The surface quality and profile accuracy of a radar fiberglass radome are determined by the manufacturing of the fiber-reinforced-plastic (FRP) complex curved mold. The surface quality, thickness uniformity, and shape accuracy of the mold seriously affect the temperature and deformation control during the manufacturing process of the radome, thus affecting the antenna's serviceability, including its wave permeability and stability. Abrasive belt grinding is an effective method for processing FRP materials. However, issues regarding the profile fitting of the abrasive belt section line contact state and its influence on the precision of complex curved surfaces have not been solved, which seriously affects the processing quality. Here, an FRP complex curved surface mold surface based on the least-squares method was established. The local two-dimensional line contact and profile contour trajectory were obtained by the algorithm of optimal trajectory planning. Based on this, a grinding experiment was carried out. The experiments showed that the surface roughness based on this method was reduced from 0.503 to 0.289 μm, and the contour accuracy was improved by 16.9% compared with the conventional error. Through our analysis, the following conclusions can be drawn: the algorithm can effectively solve the problem of line contact surface fitting and significantly improve the precision of an FRP complex surface.
Keywords: FRP complex curved surface; belt grinding line contact; least-squares fitting; trajectory optimization.