thickness measuring device, the processing areas of two adjacent layers of tool paths are overlapped too much, so that step tool difference exists in the measuring area of the thickness measuring sensor, signals are disordered, and the measuring precision of the thickness measuring sensor is influenced. In addition, because the requirement on the surface roughness of the skin is high, the tool path needs to be smooth as much as possible, and the sharp rotation of the tool is not avoided. Because the shoring device and the cutter need to keep mirror image follow-up all the time, and each time the cutter is fed, a section of cutter track is needed for mirror image calibration, so that in order to avoid mirror image calibration, cutter lifting should be avoided in the skin mirror image milling process.
The line cutter track and the ring cutter track are two common cutter track forms in milling processing. When the shape of the processing area is complex, the row cutter rail faces the frequent withdrawal and the right-angle rotation of the cutter, the cutter is accelerated and decelerated frequently, and the processing efficiency is reduced. The processing mode of the row cutting tool path is continuously switched between forward milling and backward milling, the service life of the tool is shortened, and the quality of the processed surface is also reduced. And the line cutter rail is not well adapted to the boundary of a processing area, so that local processing residues are easily generated, and the cutter rail needs to be subjected to post-treatment to be optimized to remove the local residues. Compared with a line cutting tool path, the circular cutting tool path is composed of a plurality of layers of tool paths similar to the boundary contour line of a machining area, is more suitable for a complex machining area, can keep the reverse milling unchanged in a machining mode, does not have the phenomena of frequent acceleration and deceleration and sharp rotation, is higher in machining quality, and is wider in application.
The traditional method for generating the circular cutter path mainly comprises a geometric figure method and an image method, wherein the geometric figure method is divided into a Voronoi diagram method and a bilateral offset method, the two methods are based on the offset of the sides, and the circular cutter path is generated by detecting self-intersection and invalid rings. The image method decomposes the processing boundary into discrete pixels, and performs processing simulation by changing the values of the pixels. These methods generate the tool path inward from the boundary, and inevitably generate machining residues and sharp corners due to geometric degradation. At present, from the angle of geometric figure and image processing, students add extra local tool paths or apply Gaussian smoothing and sharpening to images of areas to be processed so as to remove local processing residues, but sharp corners still exist, the generated circular cutting tool paths are poor in smoothness, the step pitch is difficult to guarantee, and the circular cutting tool paths are not suitable for a process constraint skin mirror milling system.
The traditional tool path generation method is started from a local part, but the local optimization is difficult to meet the process constraint conditions, and other process requirements are often sacrificed in order to meet a certain constraint condition, so that the traditional tool path generation method is difficult to be applied to a skin mirror milling system with strict process requirements. The invention provides a method for generating and optimizing a process constraint circular cutting tool path based on image processing. And optimizing the tool path by using an image processing technology until the process constraint is met, so that the tool path suitable for skin mirror milling is obtained, and the processing requirement is met.
Disclosure of Invention
The invention aims to solve the problems that the traditional tool path generating method is difficult to meet the process constraint and is not suitable for skin mirror milling, and provides an image processing-based circular cutting tool path generating method under the constraint condition of the skin mirror milling process.
The specific technical scheme of the invention is as follows:
a method for generating a circular cutter path based on image processing under the constraint condition of a skin mirror milling process comprises the following steps:
firstly, extracting the boundary geometric characteristics of a cavity region to be processed on a skin, and converting the boundary geometric characteristics into an image;
secondly, extracting a central skeleton of the binary image, and calculating the shortest Euclidean distance between a contour line pixel point and the central skeleton;
thirdly, an initial circular cutting tool track is generated by outwards biasing with the central framework as the center;
and finally, converting the initial tool path into an image, carrying out process constraint verification on the tool path, and optimizing the tool path by utilizing iterative deformation of an image processing technology, so as to ensure that the finally generated tool path meets process constraints and meets processing requirements.
The process constraints comprise no residue in processing, qualified step pitch, smooth track and no tool lifting.
The image converted from the boundary geometric characteristics of the cavity region to be processed is a binary image, wherein the pixel point value passed by the boundary contour line is 1, and the other pixel point values are 0.
The central skeleton is obtained by extracting a skeleton from a cavity boundary image and removing skeleton branches.
The shortest Euclidean distance between the calculated contour line pixel point and the central framework refers to a pixel point cs on the central frameworkjCompared with other central skeleton pixel points and a pixel point b on the contour line of the processing areaiHaving the shortest Euclidean distance LiCalculating pixel points { b ] on contour lines of all processing regionsiThe corresponding shortest Euclidean distances form a set { L }i}。
The method for generating the initial circular cutting tool path comprises the following specific steps:
first, according to the shortest Euclidean distance { LiCalculating the optimal number n of tool paths of the cavity and an offset value offset;
secondly, an initial circular cutter track is generated by utilizing mathematical morphology and taking the central skeleton as a center to bias outwards. And (4) outwards offsetting for n times by taking the central skeleton as the center, wherein the offset value is offset, and generating an initial annular cutter track.
The initial tool path is regarded as an image which is a binary image, the value of the pixel point through which the tool path passes is 1, and the rest are 0.
The process constraint verification of the tool path means that whether the processing residual area and the step pitch of the tool path meet preset threshold values or not, if the processing residual area and the step pitch meet the threshold value requirements, the process constraint requirements are met, and if the processing residual area and the step pitch do not meet the process constraint requirements, the process constraint requirements are not met.
The image processing technology comprises image morphological processing and image deformation.
The step pitch refers to the shortest Euclidean distance between a pixel point on the outer layer tool path and a pixel point on the inner layer tool path between two adjacent layers of tool paths.
The size of the image can be adjusted according to the requirement of the required processing precision.
The invention has the beneficial effects that:
the method can overcome the defect that the traditional tool path generation method is difficult to be suitable for the skin mirror image milling process constraint, realizes the generation of the tool path under the process constraint, finally obtains the mirror image milling tool path which has no residue during processing, qualified step pitch, smooth track and no tool lifting, and meets the skin mirror image milling processing requirement.
The method can generate the initial circular cutting tool path according to the geometric boundary of the processing area, avoid the phenomenon that the tool path is not smooth due to geometric degradation, iteratively deform the tool path by utilizing an image processing technology, and enable the finally generated tool path to meet the process constraint of skin mirror milling through integral optimization.
Drawings
FIG. 1 is a two-value graph of a boundary contour of a slot feature according to an embodiment of the present invention.
Fig. 2 is a schematic diagram of the shortest euclidean distance between the boundary contour and the central skeleton.
FIG. 3(a) is a schematic view of an initial ring cutter path.
Fig. 3(b) is a schematic diagram of the primary optimized circular cutter path.
Fig. 4 is a schematic diagram of deformation control point selection.
FIG. 5 is a schematic diagram of process constraint verification.
Fig. 6 is a schematic diagram of deformation control point adjustment.
FIG. 7 is a schematic diagram of a process-constrained annular cutter track generation and optimization flow for a groove feature machining region.
FIG. 8 is a schematic diagram of the circular cutter path generated in the other three groove feature machining areas and the satisfaction of process constraints.
Detailed Description
The invention is further described with reference to the following figures and detailed description.
A method for generating a circular cutting tool path based on image processing under the constraint condition of a skin mirror milling process comprises the following steps:
s1: establishing a binary image with the size of a x b according to the geometric boundary contour line of the region to be processed, wherein the value of a pixel point through which the contour line passes is 1, and the values of the other pixel points are 0; a is more than or equal to xmax-xmin,b≥ymax-yminAnd x and y are the coordinates of the geometric boundary plane of the processing area.
S2: extracting a framework of the binary image, removing framework branches, keeping a central framework, and calculating the shortest Euclidean distance between a contour line pixel point and the central framework;
s3, generating an initial circular cutting tool track by taking the central skeleton as a center and outwards biasing;
s4: and (4) carrying out constraint verification on the tool path, and carrying out iterative optimization on the tool path by using an image processing technology until the generated tool path meets the process constraint and meets the skin mirror milling requirement.
Wherein:
the size of the binary image in step S1 may be adjusted according to the required machining accuracy.
In step S2, contour line pixel point b is calculatedi} and central skeleton { csjThe shortest Euclidean distance between the pixels is to select any contour line pixel point biCalculating all pixel points and b on the binary imageiEuclidean distance of { cs }jThe pixel point cs with the minimum pixel value in the pixeljIs biCorresponding pixel point, csjPixel value L ofiIs biThe shortest euclidean distance to the central skeleton. Repeating the processes until the shortest Euclidean distances between all the contour line pixel points and the central framework are calculated, and obtaining an Euclidean distance set { L }i}。
The step S3 of generating the initial ring cutter path by taking the central skeleton as the center and outwards biasing is based on the Euclidean distance set { L }iThe method comprises the following specific steps:
first, according to the shortest Euclidean distance { LiAnd calculating the optimal number n of layers of the tool path of the cavity and an offset value offset. Tool pathThe number of layers n is calculated from the following formula:
wherein
LmaxAnd LminIs divided into { LiAnd f, the maximum value and the minimum value of the ultrasonic thickness measuring device, wherein R is the radius of the cutter, and e is the safe use distance reserved by the ultrasonic thickness measuring device.
Offset value offset takes the average of the steps:
secondly, an initial circular cutter track is generated by utilizing mathematical morphology and taking the central skeleton as a center to bias outwards. The initial equidistant circular cutting path is generated by taking a central framework as a center through a mathematical morphology method and outwards biasing for n times, wherein n is the pre-calculated number of the tool path layersinitialThe tool path step is a pre-calculated offset value offset.
The step S4 of verifying the tool path as constrained means that an image processing method is used to verify whether the tool path meets the preset threshold of machining residue and step pitch, if yes, the tool path meets the constraint requirement, otherwise, the tool path needs to be optimized.
In step S4, the iterative optimization of the tool path by using the image processing technology mainly means that the tool path is continuously optimized by using a mathematical morphology method and an image deformation technology with the purpose of skin mirror milling process constraint until the finally generated tool path meets the process constraint.
The process constraints in step S4 include no residue in processing, qualified step pitch, smooth trajectory, and no tool lifting.
The details are as follows:
taking the skin-over-groove feature shown in fig. 1 as an example, the following method is implemented. The boundary contour line of the characteristics of the groove to be processed is extracted and converted into a binary image, a central skeleton is extracted by using a mathematical morphology method, and the central skeleton is outwardly biased to generate an initial circular cutting tool path. And (3) performing constraint verification on the circular cutting tool path, and integrally and iteratively optimizing the tool path through an image processing technology, so that the finally generated tool path meets the process constraints of no residue, qualified step pitch, smooth track and no tool lifting during processing, and meets the processing requirements of skin mirror milling.
Referring to fig. 1, the implementation of the above method is described by preferably extracting four groove features from the skin, and in this example, the example test is preferably performed on a MATLAB platform.
The method of the present example specifically includes the following steps:
before describing the implementation process, the parameters to be provided are: the groove characteristic geometric boundary contour line, the cutter radius R and the safe use distance e reserved by the ultrasonic thickness measuring device meet the threshold values of the machining allowance residual area residual and the step pitch unqualified rate f _ R of the skin mirror milling machining precision.
1. Imaging the characteristic geometric boundary of the groove to be processed:
and setting a binary image size according to the required machining precision of the skin mirror milling, wherein each millimeter occupies 8 pixels on the image. According to the image resolution, the radius of the cutter is set to be 8R pixels, the reserved safe use distance of the ultrasonic thickness measuring device is set to be 8e pixels, and therefore the step distance is limited to be more than or equal to d and less than or equal to 16R and more than or equal to 8R +8 e. The pixel point value of the binary image where the groove contour line passes through is 1, the rest is 0, and the obtained contour line pixel point set is { b }iAnd (5) obtaining a binary image as shown in the figure 1.
2. Extracting a skeleton, and calculating the shortest Euclidean distance:
extracting the skeleton of the binary image by using mathematical morphology, removing skeleton branches, and reserving central skeleton pixel points { csj}. Selecting any contour line pixel point biCalculating all pixel points and b on the binary imageiOf (c), wherein { csjThe pixel point cs with the minimum pixel value in the pixeljIs biCorresponding pixel point, csjThe pixel value of (a) is the shortest Euclidean distance L between the twoi. Repeating the selection until the shortest Euclidean distance between all contour line pixel points and the central framework is obtainedAfter all distances are calculated, a Euclidean distance set { L } is obtainedi}。
3. Initial circular cutting tool pathinitialGeneration of (1):
using the Euclidean distance set { LiCalculating the total layer number n and the offset value offset of the tool path, and generating the equal-step-distance initial ring cutting tool path by taking a central framework as a center and outwards offsetting, wherein the method comprises the following specific steps of:
first, according to the shortest Euclidean distance { LiAnd calculating the optimal number n of layers of the tool path of the cavity and an offset value offset. The number n of the tool path layers is calculated by the following formula:
wherein
LmaxAnd LminIs divided into { LiAnd f, the maximum value and the minimum value of the ultrasonic thickness measuring device, wherein R is the radius of the cutter, and e is the safe use distance reserved by the ultrasonic thickness measuring device.
Offset value offset takes the average of the steps:
secondly, an initial circular cutter track is generated by utilizing mathematical morphology and taking the central skeleton as a center to bias outwards. The initial equidistant circular cutting path is generated by taking a central framework as a center through a mathematical morphology method and outwards biasing for n times, wherein n is the pre-calculated number of the tool path layersinitialThe tool path step is a pre-calculated offset value offset.
Generating an initial equidistant circular cutting pathinitialThe tool path step distance is offset.
As shown in fig. 3(a), the initial equal-step-pitch circular cutting path is generated by using a mathematical form method and taking a central skeleton as a center and outwards biasinginitial。
4. The circular cutting tool path based on image processing iterative optimization process constraint:
the method comprises the following steps of performing process constraint verification on the generated circular cutting tool path, and performing overall iterative optimization on the circular cutting tool path by using image processing technologies such as mathematical morphology, image deformation and the like until the circular cutting tool path meets the process constraint of skin mirror milling and meets the processing requirement, wherein the specific steps are as follows:
firstly, to the initial circular cutting tool pathinitialAnd performing primary deformation optimization.
Due to pathinitialBased on the outward bias of the central skeleton, the overall shape of which is quite different from the shape of the groove, and further optimization is needed. In order to ensure the final shape of the groove feature, as shown in fig. 4, the contour line of the groove boundary is biased inwards by R to generate a contour C, which is the outermost tool path meeting the machining requirements and is also the optimization target of the initial deformation. At pathinitialN equidistant sampling as deformation control point pi}，{qiIs { p } on CiThe deformation control point set cp is generated as { p, q }. Optimization of deformation path using rigid Moving Least Squares (MLS) image deformation techniques based on cp-point controlinitialGet pathoptimizedSo that the overall shape of the device meets the processing requirements. As shown in FIG. 3(b), the path obtained by deforming the initial circular cutting track by the above methodoptimized。pathoptimizedThe outermost layer tool path is C, so that the processing requirement is met, and optimization is not needed. Therefore, let i equal n-1, which means that the optimization object is path thereafteroptimized{1} to pathoptimizedKnife track of { i }.
Verifying the process constraint of the circular cutting tool path:
and verifying the machining residues and the step constraint of the tool rail layer by layer from outside to inside. As shown in FIG. 5, the path is calculated by mathematical morphology milling simulationoptimized{ i } and pathoptimizedThe { i +1} inter-process residual area residue and the pitch fraction off-spec f _ r.
If the preset threshold range is met, the path is indicatedoptimized{ i } meets the process constraint, i is i-1, if i is more than 0, repeating the step II, and carrying out process constraint verification on the inner layer tool path; if i is 0, the process proceeds to step (iv).
If not, go to step c and need to go to pathoptimized{ i } for further optimization.
Thirdly, optimizing the circular cutting tool path under process constraint:
will pathoptimized{1} to pathoptimizedAnd (4) taking the tool path of { i } as a binary picture, and optimizing the circular cutting tool path under the process constraint. Since the root cause for the occurrence of machining residues is that the tool path pitch is greater than the tool diameter, removing machining residues can also translate into a pitch adjustment problem. As shown in figure 6 of the drawings,
c is offset inward by R + e,
is obtained by inward biasing of C by 2R, and path is used for meeting the processing residue-free and step-pitch constraintoptimized{ i } should fall within
And
target deformation region in between.
According to pathoptimized{ i } and pathoptimizedThe step distances between { i +1} are divided into three categories: d is more than 2R, d is more than R + e, and R + e is less than or equal to d and less than or equal to 2R, and deformation control points are selected according to the step pitch.
pathoptimizedThe step distance of pixel points on { i } satisfies d > 2R and is recorded as { p1j}，{p1jThe pixel points in the target deformation region fall within the target deformation region and need to move outwards, and the pixel points (q 1) with the step pitch meeting the requirements in the target deformation region are selectedjAs deformed points; in the same way, pathoptimizedThe { i } pixel point step distance satisfying d < R + e is recorded as { p2jH, then { p2jThe pixel points in the target deformation region fall outside the target deformation region and need to move inwards, and the pixel points (q 2) with the step pitch meeting the requirements in the target deformation region are selectedjAs deformed points; however, pathoptimizedThe step pitch of the pixel points on the { i } satisfies that R + e is more than or equal to d is less than or equal to 2R, so the positions of the pixel points do not need to be changed, and the { p3 is formed by sampling every 20 points in order to avoid over-deformationjAnd { q3}j}。
{ p1, p2, p3} and { q1, q2, q3} update cp, control path with cpoptimizedRigid deformation of (2). Get a new pathoptimizedThen, go back to the second stepoptimized{ i } performing constraint verification.
Output of the optimal circular cutting tool track:
if i is 0, all tool paths are shown to be subjected to deformation optimization and meet all process constraints, so pathoptimizedIs pathfinalWill pathfinalAnd outputting to obtain the ring cutter meeting all process constraints of skin mirror milling, and meeting the processing requirements.
According to the method for generating the circular cutting tool path based on the image processing under the constraint condition of the skin mirror image milling process, the traditional geometric optimization problem is ingeniously converted into the image processing problem, the tool path is optimized in an overall iteration mode by using image technologies such as mathematical morphology, image deformation and the like, the defect that the traditional local optimization method cannot give consideration to all process requirements is overcome, the method is universal, the constraint of the skin mirror image milling process can be met, and the processing requirement is met.
Fig. 7 shows a process of generating and optimizing a groove feature process constraint ring cutter path completely, fig. 8 shows a final generated cutter path of other groove features and conditions that machining residues and step distribution constraints meet, and experimental results prove the effectiveness of the method.
The present invention is not concerned with parts which are the same as or can be implemented using prior art techniques.
Claims (10)
1. A method for generating a circular cutting tool path based on image processing under the constraint condition of a skin mirror milling process is characterized by comprising the following steps of:
firstly, extracting the boundary geometric characteristics of a cavity region to be processed on a skin, and converting the boundary geometric characteristics into a binary image;
secondly, extracting a central skeleton of the binary image, and calculating the shortest Euclidean distance between a contour line pixel point and the central skeleton;
thirdly, an initial circular cutting tool track is generated by outwards biasing with the central framework as the center;
and finally, converting the initial tool path into an image, carrying out process constraint verification on the tool path, and carrying out iterative deformation on the tool path image by using a mobile least square technology to optimize the tool path, so as to ensure that the finally generated tool path meets the process constraint and meets the processing requirement.
2. The method of claim 1 wherein said process constraints include process residue-free, pitch-qualified, smooth trajectory, and tool lift-free constraints.
3. The method as claimed in claim 1, wherein the image converted from the boundary geometric characteristics of the cavity region to be processed is a binary image, wherein the boundary contour line passes through pixel values of 1 and the remaining pixel values are 0.
4. The method of claim 1, wherein the central skeleton is obtained by extracting skeleton from the cavity boundary image and removing skeleton branches.
5. The method of claim 1, wherein said calculating the shortest euclidean distance between a contour line pixel point and a central skeleton means that a pixel point on the central skeleton has the shortest euclidean distance with a pixel point on the contour line of the processing region compared to pixel points on other central skeletons, and the shortest euclidean distances corresponding to pixel points on all contour lines of the processing region are calculated to form a set.
6. The method of claim 1, wherein said step of creating an initial circular cutting path comprises the steps of:
firstly, calculating the optimal number of tool paths and an offset value of the cavity according to the shortest Euclidean distance;
secondly, generating an initial circular cutting tool path by utilizing mathematical morphology and taking a central framework as a center to bias outwards; and (4) outwards offsetting times by taking the central skeleton as a center, wherein the offset value is as follows, and generating an initial circular cutting tool path.
7. The method of claim 1, wherein the initial tool path is regarded as an image, which is a binary image, and the tool path passes through pixel points with a value of 1 and the rest of the pixel points with a value of 0.
8. The method as claimed in claim 1, wherein the process constraint verification of the tool path means verifying whether the machining residual area and the step pitch of the tool path meet a preset threshold, and if the threshold is met, the process constraint requirement is met, otherwise, the process constraint requirement is not met.
9. The method of claim 1, wherein the image processing techniques include image morphological processing and image warping.
10. The method as claimed in claim 2, wherein the step distance is the shortest euclidean distance between a pixel point on the outer layer tool path and a pixel point on the inner layer tool path between two adjacent layers of tool paths.
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| CN104573692A (en) * | 2014-12-18 | 2015-04-29 | 厦门翼歌软件科技有限公司 | Vehicle license plate binarizing method based on fuzzy degradation model |
| CN107344251A (en) * | 2017-07-13 | 2017-11-14 | 上海拓璞数控科技股份有限公司 | The mirror image method for milling and system of covering processing |
| CN109299556A (en) * | 2018-10-08 | 2019-02-01 | 南京航空航天大学 | A kind of ring cutting cutter orbit making and optimization method based on image procossing |
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