A deterministic polishing and shaping method and system for carbon fiber antenna reflector

Abstract

This invention discloses a deterministic polishing and shaping method and system for carbon fiber antenna reflectors. The method includes calculating the nearest sphere radius R and the similar nearest sphere radius R' of the carbon fiber antenna reflector, measuring the surface shape, and calculating the dwell time T for deterministic polishing and shaping. If R ≥ R', then deterministic polishing and shaping is performed based on T, and full-body shaping is achieved through R. Otherwise, the normal pressure error at different positions on the surface of the carbon fiber antenna reflector is calculated under the full-body shaping method using R', and the dwell time is used to compensate for the normal pressure error to obtain the compensated dwell time T'. Deterministic polishing and shaping is then performed based on T', and full-body shaping is achieved through R'. This invention aims to overcome the existing problem of high-precision machining of large-diameter carbon fiber antenna reflectors, solving the problems of low manufacturing precision and poor milling machinability of traditional antenna panel molding processes, and realizing the machining of large-diameter carbon fiber antenna reflectors.

Description

Technical Field

[0001] This invention relates to the processing technology of carbon fiber antenna reflector surfaces for microwave detection systems, specifically to a deterministic polishing and shaping method and system for carbon fiber antenna reflector surfaces. Background Technology

[0002] With the continuous development of space exploration technology and the increasing technical requirements, antenna reflectors, as core functional components of microwave detection systems, determine the resolution and sensitivity of the system through the surface accuracy of their reflective surfaces. Domestic and international professional companies and research institutions have conducted comprehensive work in the design and manufacturing of reflector structures. Considering the weight reduction requirements of large-aperture reflectors, "sandwich" structures are commonly used, primarily consisting of aluminum skin and aluminum honeycomb sandwich, nickel skin and aluminum honeycomb sandwich, and composite material skin and aluminum honeycomb sandwich. Composite material skin / aluminum honeycomb sandwich panels are currently the most widely used microwave detector antenna reflectors. Examples include the sub-reflector of the large submillimeter-wave interferometer array in Chile, with an aperture of 0.75m and a surface accuracy of 5μm rms; the main reflector panel developed by MTM in Germany, used in the Arizona HHT telescope in the United States, with a single piece size of 1.6m and a surface accuracy of 7μm rms; and the reflector panel developed by the Xi'an Branch of the China Academy of Space Technology, with an aperture of 1.1m and a surface accuracy of 25μm rms, used in the FY-3 microwave imager. With the continuous development of space exploration technology, the requirements for the surface accuracy of antenna reflectors are becoming increasingly higher.

[0003] Chinese patent document CN112721234A discloses a method for molding a high-precision composite material antenna reflector skin. The process includes: S1, coating the surface of a high-precision mold with a release agent; S2, preheating a prepreg and then laying it on the surface of the high-precision mold; S3, covering the prepreg surface with a low-permeability release cloth with an air permeability of 0.05 m / s to 0.1 m / s; S4, placing the mold, after laying the release cloth, into an autoclave for vacuuming, heating, and pressing to cure and demold. Based on the above high-precision mold, the mold-making process can achieve an RMS surface accuracy of 30 μm for a 1m diameter antenna reflector. However, due to limitations in the mold's own precision and errors introduced during the mold-making process, further improving the surface accuracy of large-diameter antenna reflectors is extremely difficult. Furthermore, precision milling cannot process the soft, viscoelastic surface resin layer, making it difficult for the surface accuracy of large antenna reflectors to meet application requirements.

[0004] Therefore, in order to improve the surface accuracy of large antenna reflectors and avoid the limitation of machining accuracy by machine tool motion accuracy, a grinding and polishing method for carbon fiber antenna reflectors is proposed. By controlling the grinding and polishing dwell time, the amount of material removed can be controlled, which is of great significance for promoting high-precision machining of large antenna reflectors. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to provide a deterministic grinding and shaping method and system for carbon fiber antenna reflectors, which addresses the above-mentioned problems in the prior art. The present invention aims to overcome the high-precision machining problem of large-diameter carbon fiber antenna reflectors and solves the problems of low manufacturing precision and poor machinability of traditional antenna panel molding process, thereby realizing the machining of large-diameter carbon fiber antenna reflectors.

[0006] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows:

[0007] A deterministic polishing and shaping method for the reflector surface of a carbon fiber antenna includes the following steps:

[0008] S1, calculate the closest sphere radius R based on the surface shape equation of the carbon fiber antenna reflector, and calculate the similar closest sphere radius R' based on the antenna reflector aperture and the machine tool limit swing angle;

[0009] S2, Measure the surface shape of the carbon fiber antenna reflector and calculate the dwell time T of deterministic polishing and shaping based on the surface shape error;

[0010] S3, if R≥R', then the carbon fiber antenna reflector is deterministically polished and shaped based on the dwell time T. The carbon fiber antenna reflector is shaped by the closest sphere radius R. After the execution is completed, jump to step S6.

[0011] S4, calculate the normal pressure error at different positions on the surface of the carbon fiber antenna reflector under the full-shape processing method by using the closest sphere radius R', and use the dwell time to compensate for the normal pressure error to obtain the compensated dwell time T';

[0012] S5, based on the compensated dwell time T', the carbon fiber antenna reflector is deterministically polished and shaped, and the full-scale shaping of the carbon fiber antenna reflector is achieved by using the radius R' of the closest sphere.

[0013] S6, measure the surface shape of the carbon fiber antenna reflector. If the surface shape meets the requirements, exit; otherwise, jump to step S2.

[0014] Optionally, step S4 includes:

[0015] S4.1, calculate the normal pressure error at different positions on the carbon fiber antenna reflector surface under the full-shape processing method by using the closest sphere radius R' as an example, according to the following formula. :

[0016] ,

[0017] In the above formula, For position Normal pressure at the point, For position Apply pressure at the location;

[0018] S4.2, based on normal pressure deviation The compensated residence time T' is calculated using the following formula:

[0019] ,

[0020] In the above formula, Position in the compensated stay time T' The length of stay at the place, Position in the dwell time T The length of stay at the location.

[0021] Optionally, in step S3, when performing deterministic polishing and shaping of the carbon fiber antenna reflector based on the dwell time T, it includes performing deterministic polishing and shaping of the carbon fiber antenna reflector layer by layer according to a specified number of layers n, and the dwell time corresponding to each layer is T / n; in step S5, when performing deterministic polishing and shaping of the carbon fiber antenna reflector based on the compensated dwell time T', it includes performing deterministic polishing and shaping of the carbon fiber antenna reflector layer by layer according to a specified number of layers n, and the dwell time corresponding to each layer is T' / n.

[0022] Optionally, the number of layers n satisfies the constraint shown in the following formula:

[0023] ,

[0024] In the above formula, The thickness is the total amount of material removed. This represents the peak removal efficiency.

[0025] Optionally, step S2 includes:

[0026] S2.1, Select the size and shape of the polishing disc according to the surface shape and size of the carbon fiber antenna reflector, so that the polishing disc can always stay in contact with the antenna reflector during the processing;

[0027] S2.2, Determine the process parameters applicable to the carbon fiber antenna reflector, including abrasive, processing pressure and motion form, and obtain the removal function at each position of the carbon fiber antenna reflector using a carbon fiber antenna reflector template;

[0028] S2.3, Based on the surface shape error, determine the total thickness of the material removed at each location on the carbon fiber antenna reflector. Combining the total thickness of the material removed at each location with the removal function, calculate the dwell time T of the deterministic polishing and shaping according to the following formula:

[0029] ,

[0030] In the above formula, For position The thickness of the material removed from the area. By location The surface shape error at that location determines, This is a two-dimensional convolution operation. For position The removal function at the location, Position in the dwell time T The length of stay at the location.

[0031] Optionally, in step S2.2, when determining the process parameters suitable for the carbon fiber antenna reflector, the determined abrasive is diamond with a particle size of 15~20μm, the processing pressure is 0.05~0.2Mpa, and the motion mode is planetary. The planetary mode refers to the polishing disc rotating on its own axis and revolving around the carbon fiber antenna reflector at the same time. The rotation speed range of the polishing disc's own axis and revolution, and the rotation speed of the carbon fiber antenna reflector are 100~140rpm.

[0032] Optionally, the calculation function expression for calculating the radius R' of the closest similar sphere based on the antenna reflector aperture and the machine tool's limit swing angle in step S1 is as follows:

[0033] ,

[0034] In the above formula, The aperture of the antenna reflector. This represents the machine tool's limit swing angle.

[0035] Optionally, in step S3, the deterministic polishing and shaping of the carbon fiber antenna reflector based on the dwell time T refers to using a constant pressure polishing device to perform CCOS-based polishing and shaping of the carbon fiber antenna reflector according to the dwell time T. The phrase "achieving full-body shaping of the carbon fiber antenna reflector by using the closest sphere radius R" means that the constant pressure polishing device maintains constant pressure and rotation speed during the processing, and the pressure direction is consistent with the spherical normal corresponding to the closest sphere radius R. In step S5, the deterministic polishing and shaping of the carbon fiber antenna reflector based on the compensated dwell time T' refers to using a constant pressure polishing device to perform CCOS-based polishing and shaping of the carbon fiber antenna reflector according to the compensated dwell time T'. The phrase "achieving full-body shaping of the carbon fiber antenna reflector by using a similar closest sphere radius R'" means that the constant pressure polishing device maintains constant pressure and rotation speed during the processing, and the pressure direction is consistent with the spherical normal corresponding to the similar closest sphere radius R'.

[0036] Furthermore, the present invention also provides a deterministic polishing and shaping system for carbon fiber antenna reflectors, comprising a microprocessor and a memory interconnected thereto, wherein the microprocessor is programmed or configured to execute the deterministic polishing and shaping method for carbon fiber antenna reflectors.

[0037] Furthermore, the present invention also provides a computer-readable storage medium storing a computer program that is programmed or configured by a microprocessor to execute the deterministic polishing and shaping method for the carbon fiber antenna reflector.

[0038] Compared with the prior art, the present invention has the following main advantages:

[0039] 1. To address the issues of large accuracy loss and poor machinability in existing molding processes for carbon fiber antenna reflectors in microwave detection systems, this invention provides a deterministic polishing and shaping method for carbon fiber antenna reflectors based on the CCOS principle. This method can be used to process carbon fiber antenna reflectors with large diameters and complex curved surfaces, effectively solving the problems of large accuracy loss and poor machinability in existing molding processes for carbon fiber antenna reflectors.

[0040] 2. Addressing the high-steepness surface characteristics of carbon fiber antenna reflectors in microwave detection systems, this invention includes calculating the normal pressure error at different positions on the surface of the carbon fiber antenna reflector under a full-body shaping process using a similar closest sphere radius R'. The normal pressure error at each position is compensated using dwell time to obtain a compensated dwell time T'. Based on the compensated dwell time T', the carbon fiber antenna reflector is subjected to deterministic polishing and shaping, thereby achieving normal pressure error compensation during the high-steepness surface machining process. This overcomes machine tool precision limitations and improves machining accuracy and efficiency. Attached Figure Description

[0041] Figure 1 This is a schematic diagram of the basic process of the method in an embodiment of the present invention.

[0042] Figure 2 This is the measurement result of the initial surface shape of the carbon fiber antenna reflector in this embodiment of the invention.

[0043] Figure 3 The rotational, translational, and planetary motion forms of the grinding disc.

[0044] Figure 4 This is for removing the outline of the self-rotating function.

[0045] Figure 5 This is a translational function to remove the contour.

[0046] Figure 6 This is the planetary removal function contour used in the embodiments of the present invention.

[0047] Figure 7 This shows the relationship between the removal efficiency of different types of abrasives in the embodiments of the present invention.

[0048] Figure 8 This shows the relationship between the removal efficiency of abrasives of different particle sizes in the embodiments of the present invention.

[0049] Figure 9 This shows the relationship between removal efficiency under different pressures in the embodiments of the present invention.

[0050] Figure 10 This shows the removal efficiency relationship at different rotation speeds in the embodiments of the present invention.

[0051] Figure 11 This is a schematic diagram of five removal functions under the process parameters used in the embodiments of the present invention.

[0052] Figure 12 The graph shows the test results of the removal function under the process parameters used in the embodiments of the present invention.

[0053] Figure 13 This is a comparison of roughness test results under the process parameters used in the embodiments of the present invention.

[0054] Figure 14 This is a schematic diagram of the normal pressure deviation in an embodiment of the present invention.

[0055] Figure 15 This is a curve showing the change in pressure angle deviation at different locations on the surface in an embodiment of the present invention.

[0056] Figure 16 This is a curve showing the change in pressure along the normal direction at different locations on the surface in an embodiment of the present invention.

[0057] Figure 17 This is a schematic diagram illustrating the principle of layered removal in an embodiment of the present invention.

[0058] Figure 18 This is a schematic diagram of the process of layered removal in the embodiment of the present invention.

[0059] Figure 19 This is a schematic diagram illustrating the working principle of the polishing disc in an embodiment of the present invention.

[0060] Figure 20 The measurement results show the shape of the carbon fiber antenna reflector surface after processing in this embodiment of the invention. Detailed Implementation

[0061] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. The following will take a parabolic carbon fiber antenna reflector with a diameter of 350mm as an example to further illustrate the processing method used in the present invention. Unless otherwise specified, the equipment, processes, and testing methods used are all conventional technologies in the art.

[0062] like Figure 1 As shown, the deterministic polishing and shaping method for the carbon fiber antenna reflector in this embodiment includes the following steps:

[0063] S1, calculate the closest sphere radius R based on the surface shape equation of the carbon fiber antenna reflector, and calculate the similar closest sphere radius R' based on the antenna reflector aperture and the machine tool limit swing angle;

[0064] S2, Measure the surface shape of the carbon fiber antenna reflector and calculate the dwell time T of deterministic polishing and shaping based on the surface shape error;

[0065] S3, if R≥R', then the carbon fiber antenna reflector is deterministically polished and shaped based on the dwell time T. The carbon fiber antenna reflector is shaped by the closest sphere radius R. After the execution is completed, jump to step S6.

[0066] S4, calculate the normal pressure error at different positions on the surface of the carbon fiber antenna reflector under the full-shape processing method by using the closest sphere radius R', and use the dwell time to compensate for the normal pressure error to obtain the compensated dwell time T';

[0067] S5, based on the compensated dwell time T', the carbon fiber antenna reflector is deterministically polished and shaped, and the full-scale shaping of the carbon fiber antenna reflector is achieved by using the radius R' of the closest sphere.

[0068] S6, measure the surface shape of the carbon fiber antenna reflector. If the surface shape meets the requirements, exit; otherwise, jump to step S2.

[0069] In step S1, the method for calculating the radius R of the closest sphere based on the surface shape equation of the carbon fiber antenna reflector is a well-known method. Pass PassThe point on the carbon fiber antenna reflector is used to fit the closest sphere, and the radius of the closest sphere is the radius R of the closest sphere. The specific solution method can be adopted according to the existing solution method as needed. The method used in this embodiment can be found in the literature: Wang Quandou, Yu Jingchi, Zhang Xuejun, et al. Solution of the radius and asphericity of the closest sphere of off-axis aspherical surface [J]. Optoelectronic Engineering, 2000, 27(3):16-19. DOI:10.3969 / j.issn.1003-501X.2000.03.005. In addition, the calculation function expression of the radius R' of the similar closest sphere based on the aperture of the antenna reflector and the limit swing angle of the machine tool in step S1 of this embodiment is:

[0070] ,

[0071] In the above formula, The aperture of the antenna reflector. This represents the machine tool's limit swing angle.

[0072] In this embodiment, the carbon fiber antenna is formed by molding a carbon fiber skin and then bonding and curing it with a honeycomb sandwich material to create a "sandwich-style" parabolic carbon fiber antenna reflector panel with a diameter of 350mm. The result of measuring the surface shape of the carbon fiber antenna reflector in step S1 of this embodiment is as follows: Figure 2 As shown, the RMS (root mean square) value of the initial surface shape error is 43.514 μm, and the PV (Peak-to-Veally) value is 211.254 μm.

[0073] In this embodiment, step S2 includes:

[0074] S2.1, Select the size and shape of the polishing disc according to the surface shape and size of the carbon fiber antenna reflector, so that the polishing disc can always stay in contact with the antenna reflector during the processing;

[0075] S2.2, Determine the process parameters applicable to the carbon fiber antenna reflector, including abrasive, processing pressure and motion form, and obtain the removal function at each position of the carbon fiber antenna reflector using a carbon fiber antenna reflector template;

[0076] S2.3, Based on the surface shape error, determine the total thickness of the material removed at each location on the carbon fiber antenna reflector. Combining the total thickness of the material removed at each location with the removal function, calculate the dwell time T of the deterministic polishing and shaping according to the following formula:

[0077] ,

[0078] In the above formula, For position The thickness of the material removed from the area. By location The surface shape error at that location determines, This is a two-dimensional convolution operation. For position The removal function at the location, Position in the dwell time T The dwell time at the location. Step S2 calculates the dwell time based on Computer Controlled Optical Surfacing (CCOS) technology. CCOS technology's processing accuracy does not overly rely on machine tool accuracy, but rather achieves processing accuracy through time control. According to Preston's hypothesis, the amount of material removed at the processed location Δ during the processing time... H(x,y) It can be expressed by the following formula:

[0079] ,

[0080] In the above formula, K These represent process parameters, which are related to factors such as abrasive (size, shape, hardness) and machining tool material. Indicates the machining tool's position on the workpiece. Pressure at a point; Indicates the contact area between the machining tool and the workpiece. The relative velocity at the point. The amount of material removed from the optical component when pressure, relative velocity, and other process parameters remain constant. The removal function equal to the polishing mold formation R(x,y) Duration of stay T(x,y) Convolution along the processing trajectory:

[0081] ,

[0082] In the above formula, For position The removal function at the location, For convolution, Position in the dwell time T The length of stay at the location. This can be summarized as:

[0083] ,

[0084] In the above formula, For position The thickness of the material removed from the area. By location The surface shape error at that location determines, This is a two-dimensional convolution operation. For position The removal function at the location, Position in the dwell time T The dwell time at the location. Therefore, the functional expression for calculating the dwell time T of the CCOS-based polishing and shaping based on the current surface shape error in step S2 of this embodiment is:

[0085] ,

[0086] In the above formula, For position The thickness of the material removed from the area. By location The surface shape error at that location determines, This is a two-dimensional convolution operation. For position The removal function at the location, Position in the dwell time T The dwell time at the location. Given the removal function. In this case, based on the amount of material removed The size controls the dwell time of the polishing pad in each area. This enables the processing of a fixed quantity.

[0087] CCOS technology requires the removal function to have the characteristics of linear time invariance: (1) It has time and space invariance. During the polishing process of carbon fiber antenna reflector, the removal function does not change with the processing position and processing time, that is, the removal function has stability. (2) It has time linearity. During the polishing process of carbon fiber antenna reflector, the amount of material removed is linearly related to the dwell time of the removal function. For CCOS technology, the profile characteristics of the removal function have an important impact on the result and directly affect whether the processing surface shape can finally converge. The profile characteristics of the removal function depend on the motion form of the polishing disk. The commonly used polishing disk motion forms are rotational, translational and planetary. For example, the rotational type is as follows: Figure 3 As shown in (a) in the figure, the translational form is as follows: Figure 3 As shown in (b) in the diagram, the planetary configuration is as follows: Figure 3 As shown in (c), in the figure, a represents the polishing disc, b represents the workpiece (carbon fiber antenna), ω is the rotational speed of the polishing disc, r is the radius of the polishing disc, ω1 is the rotational speed of the workpiece (the revolution speed of the polishing disc), o is the center of the workpiece, and e is the distance between the center o of the polishing disc and the workpiece. The profile of the rotational removal function is as follows: Figure 4 As shown, the contour of the translational removal function is as follows: Figure 5 As shown, the contour of the planetary removal function is as follows: Figure 6 As shown. By Figures 4-6 It can be seen that the removal function under planetary motion is closest to the Gaussian type and has the best shaping effect.

[0088] Furthermore, the removal efficiency under different polishing parameters was obtained on a carbon fiber antenna reflector sample using a Φ20mm cast iron disc to determine the optimal process parameters. Specific process parameters included abrasive type, particle size, pressure, and velocity. Experimental results are shown below. Figures 7-10 As shown, where Figure 7 This relates to the removal efficiency of different types of abrasives. Figure 8 This relates to the removal efficiency of abrasives with different particle sizes. Figure 9 This represents the relationship between removal efficiency under different pressures. Figure 10 This describes the relationship between removal efficiency at different rotational speeds. Experimental results show that corundum abrasive has a higher removal efficiency compared to diamond abrasive. Considering the inherent gaps on the surface of carbon fiber composite materials and the potential for various minute defects during manufacturing, W20 abrasive grains with larger diameters are selected during processing to prevent excessively fine abrasive grains from embedding into the material surface and affecting its performance and precision. Because the carbon fiber antenna reflector has low stiffness, excessive pressure can cause deformation of the reflector panel, ultimately affecting its precision; therefore, a grinding pressure of 0.1 MPa is chosen. Due to the brittleness of carbon fiber, to avoid damage from excessive rotational speeds, the planetary rotation speed of the polishing disc is 120 rpm, its revolution speed is 125 rpm, and its eccentricity is 1 / 4 of the disc diameter. Based on the experimental results, in step S2.2 of this embodiment, when determining the process parameters suitable for the carbon fiber antenna reflector, the determined abrasive is diamond with a particle size of 15~20μm, the processing pressure is 0.05~0.2Mpa, and the motion mode is planetary. The planetary motion refers to the polishing disc rotating on its own axis and revolving around the carbon fiber antenna reflector simultaneously. The rotational speeds of the polishing disc and the carbon fiber antenna reflector are within the range of 100~140rpm. As an optional implementation method, the process parameters used in this embodiment are shown in Table 1.

[0089] Table 1. Process parameters of carbon fiber antenna reflector.

[0090]

[0091] Using the process parameters in Table 1, five removal functions were continuously performed on a 150×150mm sample using fixed-point grinding, such as... Figure 11 As shown, each removal function takes 5 minutes, with a removal efficiency of approximately 67 μm / min and a removal efficiency change rate of less than 2%. Figure 12 As shown in the figure, the removal function of the carbon fiber composite material grinding process has good stability and meets the basic requirements for grinding and shaping of the carbon fiber antenna reflector. The roughness of the unpolished and polished areas on the sample was measured separately, and the results are shown in the figure. Figure 13As shown, the roughness Ra of the carbon fiber sample increased from 0.6296 μm before polishing to 0.3585 μm after polishing. The surface quality not only did not deteriorate but was actually improved. Therefore, the constant pressure polishing process does not affect the performance of the antenna reflector. Using the removal function obtained on a 150×150 mm carbon fiber sample with the parameters shown in Table 1, the residence time distribution was obtained by deconvolution of the surface shape error, generating a grating-type path CNC file. It can be seen that in this embodiment, considering the material properties of carbon fiber, the polishing process parameters were studied, and a set of optimal process parameters (motion form, abrasive type, particle size, pressure, rotation speed, etc.) was determined. This resulted in a stable removal function and improved surface roughness without affecting the usability of the reflector.

[0092] In this embodiment, when the full-shape processing of the carbon fiber antenna reflector is achieved by using the closest similar sphere radius R', the calculation function expression for the closest similar sphere radius R' is as follows:

[0093] ,

[0094] In the above formula, It is an aspherical aperture. This represents the machine tool's limit swing angle. Compared to general optical components, carbon fiber antennas have a steeper reflective surface, often determined by finding the closest similar sphere radius. To achieve full-shape processing, the closest approximation to the sphere radius is obtained. Aspherical and non-spherical aperture and machine tool limit swing angle The geometric relationship is shown in the above equation. In this embodiment, the parabolic equation of the Φ350mm carbon fiber antenna reflector is:

[0095] ,

[0096] In the above formula, y and x are the y-axis and z-axis coordinates of a point on the carbon fiber antenna reflector. The radius of the closest sphere to the antenna reflector is calculated using the asphericity formula for a parabolic surface. Given a radius of 308.9288 mm and a limit swing angle of ±30° for the A / B axes of the machine tool, calculate the radius of the closest similar sphere. It is 350mm. Therefore... Therefore, according to the similar nearest sphere radius During machining, the normal pressure at each position will generate an angular difference, denoted as the normal pressure deviation. ,like Figure 14 As shown.

[0097] Normal pressure With applied pressure The relationship is shown in the following formula: ,

[0098] In the above formula, For position Normal pressure at the point, For position Apply pressure at the location. Figure 15 This refers to the pressure angle deviation and the magnitude of the normal pressure at different locations on the surface of the carbon fiber antenna reflector during processing in this embodiment. The pressure deviation can be measured by the residence time. To compensate, specifically, step S3 in this embodiment includes:

[0099] S4.1, calculate the normal pressure error at different positions on the carbon fiber antenna reflector surface under the full-shape processing method by using the closest sphere radius R' as an example, according to the following formula. :

[0100] ,

[0101] In the above formula, For position Normal pressure at the point, For position Apply pressure at the location;

[0102] S4.2, based on normal pressure deviation The compensated residence time T' is calculated using the following formula:

[0103] ,

[0104] In the above formula, Position in the compensated stay time T' The length of stay at the place, Position in the dwell time T The length of stay at the location.

[0105] Research has found that compared to general optical components, the total amount of material removed during the polishing process of carbon fiber antenna reflectors is large. If residual errors are removed in a single pass, the dwell time at each point during polishing will be too long, eventually forming tiny ripples on the reflector surface or even causing localized deformation of the panel, affecting the antenna reflector's performance. However, due to limitations in panel stiffness and material properties, the pressure and rotation speed, which directly affect removal efficiency, are restricted, making it impossible to reduce the dwell time at each point by increasing removal efficiency. To address these technical problems, as an alternative implementation method, such as... Figure 17 and Figure 18As shown, in step S3 of this embodiment, when performing deterministic polishing and shaping of the carbon fiber antenna reflector based on the dwell time T, it includes performing deterministic polishing and shaping of the carbon fiber antenna reflector layer by layer according to a specified number of layers n, and the dwell time corresponding to each layer is T / n; in step S5, when performing deterministic polishing and shaping of the carbon fiber antenna reflector based on the compensated dwell time T', it includes performing deterministic polishing and shaping of the carbon fiber antenna reflector layer by layer according to a specified number of layers n, and the dwell time corresponding to each layer is T' / n. Figure 17 As shown, the layered multi-stage material removal method first removes the material from the entire workpiece surface, then removes the material from the entire workpiece surface a second time, and so on, until the nth time, the material is removed from the entire workpiece surface. This method, which addresses the weak stiffness of the antenna reflector, proposes a layered multi-stage material removal method to remove surface shape errors. This scheme achieves full processing of residual surface shape errors by removing the total amount of material from the carbon fiber antenna reflector surface in multiple stages, reducing the dwell time at a single point and effectively suppressing local deformation of the antenna reflector surface.

[0106] To achieve a balance between suppressing local deformation of the antenna reflector and processing efficiency, the number of layers n in this embodiment satisfies the constraint shown in the following formula:

[0107] ,

[0108] In the above formula, The thickness is the total amount of material removed. This refers to peak removal efficiency. As a specific implementation method, the number of layers in this embodiment... The value of is 3.

[0109] In this embodiment, step S3, the deterministic polishing and shaping of the carbon fiber antenna reflector based on the dwell time T, refers to using a constant pressure polishing device to perform CCOS-based polishing and shaping of the carbon fiber antenna reflector according to the dwell time T. The phrase "achieving full-body shaping of the carbon fiber antenna reflector by using the closest sphere radius R" means that the constant pressure polishing device maintains constant pressure and rotation speed during processing, and the pressure direction is consistent with the spherical normal corresponding to the closest sphere radius R. In step S5, the deterministic polishing and shaping of the carbon fiber antenna reflector based on the compensated dwell time T', refers to using a constant pressure polishing device to perform CCOS-based polishing and shaping of the carbon fiber antenna reflector according to the compensated dwell time T'. The phrase "achieving full-body shaping of the carbon fiber antenna reflector by using a similar closest sphere radius R'" means that the constant pressure polishing device maintains constant pressure and rotation speed during processing, and the pressure direction is consistent with the spherical normal corresponding to the similar closest sphere radius R'. Figure 19As shown, ω1 is the rotational speed of the polishing disc, and ω2 is the revolution speed of the polishing disc around the carbon fiber antenna reflector. The constant pressure polishing device has a dual-rotor structure. One rotor drives the polishing disc of the constant pressure polishing device to rotate, and the other rotor drives the polishing disc to revolve around the carbon fiber antenna reflector to achieve a planetary motion. The polishing disc of the constant pressure polishing device is made of cast iron, and the size range of the polishing disc is φ20~40mm. In this embodiment, a Φ20mm cast iron disc is specifically used. The process parameters are shown in Table 1. The polishing tool and the drive shaft are connected by a ball joint. A layered removal scheme is adopted. In this example, the polishing process is carried out in 3 stages, and each stage removes 1 / 3 of the total processing volume. The material removal efficiency of the removal function used by the constant pressure polishing device is 50~80μm / min. Finally, after processing, the surface shape of the carbon fiber antenna reflector is measured by a coordinate measuring machine. The measurement results are shown in Table 1. Figure 20 As shown, the RMS value of the surface shape error decreased to 4.859 μm (the surface shape requires an RMS value of less than 5 μm), and the PV value decreased to 98.481 μm.

[0110] In summary, addressing the issues of significant accuracy loss and poor milling machinability in existing molding processes for carbon fiber antenna reflectors in microwave detection systems, this embodiment employs a deterministic polishing and shaping method based on the CCOS principle. This effectively solves the problems of high accuracy loss and poor milling machinability in existing molding processes. Considering the high-steepness surface of the carbon fiber antenna reflector in microwave detection systems, this embodiment's deterministic polishing and shaping method includes calculating the normal pressure error at different positions on the surface of the carbon fiber antenna reflector under a full-shape machining method using the radius R' of a similar closest sphere. The normal pressure error at each position is compensated using dwell time to obtain a compensated dwell time T'. Based on the compensated dwell time T', the carbon fiber antenna reflector is polished and shaped using CCOS, thereby achieving normal pressure error compensation during the high-steepness surface machining process. The deterministic grinding and shaping method for carbon fiber antenna reflectors in this embodiment can solve the problems of low manufacturing precision and poor machinability of carbon fiber materials in traditional mold-making processes for carbon fiber antenna reflectors. It breaks through the limitations of machine tool precision and can be used for the processing of large-diameter complex curved carbon fiber antenna reflectors, improving processing precision and efficiency, and has broad application prospects.

[0111] Furthermore, this embodiment also provides a deterministic polishing and shaping system for a carbon fiber antenna reflector, including a microprocessor and a memory interconnected thereto. The microprocessor is programmed or configured to execute the deterministic polishing and shaping method for the carbon fiber antenna reflector. Additionally, this embodiment also provides a computer-readable storage medium storing a computer program for being programmed or configured by the microprocessor to execute the deterministic polishing and shaping method for the carbon fiber antenna reflector.

[0112] The above description is merely a preferred embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principles of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. A method for deterministic polishing and shaping of the reflector surface of a carbon fiber antenna, characterized in that... Includes the following steps: S1, calculate the closest sphere radius R based on the surface shape equation of the carbon fiber antenna reflector, and calculate the similar closest sphere radius R' based on the antenna reflector aperture and the machine tool limit swing angle; S2, Measure the surface shape of the carbon fiber antenna reflector and calculate the dwell time T of deterministic polishing and shaping based on the surface shape error; S3, if R≥R', then the carbon fiber antenna reflector is deterministically polished and shaped based on the dwell time T. The carbon fiber antenna reflector is shaped by the closest sphere radius R. After the execution is completed, jump to step S6. S4, calculate the normal pressure error at different positions on the surface of the carbon fiber antenna reflector under the full-shape processing method by using the closest sphere radius R', and use the dwell time to compensate for the normal pressure error to obtain the compensated dwell time T'; S5, based on the compensated dwell time T', the carbon fiber antenna reflector is deterministically polished and shaped, and the full-scale shaping of the carbon fiber antenna reflector is achieved by using the radius R' of the closest sphere. S6, Measure the surface shape of the carbon fiber antenna reflector. If the surface shape meets the requirements, exit; otherwise, jump to step S2. Step S4 includes: S4.1, calculating the normal pressure error at different positions on the surface of the carbon fiber antenna reflector under the full-shape processing method by using the radius R' of the closest similar sphere according to the following formula. : ， In the above formula, For position Normal pressure at the point, For position Apply pressure at the location; S4.2, based on normal pressure deviation The compensated residence time T' is calculated using the following formula: ， In the above formula, Position in the compensated stay time T' The length of stay at the place, Position in the dwell time T Length of stay at the location; Step S2 includes: S2.1, selecting the size and shape of the polishing disc according to the surface shape and size of the carbon fiber antenna reflector, so that the polishing disc can always remain in contact with the antenna reflector during the processing; S2.2, Determine the process parameters applicable to the carbon fiber antenna reflector, including abrasive, processing pressure and motion form, and obtain the removal function at each position of the carbon fiber antenna reflector using a carbon fiber antenna reflector template; S2.3, Based on the surface shape error, determine the total thickness of the material removed at each location on the carbon fiber antenna reflector. Combining the total thickness of the material removed at each location with the removal function, calculate the dwell time T of the deterministic polishing and shaping according to the following formula: ， In the above formula, For position The thickness of the material removed from the area. By location The surface shape error at that location determines, This is a two-dimensional convolution operation. For position The removal function at the location, Position in the dwell time T The length of stay at the location.

2. The method for deterministic polishing and shaping of the carbon fiber antenna reflector surface according to claim 1, characterized in that, In step S3, when performing deterministic polishing and shaping of the carbon fiber antenna reflector based on the dwell time T, it includes performing deterministic polishing and shaping of the carbon fiber antenna reflector layer by layer according to the specified number of layers n, and the dwell time corresponding to each layer is T / n; in step S5, when performing deterministic polishing and shaping of the carbon fiber antenna reflector based on the compensated dwell time T', it includes performing deterministic polishing and shaping of the carbon fiber antenna reflector layer by layer according to the specified number of layers n, and the dwell time corresponding to each layer is T' / n.

3. The method for deterministic polishing and shaping of the carbon fiber antenna reflector surface according to claim 2, characterized in that, The number of layers n satisfies the constraint shown in the following formula: ， In the above formula, The thickness is the total amount of material removed. This represents the peak removal efficiency.

4. The method for deterministic polishing and shaping of the carbon fiber antenna reflector surface according to claim 1, characterized in that, In step S2.2, when determining the process parameters suitable for the carbon fiber antenna reflector, the abrasive is determined to be diamond with a particle size of 15~20μm, the processing pressure is 0.05~0.2Mpa, and the motion mode is planetary. The planetary mode refers to the polishing disc rotating on its own axis and revolving around the carbon fiber antenna reflector at the same time. The rotation speed range of the polishing disc's own axis and revolution, and the rotation speed of the carbon fiber antenna reflector are 100~140rpm.

5. The method for deterministic polishing and shaping of the carbon fiber antenna reflector surface according to claim 1, characterized in that, The calculation function expression for calculating the radius R' of the closest similar sphere based on the antenna reflector aperture and the machine tool's limit swing angle in step S1 is as follows: ， In the above formula, The aperture of the antenna reflector. This represents the machine tool's limit swing angle.

6. The method for deterministic polishing and shaping of the carbon fiber antenna reflector surface according to claim 1, characterized in that, In step S3, the deterministic polishing and shaping of the carbon fiber antenna reflector based on the dwell time T refers to using a constant pressure polishing device to perform CCOS-based polishing and shaping of the carbon fiber antenna reflector based on the dwell time T. The phrase "achieving full-body shaping of the carbon fiber antenna reflector by using the closest sphere radius R" means that the constant pressure polishing device maintains constant pressure and rotation speed during the processing, and the pressure direction is consistent with the spherical normal corresponding to the closest sphere radius R. In step S5, the deterministic polishing and shaping of the carbon fiber antenna reflector based on the compensated dwell time T' refers to using a constant pressure polishing device to perform CCOS-based polishing and shaping of the carbon fiber antenna reflector based on the compensated dwell time T'. The phrase "achieving full-body shaping of the carbon fiber antenna reflector by using a similar closest sphere radius R'" means that the constant pressure polishing device maintains constant pressure and rotation speed during the processing, and the pressure direction is consistent with the spherical normal corresponding to the similar closest sphere radius R'.

7. A deterministic polishing and shaping system for a carbon fiber antenna reflector, comprising a microprocessor and a memory interconnected, characterized in that, The microprocessor is programmed or configured to execute the deterministic polishing and shaping method for the carbon fiber antenna reflector as described in any one of claims 1 to 6.

8. A computer-readable storage medium storing a computer program, characterized in that, The computer program is used to be programmed or configured by a microprocessor to execute the deterministic polishing and shaping method for the carbon fiber antenna reflector as described in any one of claims 1 to 6.

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