CN117786931A - Sequence planning method based on laser material increasing and decreasing composite manufacturing - Google Patents
Sequence planning method based on laser material increasing and decreasing composite manufacturing Download PDFInfo
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Abstract
The invention discloses a sequence planning method based on laser material increasing and decreasing composite manufacturing, which comprises the following steps: s1: drawing a three-dimensional model of a structural member to be manufactured, and slicing the three-dimensional model to obtain a slicing file containing a plurality of layers of patterns; s2: comparing the outlines of the adjacent patterns according to the pattern stacking sequence, and if the outline of the n+1th layer pattern is equal to the outline of the n layer pattern adjacent to the n+1th layer pattern, dividing the n+1th layer pattern into a set where the n layer pattern is located; otherwise, the newly built set stores the n+1th layer of graph, wherein n is more than or equal to 1; generating an additive sequence according to the newly built sequence of the set; s3: generating an alternating sequence of increasing and decreasing materials in advance by utilizing the diameter of the graph in each set, the difference between the horizontal coordinates and the vertical coordinates of the graphs in the adjacent sets and the number of concave-convex points of the graph in each set; s4: the complexity of adjacent sets is compared, the pre-generated alternating sequence of increasing and decreasing materials is optimized and integrated, and the final alternating sequence of increasing and decreasing materials is obtained.
Description
Technical Field
The invention relates to the technical field of composite manufacturing of increasing and decreasing materials, in particular to a sequence planning method based on composite manufacturing of laser increasing and decreasing materials.
Background
Along with the improvement of the requirements of aviation, aerospace, biology, medicine and other fields on energy conversion rate, functions and performances of devices, the complexity of workpieces is increased, and the requirements on processing precision and surface quality are also higher and higher. Additive manufacturing provides complex piece preparation capability which is difficult to reach by traditional processing technology, and provides a new idea for material processing. However, even the most sophisticated additive manufacturing, such as the powder bed based laser selective fusion technique, still faces a series of problems due to excessive roughness when the geometric features produced are sufficiently fine. In particular, with complex-shaped elongated curved lumen structures, additive manufacturing techniques often fail to produce a clear inner diameter when the inner diameter is as small as tens of microns, which presents a very high challenge for post-processing of the workpiece.
To address this problem, researchers have attempted to incorporate subtractive processes into the additive manufacturing process to remove unwanted roughness in an effort to obtain a one-shot manufacturing technique that does not require further processing at a later stage. Typical equipment such as LDMD equipment with a 2kW laser, aided by a 5-axis linked numerically controlled milling machine, as proposed by DMG corporation, japan, can mill inaccessible parts of the final part during the manufacturing process. The equipment proposed by Mazak corporation in Japan can perform 5-axis turning and milling composite machining, and the used objects comprise polygonal forgings or castings, revolving body parts and complex special-shaped parts.
However, with the continuous improvement of design complexity and fineness of products in the fields of aviation, aerospace, medical treatment and the like, the structure of parts is more complicated in internal and external geometric shapes, and the requirements on manufacturing precision are more severe, so that the requirements on fineness and complexity of the composite manufacturing of the increase and decrease materials combined with the numerical control machine tool cannot be met. Because numerical control machining has low material utilization rate, tool accessibility, collision problems, wear of a material reducing tool, mechanical or thermal damage to the surface of a workpiece, displacement of the position of the workpiece due to collision during machining, and the like are difficult to avoid, it is almost impossible to prepare parts with complex and minute internal geometric features by such a hybrid manner. In order to meet the increasing manufacturing demands, improve the processing efficiency and improve the precision of composite manufacturing of the additive and the material, the invention provides a method and a device (ZL 201910169132. X) for synchronously processing additive manufacturing and surface polishing, which provides a composite manufacturing technology for increasing and decreasing the material based on laser, and discloses a manufacturing method for alternately adopting the additive laser and the material-decreasing laser, so that the upper limit of the capability of additive manufacturing can be further expanded. But the efficiency of the final composite fabrication is affected by its frequent switching of the additive and subtractive lasers.
Therefore, how to optimize the number of times of material reduction laser intervention and reasonably plan the process sequence to improve the efficiency of material increase and decrease composite manufacturing based on laser is a problem to be solved by those skilled in the art.
Disclosure of Invention
In view of the above, the present invention aims to provide a sequence planning method based on laser material increasing/decreasing composite manufacturing, so as to optimize the number of times of material decreasing laser intervention, and thereby improve the efficiency of material increasing/decreasing composite manufacturing based on laser.
In order to achieve the above purpose, the present invention adopts the following technical scheme:
a sequence planning method based on laser material increase and decrease composite manufacturing comprises the following steps:
s1: drawing a three-dimensional model of a structural member to be manufactured, and slicing the three-dimensional model to obtain a slicing file containing a plurality of layers of patterns;
s2: comparing the outlines of the adjacent patterns according to the pattern stacking sequence, and if the outline of the n+1th layer pattern is equal to the outline of the n layer pattern adjacent to the n+1th layer pattern, dividing the n+1th layer pattern into a set where the n layer pattern is located; otherwise, the newly built set stores the n+1th layer of graph, wherein n is more than or equal to 1; generating an additive sequence according to the newly built sequence of the set;
s3: generating an alternating sequence of increasing and decreasing materials in advance by utilizing the diameter of the graph in each set, the difference between the horizontal coordinates and the vertical coordinates of the graph between adjacent sets and the number of concave-convex points of the graph in each set;
s4: and comparing the complexity of adjacent sets, and optimally integrating the pre-generated alternating sequence of increasing and decreasing materials to obtain a final alternating sequence of increasing and decreasing materials.
Preferably, the slicing operation in S1 is a non-uniform thickness slicing operation:
for complex models, slice thickness is inversely proportional to the degree of change in model curvature.
Preferably, the step S2 further includes:
comparing the contours of adjacent graphs by using a Hu movements function and a MatchShapes function in OpenCV; if the function return value is 0, which represents that the adjacent patterns are completely equal, the corresponding patterns are classified into the same set; otherwise, the new set stores the corresponding graph.
Preferably, the step S3 further includes:
if the diameter of the graph in a certain set is smaller than a set threshold value, introducing a material reduction operation for the set.
Preferably, the step S3 further includes:
the diameter measuring method comprises the following steps: selecting any point in the graph as a starting point, and acquiring the point farthest from the starting point as one end point of the diameter; and selecting one end point of the diameter as a starting point, and acquiring the other end point farthest from the one end point of the diameter, wherein the distance between the two end points is the diameter.
Preferably, the step S3 further includes:
if the difference between the abscissa and the ordinate of the first point of the graph in the adjacent sets is larger than the corresponding set threshold, introducing a material reduction operation in the middle of the corresponding sequence positions of the two sets.
Preferably, the step S3 further includes:
if the graph in a certain set is larger than the set threshold, introducing a material reduction operation for the set.
Preferably, the step S3 further includes:
the method for calculating the number of concave-convex points of the graph in a certain set comprises the following steps:
s31: calculating the simpson area of the graph in the current set by using a simpson area calculation formula;
s32: acquiring coordinate values of any point in the graph as coordinate values of a target point, acquiring coordinate values of two points adjacent to the target point, and calculating the area of a triangle formed by the three points by utilizing a Simpson area formula according to the coordinate values of the three points;
s33: if the product of the simpson area of the graph and the area of the triangle is larger than zero, the target point is a convex point, otherwise, the target point is a concave point;
s34: if the concave points or the convex points appear in the step S33, the number of the concave-convex points is increased by 1;
s35: and repeating S32-S34 until all points in the graph are calculated, so as to obtain the number of concave-convex points of the graph in the current set.
Preferably, the S4 further includes:
and if the complexity difference of the adjacent sets is smaller than the set threshold, optimizing and integrating the material increasing and decreasing operation sequences corresponding to the corresponding sets.
Preferably, the complexity includes a number of bumps.
Compared with the prior art, the invention provides a sequence planning method based on laser material increasing and decreasing composite manufacturing, which is characterized in that the diameter of the graph in each set, the difference between the horizontal coordinates and the vertical coordinates of the graph in the adjacent set and the number of concave-convex points of the graph in each set are calculated to pre-generate material increasing and decreasing alternating sequences, and finally the complexity difference of the adjacent sets is utilized to optimize the pre-generated material increasing and decreasing alternating sequences so as to obtain the final material increasing and decreasing alternating sequences. The optimized material increasing and decreasing alternating sequence reduces the intervention times of material decreasing operation and improves the processing efficiency based on laser material increasing and decreasing composite manufacturing.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings that are required to be used in the embodiments or the description of the prior art will be briefly described below, and it is obvious that the drawings in the following description are only embodiments of the present invention, and that other drawings can be obtained according to the provided drawings without inventive effort for a person skilled in the art.
Fig. 1 is a flow chart of a sequence planning method based on laser additive and subtractive composite manufacturing.
Fig. 2 is a three-dimensional model of a structure to be manufactured in accordance with an embodiment of the present invention.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
The embodiment of the invention discloses a sequence based on laser material increasing and decreasing composite manufacturing
The planning method comprises the following steps:
s1: drawing a three-dimensional model of a structural member to be manufactured, and slicing the three-dimensional model to obtain a slicing file containing a plurality of layers of patterns;
in a certain embodiment, the three-dimensional model of the structural member to be manufactured is an STL model, and if the three-dimensional model of the structural member to be manufactured is a complex model, the part with the larger model curvature change is sliced by adopting a smaller layer thickness, the part with the smaller model curvature change is sliced by adopting a larger layer thickness, and finally, the slice file with the CLI format with different thicknesses is generated.
S2: comparing the outlines of the adjacent patterns according to the pattern stacking sequence, and if the outline of the n+1th layer pattern is equal to the outline of the n layer pattern adjacent to the n+1th layer pattern, dividing the n+1th layer pattern into a set where the n layer pattern is located; otherwise, the newly built set stores the n+1th layer of graph, wherein n is more than or equal to 1; generating an additive sequence according to the newly built sequence of the set;
in a certain embodiment, S2 further comprises:
s21: acquiring a coordinate point set of each layer of graph in a slice file, and drawing the outline of each layer of graph according to the coordinate point set;
s22: calculating Hu Moments of the n+1th layer graph and the n layer graph by using a Hu movements function in OpenCV, comparing the Hu Moments of the n+1th layer graph and the n layer graph by using a MatchShapes function, and if the return value of the MatchShapes function is 0, representing that the n+1th layer graph is completely equal to the n layer graph, and dividing the n+1th layer graph into a set where the n layer graph is located; otherwise, the new set stores the n+1st layer graph.
The Hu moments have rotational, translational and scale invariance, so matching of the graphical contours can be achieved by comparing the Hu moments. The specific calculation formula of the seven invariant moments included in the Hu moment is as follows:
h 0 ＝η 20 +η 02
h 2 ＝(η 30 -3η 12 ) 2 +(3η 21 -η 03 ) 2
h 3 ＝(η 30 +η 12 ) 2 +(η 21 +η 03 ) 2
h 4 ＝(η 30 -3η 12 )(η 30 +η 12 )[(η 30 +η 12 ) 2 -3(η 21 +η 03 ) 2 ]+(3η 21 -η 03 )[3(η 30 +η 12 ) 2 -(η 21 +η 03 ) 2 ]h 5 ＝(η 20 -η 02 )[(η 30 +η 12 ) 2 -(η 21 +η 03 ) 2 +4η 11 (η 30 +η 12 )(η 21 +η 03 )]
h 6 ＝(3η 21 -η 03 )(η 30 +η 12 )[(η 30 +η 12 ) 2 -3(η 21 +η 03 ) 2 ]+(η 30 -3η 12 )(η 21 +η 03 )[3(η 30 +η 12 ) 2 -(η 21 +η 03 ) 2 ]
wherein h is 0 -h 6 Seven moments, eta, representing Hu moments pq Represents a normalized center moment, where p=0, 1, 2, 3 …; q=0, 1, 2, 3 …; η (eta) 20 ，η 11 ，η 02 Representing a second order central moment; η (eta) 20 The meaning of (2) is: second order center distance when p=2, q=0; η (eta) 11 The meaning of (2) is: second order center distance when p=1, q=1; η (eta) 02 The meaning of (2) is: second order center distance when p=0, q=2; η (eta) 30 ，η 21 ，η 12 ，η 03 Represents a third-order central moment; η (eta) 30 The meaning of (2) is: second order center distance when p=3, q=0; η (eta) 21 The meaning of (2) is: second order center distance when p=2, q=1; η (eta) 12 The meaning of (2) is: second order center distance when p=1, q=2; η (eta) 03 The meaning of (2) is: second order center distance when p=0, q=3;
v pq the calculation formula of (2) is as follows:
wherein M and N represent the sizes of two graphs to be compared, the coordinates of the pixels of the graphs are regarded as two-dimensional random variables (x, y), and f (x, y) is a two-dimensional gray scale density function. The spatial moment being essentially the area or mass, passing through the first moment M ij Calculating centroid coordinates (x) 0 ，y 0 )。
Wherein i= 0, 1, 2 …; j= 0, 1, 2, …; m is M 10 Meaning i=1, j=0; m is M 01 Meaning i=0, j=1; m is M 00 Meaning i=0, j=0.
The specific contour comparison method is as follows:
(1) Respectively calculating seven invariant moment values of the (n+1) -th layer graph and the (n) -th layer graph by using a Hu movements function (Python self-contained library function);
(2) Substituting seven invariant moment values of the n+1th layer graph and the n layer graph into the Matchshapes function for comparison, if the return value of the Matchshapes function is 0, the n+1th layer graph is completely equal to the n layer graph, and if the return value of the Matchshapes function is 0, the n+1th layer graph is marked into a set where the n layer graph is located; otherwise, the new set stores the n+1st layer graph
(3) Repeating the steps until the graph of each layer in the slice file is traversed.
S3: generating an alternating sequence of increasing and decreasing materials in advance by utilizing the diameter of the graph in each set, the difference between the horizontal coordinates and the vertical coordinates of the graph between adjacent sets and the number of concave-convex points of the graph in each set;
in one embodiment, if the diameter of the pattern in one set is smaller than the set threshold (the threshold is set to 0.3mm in this embodiment), it indicates that clogging may occur due to too small a pore size, and thus a subtractive operation is introduced for that set.
In this embodiment, the diameter measurement method is: selecting any point in the graph as a starting point, and acquiring the point farthest from the starting point as one end point of the diameter; and selecting one end point of the diameter as a starting point, and acquiring the other end point farthest from the one end point of the diameter, wherein the distance between the two end points is the diameter.
In one embodiment, if the difference between the abscissa and the ordinate of the first point of the graph in the adjacent set (the first coordinate point of the graph outline read from the slice file) is greater than the corresponding set threshold (in this embodiment, the set threshold for the difference between the abscissas is 1cm, and the set threshold for the difference between the ordinates is 2 cm), it indicates that a larger inflection point may occur, and therefore, the subtraction operation is selected to be introduced in the middle of the corresponding sequence positions of the two sets.
In one embodiment, if the number of concave-convex points of a graph in one set is greater than a set threshold (in this embodiment, the set threshold is 8), it means that this part of the structure is relatively complex, so a material reduction operation is introduced for the set.
In this embodiment, the method for calculating the number of concave-convex points of the graph in a certain set includes:
s31: calculating the Simpson area S of the graph in the current set by using a Simpson area calculation formula i ；
S32: acquiring coordinate value of any point in the graph as a target point P i Coordinate values of (2) to obtain and target point P i Two adjacent points P i-1 、P i+1 According to the coordinate values of these three points P i 、P i-1 、P i+1 Is used to calculate the area S of the triangle formed by these three points using the simpson area formula pi ；
S33: simpson area S of the pattern i Area S with the triangle pi Product Si S pi Greater than zero, the target point P i Convex points or concave points;
s34: if the concave points or the convex points appear in the step S33, the number of the concave-convex points is increased by 1;
s35: and repeating S32-S34 until all points in the graph are calculated, so as to obtain the number of concave-convex points of the graph in the current set.
To sum up, the subtractive operation is introduced in this embodiment as long as any one of the following three conditions is satisfied:
1) The diameter of the graph in a certain set is smaller than 0.3mm;
2) The difference between the abscissas of the first points of the graphs in adjacent sets is greater than 1cm and the difference between the ordinates is greater than 2cm;
3) The number of concave-convex points of a graph in a certain set is more than 8;
s4: and comparing the complexity of adjacent sets, and optimally integrating the pre-generated alternating sequence of increasing and decreasing materials to obtain a final alternating sequence of increasing and decreasing materials.
In one embodiment, if the difference between the numbers of the concave-convex points in the adjacent sets is smaller than a set threshold (the set threshold is 2 in the present embodiment), the material increasing and decreasing operation sequences corresponding to the corresponding sets are optimally integrated.
The optimization integration mode is as follows: the additive operations are combined together and then the combined subtractive operations are reintroduced.
In this embodiment, a three-dimensional model of the structure to be manufactured is shown in fig. 2, which includes 10 sets of groups;
the pre-generated alternating sequence of increasing and decreasing materials is as follows:
{A 1 ,D 1 ,A 2 ,A 3 ,D 3 ,A 4 ,D 4 ,A 5 ,D 5 ,A 6 ,D 6 ,A 7 ,A 8 ,D 8 ,A 9 ,D 9 ,A 10 ,D 10 }
wherein A represents an additive operation, D represents a subtractive operation, and subscripts 1-10 represent newly built set numbers in a slice graph stacking order. Compared with the composite manufacturing method that each slice alternately uses the increase and decrease material in the background art, the pre-generated increase and decrease material alternating sequence reduces the switching times of the increase and decrease material operation (namely the switching times of the decrease material operation).
Optimizing and integrating the pre-generated alternating sequence of the increase and decrease materials according to the complexity difference of the adjacent sets, and obtaining the alternating sequence of the increase and decrease materials after optimizing and integrating is as follows:
{A1,D1,[A2-A5],[D3-D5],A6,D6,[A7-A9],[D8-D9],A10,D10}
it can be seen that optimizing the integrated sequence further reduces the number of switching operations between the additive operation and the subtractive operation (i.e., reduces the number of switching operations of the subtractive operation) compared to the pre-generated alternating sequence of increasing and decreasing materials.
In the present specification, each embodiment is described in a progressive manner, and each embodiment is mainly described in a different point from other embodiments, and identical and similar parts between the embodiments are all enough to refer to each other. For the device disclosed in the embodiment, since it corresponds to the method disclosed in the embodiment, the description is relatively simple, and the relevant points refer to the description of the method section.
The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
Claims (10)
1. The sequence planning method based on the laser material increasing and decreasing composite manufacturing is characterized by comprising the following steps of:
s1: drawing a three-dimensional model of a structural member to be manufactured, and slicing the three-dimensional model to obtain a slicing file containing a plurality of layers of patterns;
s2: comparing the outlines of the adjacent patterns according to the pattern stacking sequence, and if the outline of the n+1th layer pattern is equal to the outline of the n layer pattern adjacent to the n+1th layer pattern, dividing the n+1th layer pattern into a set where the n layer pattern is located; otherwise, the newly built set stores the n+1th layer of graph, wherein n is more than or equal to 1; generating an additive sequence according to the newly built sequence of the set;
s3: generating an alternating sequence of increasing and decreasing materials in advance by utilizing the diameter of the graph in each set, the difference between the horizontal coordinates and the vertical coordinates of the graph between adjacent sets and the number of concave-convex points of the graph in each set;
s4: and comparing the complexity of adjacent sets, and optimally integrating the pre-generated alternating sequence of increasing and decreasing materials to obtain a final alternating sequence of increasing and decreasing materials.
2. The sequence planning method based on laser additive and subtractive composite manufacturing according to claim 1, wherein the slicing operation in S1 is a variable thickness slicing operation:
for complex models, slice thickness is inversely proportional to the degree of change in model curvature.
3. The sequence planning method based on laser additive and subtractive composite manufacturing according to claim 1, wherein S2 further comprises:
comparing the contours of adjacent graphs by using a Humoments function and a MatchShapes function in OpenCV; if the function return value is 0, which represents that the adjacent patterns are completely equal, the corresponding patterns are classified into the same set; otherwise, the new set stores the corresponding graph.
4. The sequence planning method based on laser additive and subtractive composite manufacturing according to claim 1, wherein S3 further comprises:
if the diameter of the graph in a certain set is smaller than a set threshold value, introducing a material reduction operation for the set.
5. The sequence planning method based on laser additive and subtractive composite manufacturing according to claim 4, wherein S3 further comprises:
the diameter measuring method comprises the following steps: selecting any point in the graph as a starting point, and acquiring the point farthest from the starting point as one end point of the diameter; and selecting one end point of the diameter as a starting point, and acquiring the other end point farthest from the one end point of the diameter, wherein the distance between the two end points is the diameter.
6. The sequence planning method based on laser additive and subtractive composite manufacturing according to claim 1, wherein S3 further comprises:
if the difference between the abscissa and the ordinate of the first point of the graph in the adjacent sets is larger than the corresponding set threshold, introducing a material reduction operation in the middle of the corresponding sequence positions of the two sets.
7. The sequence planning method based on laser additive and subtractive composite manufacturing according to claim 1, wherein S3 further comprises:
if the number of concave-convex points of the graph in a certain set is larger than a set threshold value, introducing a material reduction operation for the set.
8. The sequence planning method based on laser additive and subtractive composite manufacturing according to claim 7, wherein S3 further comprises:
the method for calculating the number of concave-convex points of the graph in a certain set comprises the following steps:
s31: calculating the simpson area of the graph in the current set by using a simpson area calculation formula;
s32: acquiring coordinate values of any point in the graph as coordinate values of a target point, acquiring coordinate values of two points adjacent to the target point, and calculating the area of a triangle formed by the three points by utilizing a Simpson area formula according to the coordinate values of the three points;
s33: if the product of the simpson area of the graph and the area of the triangle is larger than zero, the target point is a convex point, otherwise, the target point is a concave point;
s34: if the concave points or the convex points appear in the step S33, the number of the concave-convex points is increased by 1;
s35: and repeating S32-S34 until all points in the graph are calculated, so as to obtain the number of concave-convex points of the graph in the current set.
9. The sequence planning method based on laser additive and subtractive composite manufacturing according to claim 1, wherein S4 further comprises:
and if the complexity difference of the adjacent sets is smaller than the set threshold, optimizing and integrating the material increasing and decreasing operation sequences corresponding to the corresponding sets.
10. The sequence planning method based on laser material increasing and decreasing composite manufacturing according to claim 9, wherein,
the complexity includes a number of bumps.
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