零件表面混合维建模理论、方法及其在产品装配质量预测中的应用
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摘要
零件表面的质量是产品性能分析与预测中不可或缺的重要因素,其几何形貌特征极大地影响了产品和零件的各种性能指标。在产品的设计和制造阶段,根据实际零件表面的局部测量数据评定其表面特征参数,模拟出该零件的表面形貌,体现真实零件的表面微观结构的特点和表面几何结构参数,分析并获得零件表面形貌对产品工作效能的影响规律,对提高零部件装配质量和产品性能具有重要的理论价值和现实意义。本文在对零件表面形貌建模及应用相关技术研究现状进行总结和分析的基础上,针对零件表面建模、特征参数识别、装配定位和配合性能分析等问题进行了深入的研究,根据研究成果开发了零件表面形貌建模与分析软件系统,并成功应用到相关的科研项目中。
论文的主要研究内容包括：
第一章概述了零件表面形貌建模研究发展历程,综述了零件表面形貌分析与应用过程中涉及的关键技术及其研究现状,指出了目前同类研究存在的不足以及本文拟解决的问题,并介绍了本文的研究内容和组织结构。
第二章提出了零件表面形貌多尺度高度场分离与修正方法。定义了多重分数维表面高度场特征函数来模拟空间表面微观结构,通过多尺度信息提取方法将表面形貌分离到四个尺度下。研究了多尺度表面高度信息的多分辨率优化方法和零件表面一致性评价方法,建立了多尺度零件表面信息传递模型。提出基于多尺度参数驱动的零件表面形貌修正方法,生成各个尺度都满足实际零件结构参数的零件表面形貌。
第三章提出了零件表面形貌混合维融合及特征参数识别方法。定义了体现微观表面形貌对实际表面形貌影响力大小的混合维影响因子,研究了零件表面形貌整数维分量和分数维分量的构造和融合方法,建立的混合维表面模型在整体上表达零件表面整数维信息的同时,很好地表达了零件表面的分数维细节。提出零件表面形貌模型的混合维特征参数识别方法,从而能在宏观层面和微观层面评估零件表面的加工质量。
第四章提出了基于混合维的零件真实几何实体特征构建与装配定位方法。定义了集成理想几何、变动几何和分数维几何的零件真实几何的概念,提出了层次化的零件真实几何特征信息的表示方法,并给出具体的零件真实几何实体特征生成方法和步骤。研究了零件真实几何模型的面面贴合装配定位和接触分析方法,提高了装配仿真的精度。
第五章研究了基于真实几何的配合性能分析及其在伺服阀泄漏特性预测中的应用。建立了包含尺寸偏差和形状误差的精密偶件配合面真实几何特征模型,以间隙截面积为评价指标考察了精密偶件的真实几何配合面对配合性能的影响规律。提出了基于真实几何模型的伺服阀油液泄漏量预测方法,通过计算的间隙截面积预测了不同因素影响下的精密偶件油液泄漏量。
第六章介绍了零件表面形貌建模与分析软件系统的设计与开发,论述了软件系统的体系结构、各项功能的设计思路及其编程实现。该软件系统有效地提高了零件表面形貌特征建模与分析的效率,验证了本文提出理论与方法的正确性和可行性。
第七章对本文进行了总结,归纳了本文的主要研究成果和创新之处,并对今后的研究工作进行了展望。
The quality of part surface is a key factor in analysis and prediction of product performance, and the geometric topography of part surface has a great influence on various performance indexes of products and parts. In product design and manufacture stage, evaluating the characteristic parameters of a real part surface from its local measured data, simulating the realistic topography which reflects the surface microstructures and the geometric structural parameters of the real part surface, and obtaining the influence of the topography on product working efficiency will make sense for the improvement of assembly quality and product performance. Basing on analysis and overview of the literature of modeling and simulation of part surface topography, the technologies and methodologies including part surface modeling, characteristic parameter identification, assembly positioning and fitting performance analysis are deeply studied. According to the research achievements, the software system for modeling and analysis of part surface topography is developed and applied successfully to the related projects.
The dissertation is organized as follows:
In chapter1, the history and state-of-art of modeling of part surface topography are reviewed. The key technologies for analysis of part surface topography and performance prediction are discussed, and the shortages of present similar researches are proposed. Then the research contents and architecture of the dissertation are presented.
In chapter2, the separation and revision methods of multi-scale part surface topography altitude field are proposed. A multi-fractal characteristic function of part surface altitude field is defined to describe the microstructures of a spatial rough surface, and the surface topography is decomposed into four scales by the multi-scale information extraction method. Then the multi-resolution optimization method and the part surface consistency evaluation method are studied, and the information transmission model of multi-scale part surface is also built. The revision technology of part surface topography based on multi-scale parameter driving is proposed, so the part surface topography is generated, which meets the structural parameters at each scale of a real part.
In chapter3, the hybrid dimensional fusion and characteristic parameter identification methods of part surface topography are proposed. The innovative concept of Hybrid Dimensional Impact Factor is defined which reflects the influence of the micro topography on the practical topography of a part surface. The constitution and fusion methods of integral dimensional component and fractal dimensional component of part surface topography are studied, and the established hybrid dimensional surface model can express both the integral dimensional information of part surface in macro level, and the fractal dimensional detail in micro level. Moreover, the hybrid dimensional characteristic parameter identification method for the part surface topography model is proposed, so the machining quality of part surface can be evaluated in both macro level and micro level.
In chapter4, the hybrid dimension based feature construction and assembly positioning methods of part realistic geometric solid are proposed. The innovative concept of part realistic geometry is defined which integrates ideal geometry, variational geometry and fractal geometry. The hierarchical representation method of part realistic geometric feature information is proposed, and the specific generation method of part realistic geometric solid feature is presented. Then the assembly positioning and contact analysis methods of part realistic geometric model are studied, so the accuracy of assembly simulation is improved.
In chapter5, the realistic geometry based fitting performance analysis and its application in leakage characteristic prediction of electro-hydaulic servo valve are studied. The realistic geometric feature model of precision couplings is built which includes the fitting surfaces with dimensional discrepancy and form error, and the influence of realistic geometric fitting surfaces of precision couplings on fitting performance is investigated according to the evaluation index of interval sectional area. Then the realistic geometric model based fluid leakage prediction method of electro-hydraulic·servo·valve is proposed, so the fluid leakage of precision couplings under various factors can be predicted according to the calculated interval sectional area.
In chapter6, the software system for modeling and analysis of part surface topography is developed. The architecture of the software system, the design idea of each function and its programming realization are discussed. The efficiency of modeling and analysis of part surface topography can be improved effectively by the software system, which shows the validity and feasibility of the new theories and methods proposed in this dissertation.
In chapter7, the conclusions and innovations of this dissertation are given along with future prospects of these research topics.
论文的主要研究内容包括：
第一章概述了零件表面形貌建模研究发展历程,综述了零件表面形貌分析与应用过程中涉及的关键技术及其研究现状,指出了目前同类研究存在的不足以及本文拟解决的问题,并介绍了本文的研究内容和组织结构。
第二章提出了零件表面形貌多尺度高度场分离与修正方法。定义了多重分数维表面高度场特征函数来模拟空间表面微观结构,通过多尺度信息提取方法将表面形貌分离到四个尺度下。研究了多尺度表面高度信息的多分辨率优化方法和零件表面一致性评价方法,建立了多尺度零件表面信息传递模型。提出基于多尺度参数驱动的零件表面形貌修正方法,生成各个尺度都满足实际零件结构参数的零件表面形貌。
第三章提出了零件表面形貌混合维融合及特征参数识别方法。定义了体现微观表面形貌对实际表面形貌影响力大小的混合维影响因子,研究了零件表面形貌整数维分量和分数维分量的构造和融合方法,建立的混合维表面模型在整体上表达零件表面整数维信息的同时,很好地表达了零件表面的分数维细节。提出零件表面形貌模型的混合维特征参数识别方法,从而能在宏观层面和微观层面评估零件表面的加工质量。
第四章提出了基于混合维的零件真实几何实体特征构建与装配定位方法。定义了集成理想几何、变动几何和分数维几何的零件真实几何的概念,提出了层次化的零件真实几何特征信息的表示方法,并给出具体的零件真实几何实体特征生成方法和步骤。研究了零件真实几何模型的面面贴合装配定位和接触分析方法,提高了装配仿真的精度。
第五章研究了基于真实几何的配合性能分析及其在伺服阀泄漏特性预测中的应用。建立了包含尺寸偏差和形状误差的精密偶件配合面真实几何特征模型,以间隙截面积为评价指标考察了精密偶件的真实几何配合面对配合性能的影响规律。提出了基于真实几何模型的伺服阀油液泄漏量预测方法,通过计算的间隙截面积预测了不同因素影响下的精密偶件油液泄漏量。
第六章介绍了零件表面形貌建模与分析软件系统的设计与开发,论述了软件系统的体系结构、各项功能的设计思路及其编程实现。该软件系统有效地提高了零件表面形貌特征建模与分析的效率,验证了本文提出理论与方法的正确性和可行性。
第七章对本文进行了总结,归纳了本文的主要研究成果和创新之处,并对今后的研究工作进行了展望。
The quality of part surface is a key factor in analysis and prediction of product performance, and the geometric topography of part surface has a great influence on various performance indexes of products and parts. In product design and manufacture stage, evaluating the characteristic parameters of a real part surface from its local measured data, simulating the realistic topography which reflects the surface microstructures and the geometric structural parameters of the real part surface, and obtaining the influence of the topography on product working efficiency will make sense for the improvement of assembly quality and product performance. Basing on analysis and overview of the literature of modeling and simulation of part surface topography, the technologies and methodologies including part surface modeling, characteristic parameter identification, assembly positioning and fitting performance analysis are deeply studied. According to the research achievements, the software system for modeling and analysis of part surface topography is developed and applied successfully to the related projects.
The dissertation is organized as follows:
In chapter1, the history and state-of-art of modeling of part surface topography are reviewed. The key technologies for analysis of part surface topography and performance prediction are discussed, and the shortages of present similar researches are proposed. Then the research contents and architecture of the dissertation are presented.
In chapter2, the separation and revision methods of multi-scale part surface topography altitude field are proposed. A multi-fractal characteristic function of part surface altitude field is defined to describe the microstructures of a spatial rough surface, and the surface topography is decomposed into four scales by the multi-scale information extraction method. Then the multi-resolution optimization method and the part surface consistency evaluation method are studied, and the information transmission model of multi-scale part surface is also built. The revision technology of part surface topography based on multi-scale parameter driving is proposed, so the part surface topography is generated, which meets the structural parameters at each scale of a real part.
In chapter3, the hybrid dimensional fusion and characteristic parameter identification methods of part surface topography are proposed. The innovative concept of Hybrid Dimensional Impact Factor is defined which reflects the influence of the micro topography on the practical topography of a part surface. The constitution and fusion methods of integral dimensional component and fractal dimensional component of part surface topography are studied, and the established hybrid dimensional surface model can express both the integral dimensional information of part surface in macro level, and the fractal dimensional detail in micro level. Moreover, the hybrid dimensional characteristic parameter identification method for the part surface topography model is proposed, so the machining quality of part surface can be evaluated in both macro level and micro level.
In chapter4, the hybrid dimension based feature construction and assembly positioning methods of part realistic geometric solid are proposed. The innovative concept of part realistic geometry is defined which integrates ideal geometry, variational geometry and fractal geometry. The hierarchical representation method of part realistic geometric feature information is proposed, and the specific generation method of part realistic geometric solid feature is presented. Then the assembly positioning and contact analysis methods of part realistic geometric model are studied, so the accuracy of assembly simulation is improved.
In chapter5, the realistic geometry based fitting performance analysis and its application in leakage characteristic prediction of electro-hydaulic servo valve are studied. The realistic geometric feature model of precision couplings is built which includes the fitting surfaces with dimensional discrepancy and form error, and the influence of realistic geometric fitting surfaces of precision couplings on fitting performance is investigated according to the evaluation index of interval sectional area. Then the realistic geometric model based fluid leakage prediction method of electro-hydraulic·servo·valve is proposed, so the fluid leakage of precision couplings under various factors can be predicted according to the calculated interval sectional area.
In chapter6, the software system for modeling and analysis of part surface topography is developed. The architecture of the software system, the design idea of each function and its programming realization are discussed. The efficiency of modeling and analysis of part surface topography can be improved effectively by the software system, which shows the validity and feasibility of the new theories and methods proposed in this dissertation.
In chapter7, the conclusions and innovations of this dissertation are given along with future prospects of these research topics.
引文
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