CN116532697A - Composite skin thickness self-adaptive compensation processing method - Google Patents
Composite skin thickness self-adaptive compensation processing method Download PDFInfo
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- CN116532697A CN116532697A CN202310367360.4A CN202310367360A CN116532697A CN 116532697 A CN116532697 A CN 116532697A CN 202310367360 A CN202310367360 A CN 202310367360A CN 116532697 A CN116532697 A CN 116532697A
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- 239000002131 composite material Substances 0.000 title claims abstract description 110
- 238000003672 processing method Methods 0.000 title claims abstract description 20
- 238000012545 processing Methods 0.000 claims abstract description 44
- 238000000465 moulding Methods 0.000 claims abstract description 15
- 238000004364 calculation method Methods 0.000 claims abstract description 13
- 238000012937 correction Methods 0.000 claims abstract description 5
- 238000000034 method Methods 0.000 claims description 42
- 238000003801 milling Methods 0.000 claims description 28
- 238000003754 machining Methods 0.000 claims description 12
- 238000013461 design Methods 0.000 claims description 5
- 229920001187 thermosetting polymer Polymers 0.000 claims description 4
- 238000005520 cutting process Methods 0.000 abstract description 6
- 230000007547 defect Effects 0.000 abstract description 6
- 230000008092 positive effect Effects 0.000 abstract description 6
- 238000012797 qualification Methods 0.000 abstract description 4
- 239000010410 layer Substances 0.000 description 37
- 229920000049 Carbon (fiber) Polymers 0.000 description 17
- 239000004917 carbon fiber Substances 0.000 description 17
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 17
- 238000005516 engineering process Methods 0.000 description 5
- 238000004519 manufacturing process Methods 0.000 description 5
- 238000009434 installation Methods 0.000 description 4
- 238000001914 filtration Methods 0.000 description 3
- 238000004904 shortening Methods 0.000 description 3
- 238000006243 chemical reaction Methods 0.000 description 2
- 230000000052 comparative effect Effects 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 238000005259 measurement Methods 0.000 description 2
- 230000003287 optical effect Effects 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 1
- 239000011825 aerospace material Substances 0.000 description 1
- 230000032683 aging Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 238000005253 cladding Methods 0.000 description 1
- 238000005056 compaction Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 230000002349 favourable effect Effects 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 230000035772 mutation Effects 0.000 description 1
- 239000002356 single layer Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 238000001029 thermal curing Methods 0.000 description 1
- 230000007306 turnover Effects 0.000 description 1
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23C—MILLING
- B23C3/00—Milling particular work; Special milling operations; Machines therefor
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
- G06T7/00—Image analysis
- G06T7/0002—Inspection of images, e.g. flaw detection
- G06T7/0004—Industrial image inspection
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
- G06T7/00—Image analysis
- G06T7/60—Analysis of geometric attributes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23C—MILLING
- B23C2226/00—Materials of tools or workpieces not comprising a metal
- B23C2226/27—Composites, e.g. fibre reinforced composites
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
- G06T2207/00—Indexing scheme for image analysis or image enhancement
- G06T2207/10—Image acquisition modality
- G06T2207/10028—Range image; Depth image; 3D point clouds
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
- G06T2207/00—Indexing scheme for image analysis or image enhancement
- G06T2207/30—Subject of image; Context of image processing
- G06T2207/30108—Industrial image inspection
- G06T2207/30164—Workpiece; Machine component
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
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- Computer Vision & Pattern Recognition (AREA)
- General Physics & Mathematics (AREA)
- Theoretical Computer Science (AREA)
- Mechanical Engineering (AREA)
- Quality & Reliability (AREA)
- Geometry (AREA)
- Moulds For Moulding Plastics Or The Like (AREA)
Abstract
The invention discloses a composite skin thickness self-adaptive compensation processing method, which comprises the steps of firstly carrying out three-dimensional scanning on a composite skin part in an demolding state and a mold molding surface to obtain point cloud data, then carrying out comparison calculation according to the point cloud data to obtain the actual thickness of the composite skin part, then carrying out three-dimensional scanning on the composite skin part in a clamping state to obtain coordinate data, and finally carrying out comprehensive calculation correction on the coordinate data and the actual thickness of the composite skin part to obtain an actual processing tool path, thereby effectively avoiding the defects of over-cutting or super-thickness processing of the skin part caused by deformation, obviously improving the qualification rate and the precision of a finished product of the composite skin part, effectively reducing the assembly step difference of the composite skin part, and having positive effects on improving the pneumatic performance and stealth performance of a fighter.
Description
Technical Field
The invention relates to the technical field of aerospace material processing, in particular to a composite skin thickness self-adaptive compensation processing method.
Background
The carbon fiber composite material has the outstanding advantages of high strength, high modulus, high temperature resistance, low density, corrosion resistance, ageing resistance, small thermal expansion coefficient and the like, becomes an important material in the aerospace field, and is widely applied to various types of civil and military products, in particular to the manufacture of aircraft skin parts in a large number.
In the actual production and manufacturing process, the Q235A steel is mostly selected as a forming die tooling of the existing carbon fiber composite material in consideration of manufacturing cost, but the deformation of 0.2-2 mm exists after the forming die tooling material and the carbon fiber composite material are subjected to the influence of the larger difference between the thermal expansion coefficients of the carbon fiber composite material and the thermal curing forming process characteristics of the carbon fiber composite material skin part (the carbon fiber composite material skin part is formed by laying prepregs with the single-layer thickness of 0.1-0.2 mm, the thickness is difficult to ensure and the situation of thickness mutation exists), so that the warping and rebound phenomenon exists in the forming process of the carbon fiber composite material skin part, and the performance and the application of the carbon fiber composite material skin part are seriously influenced.
In order to overcome deformation defects in the process of forming the carbon fiber composite skin part, the stealth performance and the aerodynamic performance of an airplane are prevented from being reduced due to obvious step difference generated at a joint of the carbon fiber composite skin part, and a sacrificial layer (the carbon fiber composite skin part is composed of a base layer, an indication layer and a sacrificial layer) is designed and introduced on the carbon fiber composite skin part. The upper surface of the base layer is a demolding surface of the carbon fiber composite skin part, and the demolding surface is formed by thermosetting molding on a smooth molding die, so that the demolding surface has a continuous smooth surface and can be used as a pneumatic outer molded surface of the machine body; the sacrificial layer is used as a connecting layer of the carbon fiber composite material skin and the framework, belongs to an assembled inner shape surface, and can be milled to adjust the thickness, uniformity and roughness of a connecting area due to the rough surface, so that the step difference of the seam of the skin part is reduced.
In the prior art, for processing the sacrificial layer of the carbon fiber composite material skin part, a vacuum clamp is generally adopted for clamping and milling. However, because the carbon fiber composite skin part has excessive rigidity, the demoulded skin part is difficult to be completely attached to the vacuum clamp due to deformation, and a local gap exists between the skin part interface and the clamp interface. If milling processing is carried out on the sacrificial layer according to the theoretical tool path in the state, the partial area is possibly over-cut, so that the skin part is scrapped; if milling is carried out according to the measured data of the blank profile, the thickness of a local area of the part is too thick, so that a step larger than 0.2mm is possibly formed at the joint of the skin part, and the aerodynamic performance and stealth performance of the fighter plane are affected.
Disclosure of Invention
The invention aims to overcome the defect of over-cutting or super-thickness of the existing processing method of the carbon fiber composite skin part sacrificial layer, and provides a composite skin thickness self-adaptive compensation processing method.
In order to achieve the aim of the invention, the invention provides a composite skin thickness self-adaptive compensation processing method, which comprises the following steps:
step S1: after the composite skin part is formed in a thermosetting mode, carrying out three-dimensional scanning on the lower surface of a rough blank of the composite skin part which is also arranged on the die to obtain scanning point cloud data 1;
step S2: after the scanning of the rough blank of the composite skin part is finished, taking the rough blank of the composite skin part off from the forming die, and carrying out three-dimensional scanning on the forming surface of the forming die to obtain scanning point cloud data 2;
step S3: comparing and calculating the scanning point cloud data 1 and the scanning point cloud data 2 under the same coordinate system to obtain actual thickness point cloud data 3 of the rough blank of the composite skin part;
step S4: clamping the rough blank of the composite skin part according to the milling requirement, and carrying out three-dimensional scanning on the upper surface of the clamped rough blank of the composite skin part to obtain scanning point cloud data 4;
step S5: comparing the actual thickness point cloud data 3 with the scanning point cloud data 4 in the same coordinate system, and calculating and correcting to obtain theoretical point cloud data 5 of the tool path by taking the principle that the thickness step difference of the composite skin part after milling meets the design requirement; generating an actual machining tool path by taking the theoretical point cloud data 5 as a basis;
step S6: and (5) milling the sacrificial layer on the lower surface of the composite skin part according to the actual processing tool path generated in the step (S5) to obtain a finished product of the composite skin part with the thickness step meeting the requirement.
According to the method for adaptively compensating and processing the thickness of the composite skin, disclosed by the invention, the lower surface of the composite skin part in an demolding state and the molding surface of a mold are subjected to three-dimensional scanning to obtain point cloud data, then the actual thickness of the composite skin part is obtained by comparison calculation according to the point cloud data, then the upper surface of the composite skin part in a clamping state is subjected to three-dimensional scanning to obtain coordinate data, and finally the coordinate data and the actual thickness of the composite skin part are subjected to comprehensive calculation and correction to obtain an actual processing tool path, so that the defects of over-cutting or super-thickness processing of the skin part caused by deformation are effectively avoided, the qualification rate and the precision of a finished product of the composite skin part are remarkably improved, the step difference of assembly of the composite skin part is effectively reduced, and the method has a positive effect on improving the pneumatic performance and stealth performance of a fighter; meanwhile, the method is simple to operate, high in automation degree and high in practicability, can be realized on the basis of the existing processing equipment, and has positive effects of reducing the processing cost and improving the product quality.
Preferably, in steps S1, S2 and S4, the three-dimensional scanning is three-dimensional phase coordinate scanning; the phase coordinate data of the object in the three-dimensional coordinates can be obtained through three-dimensional scanning; and the calculation of the thickness of the part and the tool path data is facilitated in the same coordinate system through three-dimensional phase scanning.
Preferably, a non-contact optical scanning device is adopted for three-dimensional scanning; the optimized optical scanning equipment has high precision, convenient operation and more accurate scanning data; most preferably, the scanning device is a three-dimensional laser scanning sensor based on a pulse-phase ranging method.
Preferably, the three-dimensional laser scanning sensor is integrated on an automation device such as an industrial robot or other mechanical power devices, so that the automation and continuous scanning of the part entity under the drive of a program can be realized.
Preferably, the detail scanning capacity of the three-dimensional laser scanning sensor is less than or equal to 0.01mm, and the three-dimensional laser scanning sensor has various resolutions; different resolutions can be set for different positions in one scanning, so that the data volume is reduced, and meanwhile, the characteristics and details of the object are guaranteed to the greatest extent.
Preferably, the three-dimensional laser scanning sensor can perform data transmission with a computer, can display three-dimensional data of an object in real time in the scanning process, previews while scanning, and can shorten the processing period.
Preferably, in the three-dimensional scanning process, the scanning precision of the sacrificial layer on the lower surface of the rough blank of the composite skin part and the molding surface of the die corresponding to the sacrificial layer is not lower than 0.05mm; and the scanning precision is optimized, so that the scanning data is more accurate, the processing precision is higher, and the precision of the obtained composite skin part finished product is better and meets the design requirement better.
Preferably, in the three-dimensional scanning process, the scanning precision of the sacrificial layer on the lower surface of the rough blank of the composite skin part and the mould forming surface corresponding to the sacrificial layer is larger than that of corresponding other areas; in the three-dimensional scanning process, the scanning precision of the sacrificial layer on the lower surface of the rough blank of the composite skin part is larger than that of other areas on the lower surface of the rough blank of the composite skin part, and the scanning precision of the mould forming surface corresponding to the sacrificial layer is larger than that of other areas on the mould forming surface; the optimized three-dimensional scanning method can reduce the data volume without affecting the processing effect, thereby shortening the data processing time, improving the data processing efficiency and having positive effects of improving the processing efficiency and shortening the processing period.
Preferably, in the three-dimensional scanning process, the scanned point cloud data can be previewed, and the point cloud data is scanned for unqualified areas and repeatedly scanned; through previewing and repeated scanning of the three-dimensional scanning, scanning data can be more accurate, and the occurrence of processing defects is reduced.
Preferably, in the three-dimensional scanning process, the scanning point cloud data can be filtered, and noise points in the scanning point cloud data can be removed; by filtering the three-dimensional scanned data, the scanned data can be more accurate, and the processing precision is improved.
Preferably, in step S2, before the rough blank of the composite skin part is removed from the forming mold, a positioning hole is further provided on the rough blank of the composite skin part; through setting up the locating hole, can be better carry out the centre gripping to the cladding skin part rough blank, be favorable to later stage milling.
Preferably, the positioning holes are arranged at two sides of the highest and/or lowest ridge line of the composite skin part; the preferred setting position, centre gripping locate function is good, does not influence the processing and the installation of part.
Preferably, in step S3, the coordinate system is a coordinate system established by taking a molding die of the composite skin part as a reference system; in the preferred coordinate system, the scanning point cloud data 1 and the scanning point cloud data 2 can be compared faster and more accurately without coordinate conversion, and the accuracy of the obtained actual thickness point cloud data 3 is higher.
In step S3, the comparison and calculation process refers to processing the point cloud coordinates and data by a point cloud process (using methods such as point cloud filtering, point cloud key points, feature and feature description, etc.), an alignment process (modes such as best fitting, reference alignment, coordinate system alignment, rps alignment, etc.), a 3D comparison process (outputting a full-size chromatographic deviation map, flag annotation, deviation comparison table, etc.), or a 2D comparison process, etc. to enable the contour of the point cloud data to correspond, subtracting the scan point cloud data 2 from the scan point cloud data 1 of the corresponding point location, that is, obtaining the actual thickness of the composite skin part blank, and finally forming the actual thickness point cloud data 3; the actual thickness of the rough blank of the composite skin part can be obtained rapidly and accurately through automatic comparison and calculation, and data support is provided for calculation of a later tool path.
In step S3, the actual thickness point cloud data of the sacrificial layer on the rough blank of the composite skin part can be obtained only through comparison and calculation; only the actual thickness point cloud data of the sacrificial layer is calculated, the data volume can be reduced, so that the data processing time is shortened, the data processing efficiency is improved, and the method has positive effects of improving the processing efficiency and shortening the processing period.
Preferably, in step S4, the clamping tool is a vacuum milling clamp; the preferred clamping tool is conventional equipment, is easy to operate, does not need equipment update, and is convenient to implement.
Preferably, in step S4, the design requirement is that the step difference is not more than ±0.2mm; the preferable step requirement is that the composite skin part has minimal influence on the aerodynamic performance and stealth performance of the aircraft.
Preferably, in step S5, the coordinate system is a coordinate system established by using the clamping tool as a reference system; in the preferred coordinate system, the scanning point cloud data 4 can be compared more quickly and accurately without coordinate conversion, theoretical point cloud data 5 of the tool path can be calculated and generated more quickly, an actual machining tool path is formed, error probability in the calculation process is reduced, machining efficiency is higher, and the obtained product qualification rate is higher.
In step S5, the comparison refers to processing the actual thickness point cloud data 3 and the scanned point cloud data 4 on the point cloud coordinates and the data by a method such as point cloud processing (using methods such as point cloud filtering, point cloud key points, feature and feature description), alignment processing (modes such as best fitting, reference alignment, coordinate system alignment, rps alignment, etc.), 3D comparison processing (outputting full-size chromatographic deviation diagrams, flag notes, deviation comparison tables, etc.), or 2D comparison processing, so that the point cloud data contour can correspond, and data support is provided for the correction of the tool path.
In step S5, the calculation correction method is as follows: and according to the compared scanning point cloud data 4 and the actual thickness point cloud data 3, adding the actual thickness point cloud data 3 to the scanning point cloud data 4 of the corresponding point position to obtain the theoretical point cloud data 5 of the tool path.
Compared with the prior art, the invention has the beneficial effects that:
1. according to the compensation processing method, the actual thickness and the outline of the composite skin part in different states can be obtained by scanning the composite skin part, so that the processing tool path is compensated based on the actual thickness and the outline, the defect of over-cutting or super-thickness processing caused by deformation of the skin part is effectively avoided, the qualification rate and the precision of a finished product of the composite skin part are obviously improved, and the assembly step difference of the composite skin part is effectively reduced.
2. The compensation processing method has the advantages of simple operation, high automation degree and strong practicability, can be realized on the basis of the existing processing equipment, and has positive effects of reducing the processing cost and improving the product quality.
Description of the drawings:
FIG. 1 is a schematic illustration of the composite skin part molding of the present invention;
FIG. 2 is a schematic illustration of the composite skin part installation of the present invention;
FIG. 3 is a schematic view of the composite skin part structure of the present invention.
Reference numerals: 1-a composite mold; 2-a base layer; 3-an indicator layer; 4-a sacrificial layer; 5-installing a framework; 6-layer loss; 7-the lower surface of the skin; 8-upper surface of the skin.
Detailed Description
The present invention will be described in further detail with reference to test examples and specific embodiments. It should not be construed that the scope of the above subject matter of the present invention is limited to the following embodiments, and all techniques realized based on the present invention are within the scope of the present invention.
Composite skin part size: 1200 x 800mm, chord height 300mm;
composite skin part structure (fig. 1, 2, 3): the device consists of a base layer 2, an indication layer 3, a sacrificial layer 4 and a lost layer 6; during molding, the base layer 2 of the composite skin part is connected with the composite mould 1; when in installation, the sacrificial layer 4 of the composite skin part is connected with the installation framework 7; one surface of the sacrificial layer 4 is a lower surface 7 of the skin; one surface of the foundation layer 2 is a skin upper surface 8;
examples:
scanning equipment model: a Haichukang three-dimensional laser scanning sensor;
milling equipment model: five axis numerically controlled machine tools (GTF 3010-9000);
the specific processing method comprises the following steps:
step S1: after the composite skin part is subjected to thermosetting molding, before the composite skin part is separated from the composite mold 1, carrying out three-dimensional scanning on the lower surface 7 of the rough blank of the composite skin part by using a Hakkan three-dimensional laser scanning sensor to obtain scanning point cloud data 1, wherein in the scanning process, the scanning precision of a sacrificial layer 4 part on the composite skin part is 0.05mm, and the scanning precision of other parts is 0.1mm; in the scanning process, the scanned point cloud data is required to be previewed, noise points in the point cloud data are required to be removed, and repeated scanning is performed on areas with unqualified point cloud data;
step S2: after the scanning of the lower surface 7 of the rough blank of the composite skin part is finished, a positioning hole is formed in the rough blank of the composite skin part, then the rough blank of the composite skin part is taken down from a forming die, and a forming surface of the forming die is subjected to three-dimensional scanning by using a Hakkan three-dimensional laser scanning sensor to obtain scanning point cloud data 2; in the scanning process, the scanning precision of the part of the molding surface of the die corresponding to the composite skin sacrificial layer 4 is 0.05mm, and the scanning precision of other parts is 0.1mm; in the scanning process, the scanned point cloud data is required to be previewed, noise points in the point cloud data are required to be removed, and repeated scanning is performed on areas with unqualified point cloud data;
step S3: establishing a coordinate system by taking a forming die of the composite skin part as a reference system, and comparing and calculating the scanning point cloud data 1 and the scanning point cloud data 2 under the coordinate system to obtain actual thickness point cloud data 3 of a rough blank of the composite skin part;
step S4: clamping the rough blank of the composite skin part by adopting a vacuum milling clamp according to the milling requirement, and three-dimensionally scanning the upper surface of the clamped rough blank of the composite skin part by using a Hakkan three-dimensional laser scanning sensor to obtain scanning point cloud data 4; in the scanning process, the scanning precision of the part of the molding surface of the die corresponding to the composite skin sacrificial layer 4 is 0.05mm, and the scanning precision of other parts is 0.1mm; in the scanning process, the scanned point cloud data is required to be previewed, noise points in the point cloud data are required to be removed, and repeated scanning is performed on areas with unqualified point cloud data;
step S5: establishing a coordinate system by taking a clamping tool as a reference system, comparing actual thickness point cloud data 3 with scanning point cloud data 4 in the coordinate system, and calculating and correcting to obtain theoretical point cloud data 5 of a tool path by taking thickness step (within +/-0.2 mm) of a composite skin part after milling; generating an actual machining tool path by taking the theoretical point cloud data 5 as a basis;
step S6: and (3) milling the sacrificial layer 4 of the composite skin part by adopting a five-axis numerical control machine tool according to the actual processing tool path generated in the step (S5) to obtain a composite skin part finished product (figure 3) with the thickness step meeting the requirement (within +/-0.2 mm).
Comparative example 1:
the conventional processing method comprises the following specific steps:
1. after the composite skin part is molded and demolded, 30 (usually 20-40) points are selected in a sacrificial layer area to be processed, the thickness of the part is measured by using a magnetic thickness meter, the measurement result is analyzed, the overall thickness condition of the skin part is judged, and the thinner and thicker area of the part is defined, so that data support is provided for subsequent numerical control processing;
2. clamping a composite skin part on a vacuum milling clamp, selecting 50 points (generally 40-100 according to the size of the part), carrying out on-line measurement on the sacrificial layer surface of the part, and carrying out tool lifting processing on the part (maximum tool lifting amount is 0.5mm in the process of processing batch parts) according to the maximum out-of-tolerance value measured by the part, wherein if the demolding deformation of the part is large, the optimal state can be achieved by repeated clamping for many times; 3. the machining is carried out according to the theoretical guide rail, the cutter lifting amount is compensated by setting the cutter length (normal cutter lifting), and the cutter lifting mode is adopted, so that the problem that the cutting amount is small and the thickness is too thick after machining can occur in the area with better fitting between the part and the milling clamp after machining; and a region with poor adhesion (the region corresponds to the part protruding upwards), the problem of large cutting amount can occur; the whole part presents a state of uneven thickness.
Comparative example 2:
the mirror image milling method comprises the following specific steps:
1. the composite material skin part is placed on a horizontal matrix type flexible fixture, and the edge of the part is clamped by a flexible chuck for one circle;
2. the clamped part is conveyed to a turnover tool, the part is turned from a horizontal state to a vertical state, and the part is conveyed to a machining area of mirror milling equipment through a conveying track;
3. scanning the molded surface of the part by using a laser scanner, performing feature matching with a theoretical curved surface of the part, reconstructing the theoretical curved surface of the part, performing tool path compensation, and correcting a machining program;
4. and (3) processing the part according to the corrected processing program, wherein the mirror milling is provided with a real-time thickness measuring and uniformity compensating system, the thickness of the part is monitored in the processing process, the tool path compensation (interpolation period 4 ms) is carried out, the thickness precision of the part can reach +/-0.1 mm, and the contour precision +/-0.3 mm. However, the mirror milling technology needs to adopt a flexible clamping mode, the curved surface of the part cannot be supported and corrected, and the profile precision cannot be controlled.
As shown by comparison of processing experiments, the thickness of the key area of the composite skin part processed by the compensation processing method is only +/-0.05 mm, the thickness deviation of the part can be controlled to be +/-0.2 mm, and compared with the conventional processing method, the thickness precision is greatly improved; meanwhile, the time required for scanning the surface contours of the die and the part is less than or equal to 30min, and the time for detecting the surface contours and correcting the paths before numerical control machining is less than or equal to 60min, which is similar to the machining preparation time of the existing machining method, so that the production preparation period is not increased; meanwhile, compared with the mirror milling technology, in terms of cost, the mirror milling technology needs special mirror milling equipment, and because the mirror milling technology is not popularized yet, the investment cost of a single domestic equipment is about 8000 ten thousand yuan, and the cost of all software and hardware equipment in the method does not exceed 300 ten thousand yuan; in the aspect of profile precision control, because the mirror milling technology needs to adopt a flexible clamping mode, a part curved surface cannot be supported and shaped, and the profile precision cannot be controlled, but the vacuum milling fixture profile in the processing method is closest to a part theoretical profile, and the part profile is shaped under the action of vacuum compaction force, so that the precision of the processed part profile can be controlled.
Claims (10)
1. The method for adaptively compensating and processing the thickness of the composite skin is characterized by comprising the following steps of:
step S1: after the composite skin part is formed in a thermosetting mode, carrying out three-dimensional scanning on the lower surface of a rough blank of the composite skin part which is also arranged on the die to obtain scanning point cloud data 1;
step S2: after the scanning of the rough blank of the composite skin part is finished, taking the rough blank of the composite skin part off from the forming die, and carrying out three-dimensional scanning on the forming surface of the forming die to obtain scanning point cloud data 2;
step S3: comparing and calculating the scanning point cloud data 1 and the scanning point cloud data 2 under the same coordinate system to obtain actual thickness point cloud data 3 of the rough blank of the composite skin part;
step S4: clamping the rough blank of the composite skin part according to the milling requirement, and carrying out three-dimensional scanning on the upper surface of the clamped rough blank of the composite skin part to obtain scanning point cloud data 4;
step S5: comparing the actual thickness point cloud data 3 with the scanning point cloud data 4 in the same coordinate system, and calculating and correcting to obtain theoretical point cloud data 5 of the tool path by taking the principle that the thickness step difference of the composite skin part after milling meets the design requirement; generating an actual machining tool path by taking the theoretical point cloud data 5 as a basis;
step S6: and (5) milling the sacrificial layer on the lower surface of the composite skin part according to the actual processing tool path generated in the step (S5) to obtain a finished product of the composite skin part with the thickness step meeting the requirement.
2. The compensation method according to claim 1, wherein in steps S1, S2 and S4, the three-dimensional scan is a three-dimensional phase coordinate scan.
3. The compensation processing method according to claim 2, wherein the scanning accuracy of the sacrificial layer on the lower surface of the composite skin part blank and the mold molding surface corresponding to the sacrificial layer is not lower than 0.05mm.
4. The compensation processing method according to claim 2, wherein in the three-dimensional scanning process, scanning precision of the sacrificial layer on the lower surface of the composite skin part blank and the molding surface of the mold corresponding to the sacrificial layer is larger than that of the corresponding other areas.
5. The compensation processing method according to claim 1, wherein the step S2 further comprises providing a positioning hole in the rough blank of the composite skin part before the rough blank of the composite skin part is removed from the molding die.
6. The compensation processing method according to claim 1, wherein the coordinate system in step S3 is a coordinate system established with a molding die of the composite skin part as a reference system.
7. The compensation processing method according to claim 1, wherein in step S3, only the actual thickness point cloud data of the sacrificial layer on the rough blank of the composite skin part can be obtained by comparison and calculation.
8. The method of claim 1, wherein the design requirement in step S4 is a step of not more than ±0.2mm.
9. The compensation method according to claim 1, wherein the coordinate system in step S5 is a coordinate system established with the clamping tool as a reference system.
10. The compensation processing method according to claim 1, wherein the calculation correction method in step S5 is: and according to the compared scanning point cloud data 4 and the actual thickness point cloud data 3, adding the actual thickness point cloud data 3 to the scanning point cloud data 4 of the corresponding point position to obtain the theoretical point cloud data 5 of the tool path.
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202310367360.4A CN116532697A (en) | 2023-04-07 | 2023-04-07 | Composite skin thickness self-adaptive compensation processing method |
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| CN117077325A (en) * | 2023-10-16 | 2023-11-17 | 成都飞机工业（集团）有限责任公司 | Vacuum-magnetic force cooperative skin profile precise milling tool design method |
| CN117077325B (en) * | 2023-10-16 | 2024-02-23 | 成都飞机工业（集团）有限责任公司 | Vacuum-magnetic force cooperative skin profile precise milling tool design method |
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