Abstract Deformation due to residual stress is a significant issue during the machining of thin-walled parts with low rigidity. If there are multiple processes with deformation during machining, some process suitability issues will appear. On this occasion, the actual geometric state of the deformed workpiece is needed for process adjustment. However, it is still a challenge to obtain the complete geometry information of deformed workpiece accurately and efficiently. In order to address this issue, a time-varying geometry modeling method, combining cutting simulation and in-process measurement, is proposed in this paper. The deformed workpiece model can be reconstructed via transforming the deformed workpiece with only a small amount of the measurement points by superimposing material removal and workpiece deformation simulation according to a time sequence, which takes advantage of the proposed Curved Surface Mapping based Geometric Representation Model (CSMGRM). Machining experiment of a typical structural part has shown that the deformed geometry model of the whole workpiece can be reconstructed within the error of 0.05mm, which is less than one tenth of the finish machining allowance in general cases, and it is sufficient to meet the accuracy requirements for interference or overcut/undercut analysis and process adjustment.

中文翻译：

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加工过程中变形零件的时变几何建模方法

摘要 残余应力引起的变形是低刚性薄壁零件加工过程中的一个重要问题。如果加工过程中存在多个有变形的工艺，就会出现一些工艺适用性问题。此时，需要根据变形工件的实际几何状态进行工艺调整。然而，准确、高效地获取变形工件的完整几何信息仍然是一个挑战。针对这一问题，本文提出了一种将切削仿真与在线测量相结合的时变几何建模方法。利用提出的基于曲面映射的几何表示模型（CSMGRM），按照时间顺序叠加材料去除和工件变形模拟，通过对变形工件进行少量测量点的变换，可以重建变形工件模型。 ）。典型结构件的加工实验表明，整个工件的变形几何模型可以在0.05mm的误差内重建，小于一般情况下精加工余量的十分之一，足以满足干涉或过切/咬边分析和工艺调整的精度要求。