激光金属沉积成形过程几何形貌的紫外结构光三维测量方法

doi:10.7527/S1000-6893.2023.29722

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激光金属沉积成形过程几何形貌的紫外结构光三维测量方法

宋泽宇¹,薛俊鹏²,徐志超¹,卢文博¹,王敏³,贾然¹,于长志⁴

1. 四川大学空天科学与工程学院
2. 四川大学
3. 中国兵器装备集团自动化研究所有限公司
4. 中国工程物理研究院机械制造工艺研究所

收稿日期:2023-10-13 修回日期:2023-12-25 出版日期:2023-12-26 发布日期:2023-12-26
通讯作者: 薛俊鹏
基金资助:
四川省科技计划资助;教育部‘春晖计划’合作科研项目

Ultraviolet structured light three-dimensional measurement method for geometric morphology of laser metal deposition forming process

Received:2023-10-13 Revised:2023-12-25 Online:2023-12-26 Published:2023-12-26
Contact: Jun-Peng XUE

摘要/Abstract

摘要： 金属增材制造领域中的激光金属沉积技术具有强光、强辐射的应用环境，导致缺乏工件的实时几何形貌三维信息的获取手段。为观测金属分层离散堆积成形过程，提出一种面向激光金属沉积成形过程三维几何信息测量的紫外结构光实时测量方法。首先，通过对激光作用下金属粉末的辐射波长以及激光等环境干扰光进行光谱分析，优化设计了紫外可选波段的窄带无干扰光路和二值抖动条纹光栅，确保获得高质量的调制条纹图像；其次，由傅里叶变换法在频域实现物体面形调制基频信息的滤波，通过傅里叶逆变换获得包裹相位信息，结合洪水填充算法实现绝对相位计算；最后根据立体视觉原理，以相位为稠密匹配辅助信息实现高精度三维数据计算。在金属增材制造真实环境下，通过对标准件的测量验证了所提方法三维测量平均误差小于0.1mm。对金属件打印过程的观测实验证明该方法可用于观测增材制造成形过程的层内和层间几何信息变化，满足工件成形过程中0.2mm~1mm层厚堆积工艺的在线尺寸测量分析需求，为激光金属沉积技术的实时闭环反馈和内部缺陷机理分析提供详细的中间数据支持。

关键词: 三维测量, 金属增材制造, 条纹结构光, 双目视觉, 相位分析

Abstract: Laser metal deposition technology in the field of metal additive manufacturing has the application environment of strong light and radiation, which leads to the lack of means to obtain the 3D information of real-time geometric morphology of parts. In order to observe the forming process of metal layered discrete stacking, a real-time measurement method based on ultraviolet structured light for the measurement of three-dimensional geometric information of laser metal deposition forming process was proposed. Firstly, the radiation wavelength of metal powder under the action of laser and the ambient interference light such as laser were analyzed. Then the narrow-band interference free optical path in the optional UV band and jittered binary fringe grating are designed to ensure high-quality modulated fringe images; Secondly, the Fourier transform method is used to filter the fundamental frequency information of the object surface modulation in the frequency domain. The wrapped phase information is obtained through the inverse Fourier transform and the absolute phase calculation is realized with the flood filling algorithm. Finally, according to the principle of stereo vision, the phase is used as dense matching auxiliary information to achieve high-precision 3D data calculation. In the real environment of metal additive manufacturing, the three-dimensional measurement average error of the proposed method is verified to be less than 0.1mm through the measurement of standard parts. The observation experiments on the printing process of metal parts show that this method can be used to observe the changes of geometric information within and between layers in the forming process of additive manufacturing. It can meet the requirements of online dimension measurement and analysis of 0.2mm~1mm layer thickness accumulation process during the forming of parts. It also provides detailed intermediate data support for real-time closed-loop feedback and internal defect mechanism analysis of laser metal deposition technology.

Key words: three-dimensional measurement, metal additive manufacturing, fringe structured light, binocular vision, phase analysis

中图分类号:

宋泽宇薛俊鹏徐志超卢文博王敏贾然于长志. 激光金属沉积成形过程几何形貌的紫外结构光三维测量方法[J]. 航空学报, doi: 10.7527/S1000-6893.2023.29722.

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激光金属沉积成形过程几何形貌的紫外结构光三维测量方法

Ultraviolet structured light three-dimensional measurement method for geometric morphology of laser metal deposition forming process

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