华中科技大学
硕士学位论文
姓名：任俊
申请学位级别：硕士
专业：材料加工工程减速机测试
指导教师：张海鸥
20060505
华中科技大学硕士学位论文突起路标
摘要
在金属模具快速制造技术中，等离子熔射快速制模工艺（RSHT）具有成本低、速度快、表面复制精度
高，对模具材料和尺寸规格限制小等优点，适用于汽车、摩托车、家电和建筑装饰等行业的覆盖件模具的快速制造，具有广阔的应用前景。为了解决熔射制造大中型汽车覆盖件模具过程中人工研磨抛光时间长、劳动强度大等问题，本文系统地概述了机器人自动研磨抛光系统的国内外现状并开发了以Motoman-UP20关节式机器人为平台的辅助曲面自动抛光实验系统。
论文首先比较了机器人抛光加工中气动和步进电机驱动的优缺点，以步进电机高速主轴为核心，建立了机器人抛光驱动系统，实现了在抛光过程中精确的磨头转速控制。比较分析了各种抛光工具的特点，确定了合适形状、材料的软质抛光工具，对游离式磨粒的成分、性能和应用范围进行比较分析，完成了磨具磨料的选型，确定了软质羊毛、不织布纤维材料磨头配合油溶性研磨膏的工具方案，从而集成了辅助模具自动抛光系统实验平台。
其次，论文根据建立的机器人抛光系统以UG为平台进行抛光轨迹规划，详细阐述了将铣削轨迹应用于抛光轨迹的关键性技术。此外，以VC为平台上开发了机器人抛光工艺软件，实现了机器人代码的读写操作，按照抛光工艺的要求实现了对工具加工角度的修正，以参数化的形式实现了磨头的刀具补偿，为开发完善的补偿程序打下了基础。由以上工作初步建立了机器人自动抛光系统原型。并采用ROTSY对生成的抛光轨迹进行机器人运动仿真，以确保抛光轨迹的无干涉和机器人运动控制的可行性。由以上工作初步建立了机器人自动抛光系统原型。
最后，在建立的机器人抛光实验平台上进行了机器人抛光工艺实验研究，得到了在本文条件下合适的步进电机主轴转速，得到了横向进给量越小越有利于表面质量提高的规律和实际应用中横向进给量的取值范围。确定了本文机器人曲面抛光系统的加工去除量在微米级，得出机器人抛光加工不会破坏等离子熔射制模工艺获得的表面皮膜完整性的结论。在以上工艺试验的基础上，进行了等离子熔射制造的汽车覆盖件模具表面抛光试验，结果表明本文系统可用于熔射制模工艺，为模具表面抛光提供有效快捷的途径。
关键词：等离子熔射制模机器人抛光系统路径规划 CAD/CAM 皮膜
美容加湿器华中科技大学硕士学位论文
105数字商城
Abstract
As a kind of rapid metal tooling method, Rapid Plasma Spray Hard Tooling（RSHT）has been used to manufacture the panel molds of the fields such as automobile, motorcycle, electrical appliance and architecture decoration. It has great application foreground because of its advantages of low cost, rapid speed, high surface reproduced accuracy and no limitation in the spray material or mould size. In order to solve the problem of long grinding time and hard labor intensity of manual grinding during polishing the big or medium-sized autobody panel moulds, this paper summarizes the latest r
esearch in the field of robotic polishing system home and abroad and then developed a robot-assisted automatic polishing system using the Motoman-UP20 6-axis robot.
Firstly, this paper compare the compress air dring style and step motor dring style in the robot-assisted automatic polishing system. The step motor has been selected as the center of the robot polishing dring system to realized the strict controlling of polishing tool rotate speed. Base on the analysis of different polishing tools, the combination of flexible polishing tools and the oiled abrasive sand has been adopted and the the robot-assisted polishing system was successfully developed.
Furthermore, the path-planning method base on the UG-CAM software has been adopted in this paper. The key technique of the using the milling path as the polishing path has been explained in detail. On the platform of Visual C++ , this paper dev eloped the polishing technologic software, so that the polishng system can accurately control the path, polishing angle and realize the compensate of the polishing tool’s consume. In order to ensure the planning polishing paths feasible, the robot simulati on software has been introduced. Through the simulating of the polishing process in ROTSY provided by MOTOMAN Company, it can be decided whether the tool intervenes with the workpiece surface and the robot can be correctly controlled.
洗瓶Finally, Based on the system, processing experiments were carried out and the effects of tool rotate speed and polishing path on the surface quality were studied and the suitable polishing parameters were obtained. And a polishing experiment on a simple freeform surface has been executed and verified the robot polishing technics would’t destroy the integrity of the film manufactured by plasma spay tooling. According to the above experiments, The polishing experiment on the surface of the mould manufactured by plasma
华中科技大学硕士学位论文
直录播系统spay were carried out by using the suitable parameters. Experimental results indicate that the system can be applied in polishing process of the moulds manufactured by plasma spay or other general moulds to obtain the high polishing quality.
Key words：Plasma spray hard tooling, Robot, Polishing system, Path planning, CAD/CAM, Film
√独创性声明
本人声明所呈交的学位论文是我个人在导师的指导下进行的研究工作及取得的研究成果。近我所知，除文中已标明引用的内容外，本论文不包含任何其他人或集体已经发表或撰写过的研究成果。对本文
的研究做出贡献的个人和集体，均已在文中以明确方式标明。本人完全意识到本声明的法律结果由本人承担。
学位论文作者签名：任俊
日期：2006年5月9日
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学位论文作者签名：任俊指导教师签名：张海鸥
日期：2006年5月9日日期：2006年5月9日
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