汽車保麗龍模具逃料與逆向工程技術整合應用研究

Reverse Engineering of Mold Back with Re-inforced Ribs for press Die Full Mold Forms

陳德治(Dei-Ze Chen)

指導教授 ： 李碩仁

元智大學/工程學院/機械工程學系/碩士(1995年)

摘要

本研究的目的是發展一套適合保麗龍模具業者模具模背逃料使用的逆向
工程整合軟體，其中包括從業者得到的量測數據或NC加工程式輸入到執行
逃料加工的NC程式雛型完成，最後再加上配合業者加工專用機切割條件的
後處理格式而完成完整NC加工程式。 文中首先指出業者執行現況與困難
點，然後再因應業者的需求來完成軟體理念進而發展軟體架構及其功能原
理，最後再以業者需求之模具模背逃料實例來應用整合驗證軟體功能與實
用性。 基於量測誤差與龐大數據運算的考量，必需要有適當方法來濾除
量測數據突點誤差與龐大數據資料簡化的平滑化動作，使CAD模型成為實
用且與原模型比較不致失真與符合需求公差。故本研究系統在未建立CAD
模型前已發展出將量測資料過濾與簡化的前處理功能。 本研究軟體在
AutoCAD/AutoSURF環境下發展與交談式視窗的安排，使得軟體更具親合性
，操作也更為方便，更能為業者所接受。軟體功能包括：圖形顯示(資料
讀入)，數據濾點資料簡化平滑化與棋盤式點群規則化等的前處理，CAD模
組崁合，逃料自動化完成，NC加工程式產生，最後整合此系統的DCL交談
式視窗等部分。將業者提供的資料型式用AutoLISP程式來串聯，從資料讀
入AutoCAD/AutoSURF環境內後經前處理動作，資料曲線、曲面的崁合，逃
料需求曲線的完成及NC加工程式的產生，並可與CNC工具機連線進行加工
製造。完成保麗龍模具模背逃料整個逆向工程的整合。

關鍵字

逆向工程 ； 保麗龍模具 ； 模背逃料

並列摘要

The objective of the thesis is to develop an integrated system
of reverse engineering and CAD/CAM for automobile press die
industry in the production of full mold forms. The system takes
the input data either from ditization or NC cutter location file
to reverse engineer the free-form surface of die cavity. Using
self-developed CAD functions,the mold back surface which is an
offset surface of the mold face (die cavity) can be created with
re-inforced ribs. NC codes with Fanuc 0m compatibility can then
be post-processed for further CNC machining.The current
productional procedure and operational problems were first
investigated on site with engineers. Based on their first hand
experience, the functional requirements of the system and the
methodological and architectural concepts were layed out. The
integrated system were verified through practical examples such
as automatic production of mold back with re-inforced ribs.
Because the immense amount of digitized data have inherent
scanning error which are impossible to detect and/or process by
manual operation, algorithms were developed in order to delete
apparent measurement error such as spikes and voids in the data.
Smoothing, thining and others algoithms may be needed in order
to creat CAD models of the digitized data. Therefore, a pre-
processor for the digitized data is essential to the integrated
system.Because of their open architecture, rich third party
libraries and popularity in the industrythe integrated system
was developed under the AutoCAD /AutoSURF /AutoLISP enviornment.
Software function include：graphical interface of user''s pop-up
manual, pre-processor for de-spiking, smothing, thinning and
checker-board regularization, surface blending and compounding
operations for CAD models, CAD functions for re-inforced rib
implementation, C program generation and DCL interactive
interface. The system has been field tested and proved to be an
enormous production tool for the industry which not only improve
product quality but, also reduce production cost.

並列關鍵字

Reverse Engineering ； Mold Back with Re-inforced Ribs ； Press Die Full Mold Forms