机器人辅助连续纤维复材增材制造系统开发

面向高性能工程材料的增材制造工艺的快速发展使得增材制造逐渐由一项快速成型技术转向一种可行的生产选择。特别是新兴的连续纤维增强复合材料增材制造工艺（CFRP-AM）由于其具有一体化快速成型高性能、轻量化结构的能力，受到了研究者们的广泛关注。然而，现有CFRP-AM系统广泛采用的三自由度运动平台阻碍了研究者们探索和利用网格加强的壳结构等一类具有非平面特征的先进结构。

本课题开发了一套机器人辅助的保形CFRP-AM制造系统，借助其多自由度运动能够直接成型非平面特征。该系统由一台六轴机器人、一个纤维-树脂共挤出打印末端和控制系统组成，通过所提出的设计-制造工作流程运行。系统工作流程包括三个主要步骤：（1）系统标定，（2）保形三维路径生成和（3）工艺执行。由不同工艺制造样件的压缩实验结果表明保形CFRP-AM工艺及其工艺流程可以显著提高制件的力学性能。

此外，由于纤维铺排路径设计对制件性能的显著影响，保形三维路径生成是本课题的主要研究内容之一。面向网格加强的壳结构，本课题提出了基于曲面映射的保形路径规划和基于图论的连续路径规划方法。其中，基于计算共形几何理论，保形三维路径规划针对曲面壳和加强筋结构的不同填充需求将对应三维曲面以不同方式映射到二维平面，进而生成多样化的纤维填充图案。基于图论的连续路径规划则面向具有格栅设计的加强筋结构，该方法将格栅结构描述为基于图的数学模型，进而将路径规划转化为特殊的中国邮递员问题，并且首次将CFRP-AM工艺的制造约束添加到路径搜索算法中，生成了具有最小化的纤维剪切频率、打印时间和总纤维路径转角的优化路径。最后，通过针对性的实验设计验证了所提出方法的有效性。具体来说，实验结果表明了多样化的纤维铺排设计可以广泛扩展CFRP-AM工艺对结构性能的调控范围，而考虑特定制造约束的算法优化可以显著提高制造效率和质量。

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