Development of the new technology of machining, measuring and control for advanced manufacturing system of metal molds

近年来，金属模具制造过程的自动化系统变得越来越重要。本研究的目的是将金属模具的加工、测量和控制技术相结合，开发先进的金属模具制造系统。本文的研究结果总结如下：(1)模拟了旋转抛光工具在模具表面精加工中的运动，讨论了旋转抛光工具在金属模具自动化加工中的可行性。(2)电解抛光应用于金属模具的精加工工艺。(3)提出了一种具有在线恒力控制系统的抛光机器人。采用模糊理论对抛光机器人的运动进行控制。机器人手臂对抛光表面的姿态角通过感应抛光力自动确定。(4)开发了一种基于CAD数据生成抛光路线的自动抛光系统，并对其性能进行了评价。(5)研制了一种三维光学形状传感器。对模具表面进行了非接触式测量，并对所研制的光学传感器的性能进行了评价。(6)研制了一种测量表面粗糙度的光学传感器。进行了模具表面粗糙度的非接触式测量试验，并对所研制的光学传感器的性能进行了评价。(7)开发了抛光工具确定专家系统。

Recently, the automated system for the manufacturing process of metal molds become important. The purpose of this research is to develop the advanced manufacturing system of metal molds by integrating the machining, measuring and control technology for metal molds. The results obtained in this research are summarized as follows.(1) The motion of rotary polishing tools for finishing of mold surface is simulated, and the availability of rotary polishing tools for automated machining of metal molds is discussed.(2) The electrolytic polishing is applied to the finishing process of metal molds.(3) A polishing robot which has an on-line constant force control system is proposed. Fuzzy theory is applied to control the movement of the polishing robot. The attitude angel of the robot arm to the polishing surface is automatically determined by sensing the polishing force.(4) An automatic polishing system, which avoids the interfere by generating the polishing route from CAD data, is developed, and its performance is evaluated.(5) A three dimensional optical form sensor is developed. The non-contact measurement of mold surface is carried out, and the performance of developed optical sensor is evaluated.(6) An optical sensor for measurement of surface roughness is developed. The non-contact measurement test of mold surface roughness is carried out, and the performance of the developed optical sensor is evaluated.(7) An expert system for the determination of polishing tools is developed.