复杂曲面车削刀具轨迹轮廓偏差一致性控制方法

doi:10.3901/JME.260390

机械工程学报 ›› 2026, Vol. 62 ›› Issue (7): 452-461.doi: 10.3901/JME.260390

• 制造工艺与装备 • 上一篇

扫码分享

复杂曲面车削刀具轨迹轮廓偏差一致性控制方法

马建伟, 李冠霖, 谢英豪, 申原同, 贾振元

大连理工大学高性能精密制造全国重点实验室大连 116024

收稿日期:2025-04-06 修回日期:2025-09-18 发布日期:2026-05-25
作者简介:马建伟(通信作者)，男，1984年出生，博士，教授，博士研究生导师。主要研究方向为难加工材料曲面加工与过程控制、激光精密加工与过程控制、机器人辅助加工规划及控制等。E-mail:mjw2011@dlut.edu.cn
李冠霖，男，1995年出生，博士研究生。主要研究方向为复杂曲面精密加工。E-mail:liguanlin@mail.dlut.edu.cn
谢英豪，男，2000年出生，硕士研究生。主要研究方向为复杂曲面加工干涉高效校验与路径优化。E-mail:534746911@qq.com
申原同，男，1999年出生，硕士研究生。主要研究方向为复杂功能结构表面精细加工。E-mail:syt0533@163.com
贾振元，男，1963年出生，博士，教授，博士研究生导师。主要研究方向为高端装备高性能零部件控形控性机械加工理论、技术与装备。E-mail:jzyxy@dlut.edu.cn
基金资助:
国家自然科学基金(52375410)、辽宁省中央引导地方科技发展资金计划(2025JH6/101100003)和中央高校基本科研业务费专项资金资助项目。

Contour Deviation Consistency Controlling Method for Turning Toolpaths of Complex Surfaces

MA Jianwei, LI Guanlin, XIE Yinghao, SHEN Yuantong, JIA Zhenyuan

State Key Laboratory of High-performance Precision Manufacturing, Dalian University of Technology, Dalian 116024

Received:2025-04-06 Revised:2025-09-18 Published:2026-05-25

摘要/Abstract

摘要： 精密物理实验、航空航天工程等高精尖科技与工业领域对复杂曲面零件有重要需求。其中有一类零件，多设计为局部曲率突变、非均匀低频起伏轮廓急变等非回转对称特征，慢刀伺服车削是实现其表面创成的有效手段。然而，由于非回转对称复杂曲面在常规精度容限范围内的可忽略因素敏感度高，致使细微工艺差别对加工精度的影响不可忽略，因而全面域一致性加工精度难以保证。为解决非回转对称复杂曲面慢刀伺服车削加工质量控制难题，提出一种复杂曲面车削刀具轨迹轮廓偏差一致性控制方法。构建非回转对称复杂曲面的法向等距偏置面作为刀具轨迹规划目标面，并基于此生成PVT插补的离散化刀具轨迹，开发PVT插补偏差约束的刀位点局部疏密化处理策略，提出虑及相邻点间轮廓偏差一致性的刀位点迭代优化调整方法。以核主泵密封圈抽象出的旋转波纹面为典型样件开展加工验证实验，结果表明，利用所提方法加工的试验件相比常规等参数法，轮廓度偏差降低32.61%、均方根轮廓度偏差降低36.36%、表面粗糙度降低28.03%，显著提升复杂曲面慢刀伺服车削的加工精度和表面质量。

关键词: 慢刀伺服车削, 非回转对称复杂曲面, 轨迹规划, 轮廓偏差一致性, PVT插补

Abstract: High-precision physics experiments, aerospace engineering and other high-tech and industrial fields have a significant demand for complex surface parts. A particular type of them is commonly designed with unrotational-symmetric features such as sudden changes in local curvature, non-uniform low-frequency undulations, and sharp contour variations. Slow tool servo turning is an effective method for creating these surfaces. However, due to the high sensitivity of unrotational-symmetric complex surfaces to factors within the tolerance limits of conventional accuracy, even minor process differences can have a significant impact on machining accuracy, making it challenging to maintain consistent accuracy for the whole region. To address the challenges of quality control in the slow tool servo turning of unrotational-symmetric complex surfaces, a contour deviation consistency controlling method for turning toolpaths is proposed. This approach constructs a normal equidistant offset surface of the unrotational-symmetric complex surface as the target for toolpath planning, and generates discretized toolpaths for PVT interpolation based on this surface. A local sparsification and densification strategy is developed for cutter location points constrained by PVT interpolation deviations, and an iterative optimization method is proposed to adjust cutter location points while maintaining consistency of contour deviations between adjacent points. A machining verification experiment is conducted using a rotating wave surface abstracted from the sealing ring of a nuclear main pump as a typical sample. The results show that the produced sample using the proposed method can reduce profile error by 32.61%, root mean square profile error by 36.36% and surface roughness by 28.03% compared to conventional equal parameter method, significantly improving the machining accuracy and surface quality for slow tool servo turning of complex surfaces.

Key words: slow tool servo turning, unrotational-symmetric complex surface, toolpath planning, contour deviation consistency, PVT interpolation

中图分类号:

TH161

马建伟, 李冠霖, 谢英豪, 申原同, 贾振元. 复杂曲面车削刀具轨迹轮廓偏差一致性控制方法[J]. 机械工程学报, 2026, 62(7): 452-461.

MA Jianwei, LI Guanlin, XIE Yinghao, SHEN Yuantong, JIA Zhenyuan. Contour Deviation Consistency Controlling Method for Turning Toolpaths of Complex Surfaces[J]. Journal of Mechanical Engineering, 2026, 62(7): 452-461.

导出引用管理器 EndNote|Reference Manager|ProCite|BibTeX|RefWorks

链接本文: http://www.cjmenet.com.cn/CN/10.3901/JME.260390

http://www.cjmenet.com.cn/CN/Y2026/V62/I7/452

参考文献

[1] CHENG H B,FENG Z J,CHENG K,et al. Design of a six-axis high precision machine tool and its application in machining aspherical optical mirrors[J]. International Journal of Machine Tools and Manufacture,2005,45(9): 1085-1094.
[2] 李敏,袁巨龙,吴喆,等. 复杂曲面零件超精密加工方法的研究进展[J]. 机械工程学报,2015,51(5):178-191. LI Min,YUAN Julong,WU Zhe. Progress in ultra-precision machining methods of complex curved parts[J]. Journal of Mechanical Engineering,2015,51(5):178-191.
[3] ZHAO B,DING W F,SHAN Z D,et al. Collaborative manufacturing technologies of structure shape and surface integrity for complex thin-walled components of aero-engine:status,challenge and tendency[J]. Chinese Journal of Aeronautics,2023,36(7):1-24.
[4] ZHANG Y L,SHI H D,JIANG H L. Polarization aberration of a non-rotationally symmetric optical system with freeform surfaces[J]. IEEE Access,2021,9:145538-145553.
[5] HUANG P,WU X Y,TO S,et al. Deterioration of form accuracy induced by servo dynamics errors and real-time compensation for slow tool servo diamond turning of complex-shaped optics[J]. International Journal of Machine Tools and Manufacture,2020,154:103556.
[6] 牛恒泰,康敏,王兴盛,等. 渐进多焦点镜片的设计与慢刀伺服车削[J]. 中国机械工程,2019,30(6):722-727. NIU Hengtai,KANG Min,WANG Xingsheng,et al. Design and slow tool servo turning of progressive-addition lenses[J]. China Mechanical Engineering,2019,30(6):722-727.
[7] 王旭初,赵亮,程凯,等. 超精密慢刀伺服车削零件的面型分析与刀具设计方法研究[J]. 机械设计与制造,2024(2):236-240,245. WANG Xuchu,ZHAO Liang,CHENG Kai,et al. Surface profile analysis of parts and tool design for ultra-precision slow cutter servo turning[J]. Machinery Design and Manufacture,2024(2):236-240,245.
[8] 秦逢泽. 复杂类回转曲面零件慢刀伺服精密车削刀轨规划与轮廓误差补偿技术[D]. 大连:大连理工大学,2023. QIN Fengze. Trajectory planning and its contouring error compensation technique for slow tool servo turning for complex similar rotation curved surface parts[D]. Dalian:Dalian University of Technology,2023.
[9] SATO Y,YAN J. Tool path generation and optimization for freeform surface diamond turning based on an independently controlled fast tool servo[J]. International Journal of Extreme Manufacturing,2022,4(2):025102.
[10] AO S J,GONG H,HUANG K T. A smooth tool path generation method for ultraprecision turning discontinuous multi-freeform-surfaces with high machining efficiency[J]. Journal of Materials Processing Technology,2021,298:117280.
[11] GUO H Y,KANG M,ZHOU W,et al. A new optimal method of tool path generation for slow tool servo turning of complex surface[J]. Manufacturing Technology,2020,20:733-747.
[12] WANG Y K,WANG J J,GUO P. Generic fabrication solution of freeform Fresnel optics using ultra-precision turning[J]. Optics Express,2023,31(26):44622-44647.
[13] 李泽骁. 脆性材料光学自由曲面超精密车削方法与工艺研究[D]. 天津:天津大学,2019. LI Zexiao. Study on ultra-precision turning methods and processes of freeform optics of brittle materials [D]. Tianjin:Tianjin University,2019.
[14] NAGAYAMA K,YAN J W. Deterministic error compensation for slow tool servo-driven diamond turning of freeform surface with nanometric form accuracy[J]. Journal of Manufacturing Processes,2021,64:45-57.
[15] 王建. 非回转对称曲面超精密车削刀具路径规划技术研究[D]. 哈尔滨:哈尔滨工业大学,2013. WANG Jian. Study of the tool path planning in ultra-precision turning to get non-rotary symmetrical curve [D]. Harbin:Harbin Institute of Technology,2013.
[16] CHEN C C,CHENG Y C,HSU W Y,et al. Slow tool servo diamond turning of optical freeform surface for astigmatic contact lens[C]// Optical Manufacturing and Testing IX. San Diego,CA. 2011,8126:358-366.
[17] GONG H,WANG Y,SONG L,et al. Spiral tool path generation for diamond turning optical freeform surfaces of quasi-revolution[J]. Computer-Aided Design,2015,59:15-22.
[18] 张海洋. 金刚石车削光学自由曲面刀具路径规划的研究[D]. 长春:吉林大学,2011. ZHANG Haiyang. Study on tool path planning in diamond turning of freeform optical surface[D]. Changchun:Jilin University,2011.
[19] HE S,XUAN J P,DU W H,et al. Spiral tool path generation method in a NURBS parameter space for the ultra-precision diamond turning of freeform surfaces[J]. Journal of Manufacturing Processes,2020,60:340-355.
[20] GUO Y J,YANG X J,KANG J,et al. Spiral tool path optimization method for fast/slow tool servo-assisted diamond turning of freeform surfaces with highly form accuracy[J]. Precision Engineering,2023,80:229-242.
[21] LIU M Y,CHEUNG C F,FENG X B,et al. Diamond machining of freeform-patterned surfaces on precision rollers[J]. The International Journal of Advanced Manufacturing Technology,2019,103(1-4):4423-4431.
[22] WANG D F,SUI Y X,YANG H J,et al. Adaptive spiral tool path generation for diamond turning of large aperture freeform optics[J]. Materials,2019,12(5):810.
[23] YIN Z Q,DAI Y F,LI S Y,et al. Fabrication of off-axis aspheric surfaces using a slow tool servo[J]. International Journal of Machine Tools and Manufacture,2011,51(5):404-410.
[24] 王兴盛,康敏. 基于Hermite插值的复杂光学曲面车削加工路径规划[J]. 机械工程学报,2012,48(11):191-198. WANG Xingsheng,KANG Min. Cutting path planning for complex optical surface using Hermite interpolation[J]. Journal of Mechanical Engineering,2012,48(11):191-198.
[25] CHEN X,KANG M,WANG X S,et al. Tool path optimal design for slow tool servo turning of complex optical surface[J]. Proceedings of the Institution of Mechanical Engineers,Part B:Journal of Engineering Manufacture,2017,231(5):825-837.
[26] QIN F Z,MA J W,JIA Z Y,et al. A toolpath generation method under the constraint of interpolation error in STS precision turning with PVT interpolation[C]// 2022 7th International Conference on Control and Robotics Engineering. Beijing,China. 2022,37-42.
[27] LIANG R B,YU Y Q,CHEN J N,et al. Tool path generation with a uniform residual error distribution considering tool contour error for ultra-precision diamond turning[J]. Journal of Manufacturing Processes,2024,115:466-480.

复杂曲面车削刀具轨迹轮廓偏差一致性控制方法

Contour Deviation Consistency Controlling Method for Turning Toolpaths of Complex Surfaces

PDF

可视化

摘要/Abstract

引用本文

使用本文

参考文献

相关文章 15

编辑推荐

Metrics

本文评价

[1]	龙秀华, 胡正国, 付涛, 连楷研, 宋学官. 基于非对称多段S型曲线的矿用电铲轨迹优化[J]. 机械工程学报, 2025, 61(5): 263-274.
[2]	陈特, 蔡英凤, 陈龙, 徐兴. 基于四阶贝塞尔曲线的应急救援车辆轨迹规划方法[J]. 机械工程学报, 2025, 61(2): 198-209.
[3]	柳献, 胡秋斌, 朱雁飞, 翟一欣, 黄德中. 盾构管片自动拼装技术研究现状与展望[J]. 机械工程学报, 2025, 61(19): 183-201.
[4]	陆天尧, 尉凌霄, 曹珍珍, 刘钢, 茅健, 李军利. 锥壳展开面的自动铺丝轨迹规划优化算法[J]. 机械工程学报, 2025, 61(11): 406-416.
[5]	贺宜, 杜宇豪, 吴钪, 邱志军. 基于层次迭代搜索的自动驾驶重载半挂牵引车轨迹规划方法[J]. 机械工程学报, 2025, 61(10): 335-348.
[6]	申世全, 任锟, 李永国, 韩蕴生, 项琬婷, 耿赫阳. 金属表面异形区域上色轨迹自动规划[J]. 机械工程学报, 2024, 60(7): 258-265.
[7]	周晨, 徐飞翔. 四轮独立转向车辆转向模式切换轨迹多目标优化方法研究[J]. 机械工程学报, 2024, 60(6): 306-320.
[8]	张鹏, 尹来容, 仝永刚, 黄龙. 基于间隙预测模型的自动铺带轨迹优化方法[J]. 机械工程学报, 2024, 60(5): 296-316.
[9]	梁亮, 吴成东, 刘世昌. 基于关节损耗约束的工业机器人最优轨迹规划算法研究[J]. 机械工程学报, 2024, 60(19): 11-19.
[10]	王洪亮, 雍健羽, 皮大伟, 谢伯元, 王尔烈, 王显会. 基于贝塞尔曲线和多目标优化方法的多车队形切换轨迹规划[J]. 机械工程学报, 2024, 60(16): 270-279.
[11]	胡俊宇, 韩旭, 陶友瑞, 李珊瑚, 张建宁. 一种考虑跟随误差的S形轨迹残余振动抑制可靠性分析方法[J]. 机械工程学报, 2024, 60(16): 390-399.
[12]	戢杨杰, 张馨雨, 杨紫茹, 周上航, 黄岩军, 曹建永, 熊璐, 余卓平. 多智能网联汽车轨迹规划：现状与展望[J]. 机械工程学报, 2024, 60(10): 129-146.
[13]	梁凯冲, 赵治国, 颜丹姝, 赵坤. 基于动态运动基元的车辆高速公路换道轨迹规划[J]. 机械工程学报, 2024, 60(10): 192-206.
[14]	周洪龙, 裴晓飞, 刘一平, 赵柯帆. 面向动态不确定场景的自动驾驶车辆时空耦合分层轨迹规划研究[J]. 机械工程学报, 2024, 60(10): 222-234.
[15]	聂士达, 刘辉, 廖志昊, 谢雨佳, 项昌乐, 韩立金, 林思豪. 考虑复杂地形的越野环境无人车辆路径规划研究[J]. 机械工程学报, 2024, 60(10): 261-272.