CN101930223A - Intelligent screening system based on numerical control processing technology for difficult-to-machine metal - Google Patents
Intelligent screening system based on numerical control processing technology for difficult-to-machine metal Download PDFInfo
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Abstract
The invention discloses an intelligent screening system based on the numerical control processing technology for difficult-to-machine metal, which comprises the following subsystems: a parameter database subsystem, a fixed data source subsystem, an online detection and feedback subsystem, a technology intelligent comprehensive screening optimized scheme system, a data mining and supplementing subsystem, a simulation verification subsystem and an application operating system. The system has the characteristic of recognizing the reasonableness, the advancement and the high efficiency property of each technology scheme in the database, and is used for collecting the processing information of difficult-to-machine metal materials, the machine tool and cutter selection experience and cutting technological parameters accumulated in production practices and experiments. The roughness test data of the optimized cutting technological parameters is selected for processing, so that a reasonable and mature technological scheme is recommended for manufacturing enterprises, and the numerical control processing precision of the difficult-to-machine metal materials is controlled. The purposes of increasing the processing efficiency of the difficult-to-machine materials, reducing processing cost and acquiring high quality products are achieved.
Description
Technical field
The invention belongs to numerically controlled processing equipment, be specifically related to a kind of intelligent screening system based on numerical control processing technology for difficult-to-machine metal.
Background technology
Follow progress of science and technology and industrial continuous development, requirement to engineering goods and parts usability thereof is more and more higher, machinework is multi-functional, the growth momentum of multifunction is more and more powerful, part must be realized miniaturization, miniaturization, this just requires material to have high rigidity, high functionality, high temperature resistant, the hot strength height, can bear complex stress and a series of excellent physical and mechanical properties such as corrosion-resistant, and has only difficult processing metal, as titanium alloy, high temperature alloy, wimet, austenitic stainless steel, potassium steel, hardened steel, antifriction cast irons etc. could satisfy these requirements, can high-level efficiency, process these materials in high quality, be directly connected to automobile, aviation, space flight, navigation, oil, the speed of development of essential industrys such as chemical industry and manufacturing integral level, we must make a breakthrough from digital control processing could solve the difficult problem that difficult-to-machine metal uses in a large number and the varieties and characteristics variation is brought.
Current, rise along with global advanced manufacturing technology, hypervelocity processing makes shaping of difficult-to-machine metal become easier relatively, the mechanics physicist Salomon of Germany proposes: between cutting temperature T in the superhigh-speed cutting and the cutting speed V particular law is arranged, its T-V curve exists A, B, three zones of C: the A district is common cutting zone, cutting temperature increases with the rising of cutting speed, and promptly T is directly proportional with V; B is not for being called the dead band by cutting zone; C is the zone of superhigh-speed cutting.In the C district, when cutting speed increases to certain value, increase again afterwards, cutting temperature descends on the contrary.If can cross the B district and enter the C district, then might carry out superhigh-speed cutting with existing cutter.This theory is progressively confirmed to have fully feasibility by high-caliber numerical control (NC) lathe.The NC lathe of speed of mainshaft 3-4 ten thousand r/min has been used for roughing, and employing magnetic suspension bearing (Magnetic Bearing), the high speed of mainshaft of Germany reach 1 * 10
5The NC lathe of r/min has been used for the finishing and the superfinishing of difficult-to-machine material.Hypervelocity processing adopts modern superhard material such as adamas, cubic boron nitride (CBN) etc. as instrument, uses that modern hypervelocity is cut, grinding technique, and modern high flexibility, high automation plant equipment, the efficient high-speedization of realization materials processing.In this century, can realize that the hypervelocity material processed will cover most engineering materials.Can foretell that along with the continuous development of advanced manufacturing technology and material science, difficult-to-machine material will be plucked the cap of " difficult processing ", is converted into the versatile material of all trades and professions.Self-evident, the market of difficult-to-machine material will infinitely be amplified, and will provide strong impetus for high speed development of national economy, and the market of difficult-to-machine material will the hypergeometry formula increase.
Because the difficult-to-machine material kind is more, and the characteristics on material structure, processing characteristics differ greatly, and are representative with titanium alloy, high temperature alloy and wimet, and the cutting of hardworking material adds and shows the characteristic that is different from general common material man-hour:
(1) cutting force is big.Difficult-to-machine material intensity height consumes greatly at the energy of plastic yield during cutting, its cutting force is more much bigger than cutting common material.
(2) cutting temperature height.The difficult-to-machine material thermal conductivity is low, thereby poor thermal conductivity, and a large amount of heats that produce during cutting are difficult to cause cutting region temperature height to the material internal conduction, even quality problems such as heavy cut, burn, crackle occur at surface of the work.
(3) cutter easily sticks wearing and tearing and diffusive wear.During the cutting titanium alloy etc materials, the cutting region workpiece material produces plastic yield, produces the serious wearing and tearing of sticking between cutter and workpiece, makes the cutter passivation, thereby the cutting force of cutter descends, and can not cut when serious, causes the tool wear aggravation.Simultaneously under the cutting high temperature action, between workpiece material and cutter material element mutually counterdiffusion cause the top layer to weaken and cause diffusive wear and erosion.
(4) work hardening is serious.Because the plastic yield of workpiece material is big in the cut, under the cutting action of high temperature, the work hardening phenomenon of machined surface is serious, and this phenomenon can increase along with the increase of traverse feed.
(5) chemical activity height during some material (as titanium alloy) high temperature.Under the heat in metal cutting effect, smear metal easily with element generation chemical reactions such as airborne oxygen, nitrogen, generate corresponding oxides of nitrogen, cause the intensity of workpiece surface and hardness to increase, toughness descends, cutting force increases, thereby the wearing and tearing of quickening cutter.
At present, the correlative study of domestic intelligent screening to numerical control processing technology for difficult-to-machine metal is less, and the future market is very big to the application demand of this material.
Summary of the invention
The purpose of this invention is to provide a kind of intelligent screening system,, satisfy the needs of the processing technology intelligent optimization of various difficult-to-machine metals to improve intelligent degree and working (machining) efficiency based on numerical control processing technology for difficult-to-machine metal.
The technical solution adopted for the present invention to solve the technical problems is: based on the intelligent screening system of numerical control processing technology for difficult-to-machine metal, comprise following subsystem:
One is used to store and extract the parameter database subsystem of difficult-to-machine material digital control processing supplemental characteristic;
One is used to store and extract the fixed data source subsystem of the no variable parameter that comprises lathe parameter, experimental data, operational characteristic data;
One is used for the online detection of component processing quality and testing result is fed back to the online detection and the feedback subsystem of parameter database subsystem;
One process intelligent that is used for the data of parameter database subsystem are carried out process synthesis screening comprehensively screens the optimization scheme system;
One is used for process intelligent is comprehensively screened data mining that the data of optimization scheme system excavate and augment and augments subsystem;
One is used for data are excavated and augmented the simulating, verifying subsystem that data that subsystem excavates and augment are verified;
One is used for each subsystem is carried out application operating system mutual and that coordinate.
Described parameter database subsystem is made up of following 7 databases:
1, is used to store and extract the difficult-to-machine material property database of all kinds of difficult-to-machine material intensity, rigidity, elasticity and plasticity, hardness, impact flexibility, fracture toughness, fatigue strength aspect data;
Three elements---speed of mainshaft S, depth of cut F when 2, being used to store and extract the digital control processing (car, mill, bore, grind) of all kinds of difficult-to-machine materials, the digital control processing of depth of cut data (car, mill, bore, grind) parameter database;
3, be used to store and extract the machine tool parameter database of aspect data such as each cutter material of lathe, geometric angle, hardness, intensity, anti-mechanical wear coefficient, red hardness parameter;
4, be used to store and extract the workpiece parameter database of aspect data such as workpiece shape, workpiece size, chipping allowance aspect parameter;
5, be used to store and extract the frock parameter database of aspect data such as frock clamp type, degree of freedom dependability parameter;
6, be used to store and extract the model parameter database of all kinds of part type supplemental characteristics;
7, be used to store and extract all kinds of existing processing instance databases of having processed parts machining process, machined parameters, process quality data
Described fixed data source subsystem is made up of following no variable parameter data:
1, lathe parameter: comprise the maximum cutting of lathe maximum machining diameter, maximum length of cut external diameter (axle class), maximum cutting external diameter (dish class), the speed of mainshaft, spindle motor power, stroke, rapid traverse speed, bearing accuracy, repetitive positioning accuracy, the reverse difference of X/Z axle, cutter turriform formula and number of cutters, tool change time (adjacent/farthest) data;
2, experimental data: comprise quiet rigidity of numerically-controlled machine and numerically-controlled machine reliability data, wherein the numerically-controlled machine reliability data is obtaining in to the simple random sampling of machine tooling example, stratified random smapling and second order sampling;
3, operational characteristic parameter: comprise by the plane of machine tooling workpiece, axle, operational characteristic parameter that the hole reflected.
Described online detection and feedback subsystem comprise static online detection and feedback system and dynamic online detection and feedback system; The online detection of described static test and feedback system by the impulsive force hammer, the two channel charge amplifiers that are arranged at force transducer on the impulsive force hammer, are arranged at small-sized accelerometer on the cutter, be connected with small-sized accelerometer with force transducer, USB four-way data acquisition unit AD8304, A/D converter that two channel charge amplifiers are connected with industry control form; This system is used for when roughing, obtain suitable resonance frequency, under this prerequisite, choose the best speed of mainshaft, when finishing, avoid resonance frequency and select the speed of mainshaft, and thick, the selected optimum speed of finishing are fed back to parameter database with acquisition suface processing quality preferably; Described dynamic online detection and feedback system adopt three digital cameras to obtain the three-dimensional imaging of taking thing, demonstrate stereo-picture by the industry control PC, and the monitoring form surface roughness carries out whole process control crudy to process in real time.
Described process intelligent comprehensively screens the embedding of optimization scheme subsystem forward direction type network---RBF (Radial Basis Function) neural network, the mapping relations of difficult processing metal digital control processing parameter and performance are described with the RBF neural network model, the input of the sample of existing processing instance in the database, output as learning object, are carried out modeling by training to machined parameters and result's mapping relations.Pursuing under best in quality, minimum cost, top efficiency, all multiple goals of rimmer knife tool life-span, numerical control processing technology and cutter parameters are implemented optimization process; Then adopt the numerical control processing technology example of searching success based on the method for case-based reasoning (CBR) for new workpiece, thereby and carry out suitable correction and more approached optimum one group solution.Process intelligent comprehensively screens the optimization scheme subsystem and has advantages such as fast, the overall approximation capability of convergence is strong etc.
Described data mining with augment subsystem and embed amphineura network structural model is arranged, the amphineura network is handled the roughness test figure of digital control processing, in described process intelligent comprehensively screens the processing three elements parameter area of the resulting optimum one group of solution of optimization scheme system, quantized machining condition by different hierarchical composition is imported as network, thereby can be with best in quality, minimum cost, top efficiency, all multiple goal influence factors of rimmer knife tool life-span are included in the model, the numerical control processing technology of the best is recorded in the middle of the existing processing instance database in the parameter database subsystem, for similar workpiece processing from now on provides the numerical control processing technology foundation.
Described simulating, verifying subsystem adopts the Cuboid2array model, this model utilizes a plurality of cube arrays near blank and cutter entity, more complete statement three-dimensional information, the three-dimensional state of multi-angle display workpiece, entity need not to recomputate display body after conversion three dimensional viewing angle, the effective approximate representation entity of model simulation status, and the simulation result data transmission shown to PC.
Described application operating system is used for importing, receive the data sharing between data and each subsystem, upgrades the result of data mining.
The advantage of intelligent screening system of the present invention:
After difficult-to-machine material workpiece input numerical control processing technology prediction scheme, native system is transferred to parameter database by online detection and feedback subsystem with cutter frequency, process quality data.The quantized machining condition of various combination is imported as network, utilize process intelligent comprehensively to screen optimization scheme system and data mining and augment subsystem data are carried out analog simulation, pursuing under best in quality, minimum cost, top efficiency, all multiple goals of rimmer knife tool life-span, choose best numerical control processing technology process, obtain optimum solution, the numerical control processing technology of the best is recorded in the middle of the existing processing instance database in the parameter database subsystem, for similar workpiece processing from now on provides the numerical control processing technology foundation.This network system can continue study and improve learning accuracy by constantly increasing new sample, dummy model and the further match of real system of processing are approached, thereby realize control, reach the working (machining) efficiency that improves difficult-to-machine material, cut down finished cost and obtain the purpose of high quality of products the difficult processing metal numerical control (NC) Machining Accuracy.Native system has the characteristics of rationality, advance and the high efficiency of each technology prediction scheme in the identification database, the Cutting Process parameter that machining information, lathe and the cutter of difficult processing metal are selected to accumulate in experience and production practices and the experiment gathers together, the roughness test figure of selecting to optimize the Cutting Process parameter is handled, thereby is that rationally ripe process program is recommended by manufacturing enterprise in process.Native system has high-intelligentization, parameter optimization adjustment, practical characteristics.
The present invention is further described below in conjunction with drawings and Examples.
Description of drawings
Fig. 1 is the structure and the principle of work block diagram of system of the present invention.
Fig. 2 is static online detection and the feedback system structural representation in the system of the present invention.
Fig. 3 is the synoptic diagram of multidiameter.
Specific embodiments
The embodiment of a system of the present invention is provided below, as shown in Figure 1,, comprises following seven subsystem 1-7 based on the intelligent screening system of numerical control processing technology for difficult-to-machine metal:
One is used to store and extract the parameter database subsystem 4 of difficult-to-machine material digital control processing supplemental characteristic, and parameter database subsystem 4 is made up of following 7 databases:
Described parameter database subsystem is made up of the following aspects data:
1, is used to store and extract the difficult-to-machine material property database of all kinds of difficult-to-machine material intensity, rigidity, elasticity and plasticity, hardness, impact flexibility, fracture toughness, fatigue strength aspect data;
Three elements---speed of mainshaft S, depth of cut F when 2, being used to store and extract the digital control processing (car, mill, bore, grind) of all kinds of difficult-to-machine materials, the digital control processing of depth of cut data (car, mill, bore, grind) parameter database;
3, be used to store and extract the machine tool parameter database of aspect data such as each cutter material of lathe, geometric angle, hardness, intensity, anti-mechanical wear coefficient, red hardness parameter;
4, be used to store and extract the workpiece parameter database of workpiece shape, workpiece size, chipping allowance aspect parameter;
5, be used to store and extract the frock parameter database of aspect data data such as frock clamp type, degree of freedom dependability parameter;
6, be used to store and extract the model database of all kinds of part type supplemental characteristics;
7, be used to store and extract all kinds of existing processing instance databases of having processed parts machining process, machined parameters, process quality data
One is used to store and extract the fixed data source subsystem 2 of the no variable parameter that comprises lathe parameter, experimental data, operational characteristic parameter, and fixed data source subsystem 2 is made up of following no variable parameter data:
1, lathe parameter: comprise the maximum cutting of lathe maximum machining diameter, maximum length of cut external diameter (axle class), maximum cutting external diameter (dish class), the speed of mainshaft, spindle motor power, stroke, rapid traverse speed, bearing accuracy, repetitive positioning accuracy, the reverse difference of X/Z axle, cutter turriform formula and number of cutters, tool change time (adjacent/farthest) data;
2, experimental data: comprise quiet rigidity of numerically-controlled machine and numerically-controlled machine reliability data, wherein the numerically-controlled machine reliability data is obtaining in to the simple random sampling of machine tooling example, stratified random smapling and second order sampling;
3, operational characteristic parameter: comprise by the plane of machine tooling workpiece, axle, operational characteristic parameter that the hole reflected.
One is used for feeding back to the online detection and the feedback subsystem 5 of parameter database subsystem to the online detection of component processing quality and with testing result, and online detection and feedback subsystem 5 comprise static online detection and feedback system and dynamic online detection and feedback system:
Online detection of described static test and feedback system are seen Fig. 2: comprise MSC-1 impulsive force hammer 11, corresponding 500kg force transducer 13, the small-sized accelerometer 12 of YD67, (collecting voltage amplifies DLF-3 type four unifications two channel charge amplifiers 14, electric charge amplifies, integration, anti-aliasing filtering is in one, Highgrade integration), A/D converter 15, USB four-way data acquisition unit (AD8304) 16, wherein force transducer 13 is arranged on the impulsive force hammer 11, small-sized accelerometer 12 is arranged on the cutter 10, the input end of two channel charge amplifiers 14 is connected with force transducer 13 with small-sized accelerometer 12 respectively, and the output terminal of two channel charge amplifiers 14 connects by A/D converter 15 and is connected with USB four-way data acquisition unit (AD8304) 16.Impulsive force hammer 11 passes through the impact force actions of different sizes on cutter 10, force transducer 13 and small-sized accelerometer 12 with detection signal by the response signal of charge amplifier 14 output by A/D converter 15 conversion of signals after, by USB four-way data acquisition unit (AD8304) 16 accumulation signal is transferred among the digital control processing dynamic characterization measurement analytic system DynaCut V1.0 in the PC.The flutter stability leaf lobe figure that is obtained by digital control processing dynamic characterization measurement analytic system DynaCut V1.0 emulation shows: the harmonic frequency (the corresponding speed of mainshaft) in process system master mode natural frequency is located, there is bigger stable leaf lobe, and the closer to natural frequency, the stabilization vane lobe is big more, has more to utilize to be worth.During roughing, select the speed of mainshaft, can obtain higher working (machining) efficiency corresponding to the process system resonance frequency.Make that the vibration phase between the inside and outside surface is synchronous, depth of cut can keep evenly choosing best speed of mainshaft data under this prerequisite, to reach the purpose that improves stock-removing efficiency.During finishing, avoid resonance frequency and select the speed of mainshaft to obtain suface processing quality preferably.In the finishing process because of the amount of feeding is too big, to surpass surfaceness too greatly be Ra0.4 μ m to cutting depth, notes the vibration frequency of bottom tool when dimensional accuracy is the 0.013mm requirement.For safety, High-efficient Production from now on as reference frame;
Described dynamic online detection with adopt three Lu100CCD cameras with feedback system, gathered the output of a triplex row CCD in per ten seconds, can realize taking the three-dimensional imaging of thing; Camera is in when work, obtains forward sight respectively, faces, the rear view picture, and (the microEnableIV capture card can be expanded in a different manner by three MicroEnable IV FULL x4 type high speed image acquisition boards.Master slave mode can be formed with the trigger board of band optocoupler, the synchronous acquisition of a plurality of capture cards can be realized; Combine with the CLIO integrated circuit board of Camera Link interface, view data can be distributed to nearly 256 integrated circuit boards, thereby realize the real-time processing of high speed image data.The PxPlant interface card can improve the data-handling capacity of capture card and handle the formation stereo-picture subsequently, demonstrates stereo-picture by industry control PC and LCD display, comes real-time monitoring form surface roughness, carries out whole process control crudy in process;
One process intelligent that is used for the data of parameter database subsystem are carried out process synthesis screening comprehensively screens optimization scheme system 1, process intelligent comprehensively screens 1 embedding of optimization scheme system forward direction type network---and RBF (Radial Basis Function) neural network (Jiao Licheng. nerve network system theory [M]. Xi'an: publishing house of Xian Electronics Science and Technology University, 1990.), by based on the finite element analogy of numerical control processing technology digital control processing result data, carry out verification experimental verification simultaneously, set up three groups of finite element models, simulation repeatedly, until approaching actual numerical control processing technology process, change input parameter, pursuing best in quality, minimum cost, top efficiency, under all multiple goals of rimmer knife tool life-span, numerical control processing technology and cutter parameters are implemented optimization process, then adopt the numerical control processing technology example of searching success based on the method for case-based reasoning (CBR) for existing similar workpiece, thereby and carry out suitable correction and more approached optimum one group solution;
One is used for process intelligent is comprehensively screened data mining that the data of optimization scheme subsystem excavate and augment and augments subsystem 6, data mining with augment subsystem 6 embed amphineura network structural model arranged (Jiao Licheng. nerve network system theory [M]. Xi'an: publishing house of Xian Electronics Science and Technology University, 1990.), the amphineura network is handled the roughness test figure of digital control processing, in described process intelligent comprehensively screens the processing three elements parameter area of the resulting optimum one group of solution of optimization scheme system, this network system can continue study and improve learning accuracy by constantly increasing new sample, dummy model and the further match of real system of processing are approached, thereby realize control to the difficult processing metal numerical control (NC) Machining Accuracy, quantized machining condition by different hierarchical composition is imported as network, thereby can be with best in quality, minimum cost, top efficiency, all multiple goal influence factors of rimmer knife tool life-span are included in the model, the numerical control processing technology of the best is recorded in the middle of the existing processing instance database in the parameter database subsystem, for similar workpiece processing from now on provides the numerical control processing technology foundation;
One is used for data are excavated and augmented the simulating, verifying subsystem 7 that data that subsystem excavates and augment are verified, simulating, verifying subsystem 7 employing Cuboid2array models (contain bright. Liao Wenhe. the Cuboid2Array Study of model [J] of support entity numerical control milling simulating, verifying. computer-aided design (CAD) and graphics journal .Vol116, No14,598-602), utilize a plurality of cube arrays near blank and cutter entity, more complete statement three-dimensional information, the three-dimensional state of multi-angle display workpiece, entity need not to recomputate display body after conversion three dimensional viewing angle, the effective approximate representation entity of model simulation status, can construct the whole simulation model, the simulation result data transmission is shown to PC;
One is used for each subsystem is carried out application operating system 3 mutual and that coordinate, is used for receiving the input of data and the data sharing between each subsystem, upgrades the result of data mining.
Principle of work:
The principle of work of intelligent screening system of the present invention (referring to Fig. 1), with the multidiameter of processing certain difficult processing metal is example, at first the multidiameter exemplar dimensional data that will process is passed through user's load module typing parameter database subsystem 4, as the similar workpiece of this workpiece is arranged in the system, to be adopted based on the method for case-based reasoning (CBR) by system utilizes parameter database subsystem 4 to search the numerical control processing technology example of success, in conjunction with the machined parameters that accesses in the existing processing instance database from parameter database subsystem 4, comprehensively screen the optimum one group of technology solution of optimization scheme subsystem 1 comprehensive screening by process intelligent.Because this workpiece is new workpiece, need by manually importing a technology prediction scheme to application operating system.Process intelligent comprehensively screens 1 embedding of optimization scheme subsystem forward direction type network---RBF (Radial Basis Function) neural network, it is by based on the finite element analogy of numerical control processing technology digital control processing result data, carry out verification experimental verification simultaneously, to three groups of finite element models, simulation repeatedly, until approaching actual numerical control processing technology process, change input parameter, pursuing best in quality, minimum cost, top efficiency, under all multiple goals of rimmer knife tool life-span, numerical control processing technology and cutter parameters are implemented optimization process, thereby more approached optimum one group technology solution.By data mining with augment subsystem 6 and utilize and extract expert knowledge system based on existing craft embodiment and excavate the process data of multidiameter digital control processing with database screening function, and thereby the correlation data of carrying out classification on optimum one group of technology solution basis obtains an optimum technology solution, and the numerical control processing technology of the best recorded in the middle of the existing processing instance database in the parameter database subsystem 4, for similar workpiece processing from now on provides the numerical control processing technology foundation.Pursuing under best in quality, minimum cost, top efficiency, all multiple goals of rimmer knife tool life-span, output result 8 in satisfactory precision, deviation carries out superhigh-speed cutting processing by 9 pairs of multidiameter exemplars of numerically-controlled machine and handles.Detection of dynamic in online detection and the feedback subsystem 5 and feedback system will be exported result 8 and feed back to parameter database subsystem 4.
After the multidiameter exemplar machines, the parameters and the desired value of dynamic online detection and the processing of feedback system output multidiameter exemplar, in conjunction with target call that the user imported (as roughness, process time etc.) scope, comprehensively screen optimization scheme subsystem 1 by process intelligent and set up three groups of finite element models, simulation repeatedly, until approaching actual numerical control processing technology process, change input parameter, pursuing under best in quality, minimum cost, top efficiency, all multiple goals of rimmer knife tool life-span, numerical control processing technology and cutter parameters are implemented optimization process; Then adopt the numerical control processing technology example of searching success based on the method for case-based reasoning (CBR) for existing similar workpiece, thereby and carry out suitable correction and more approached optimum one group solution.Data mining with augment data mining that method that subsystem 6 adopts the hierarchical technology fuzzy logic controller again carries out correlation rule and augment, set up a new digital control processing instance model, store the existing processing instance database in the parameter database subsystem 4 into, for later new exemplar processing provides the sample that calls, learns, predicts and optimize, reach the purpose of intelligent optimization database.
Detailed process is as follows:
With the turning rapidoprint is that the multidiameter (processing exemplar such as Fig. 3, each dimension precision requirement be ± 0.02 millimeter) of austenitic stainless steel 1Cr18Ni9 (parameter sees Table 1) is an example, and system work process of the present invention is described:
(1) processing instruction input
1, the difficult-to-machine material property database (see Table 1) of the performance data of input austenitic stainless steel 1Cr18Ni9 intensity, length growth rate, elasticity and plasticity, hardness, impact flexibility, yield strength aspect to the parameter database subsystem 4;
2, because this part is a non-registered new workpiece in the system, three elements when we determine roughing numerical control turning processing technology prediction scheme are earlier selected--and-cutting speed should be selected 50m/min, depth of cut F=0.25mm/ main shaft revolution, the degree of depth ap=0.5mm of feed; Determine that the finishing numerical control turning adds the three elements in man-hour and selects---cutting speed should be selected 150m/min, depth of cut F=0.06mm/ main shaft revolution, the degree of depth ap=0.12mm of feed; The existing workpiece that record is arranged in the system, the technology in the existing processing instance database in the then direct recall parameter data storehouse subsystem 4 is directly processed.
3,90 of tool selection PCBN cutter degree right angle lathe tools input to machine tool parameter database in the parameter database subsystem 4 with aspect data such as the geometric angle of cutter, hardness, intensity, anti-mechanical wear coefficient, red hardness parameters;
4, input workpiece shape, workpiece size, the chipping allowance aspect parameter workpiece parameter database to the parameter database subsystem 4;
5, input frock clamp type is that four-jaw chuck clamps the frock parameter database of mode to the parameter database subsystem 4;
6, the model parameter database of input part each several part structure type to the parameter database subsystem 4;
7, the input machined surface roughness is Ra0.4 μ m, the existing processing instance database that dimensional accuracy is 0.013mm to the parameter database subsystem 4.
More than seven item numbers according to being input in the application operating system, record parameter database subsystem 4 associated databases, for later stage process program intelligent comprehensive screening, data mining and augment the part processing data are provided.
(2) input fixed data source subsystem does not have the variable parameter data:
1, lathe is selected the CK7820 numerically controlled lathe of Great Wall machine tool plant for use, input CK7820 numerically controlled lathe parameter (lathe maximum machining diameter, the maximum cutting of maximum length of cut external diameter (axle class), maximum cutting external diameter (dish class), the speed of mainshaft, spindle motor power, stroke, rapid traverse speed, bearing accuracy, repetitive positioning accuracy, the reverse difference of X/Z axle, cutter turriform formula and number of cutters, tool change time (adjacent/farthest) data);
2, the operational characteristic parameter that reflects of machine tooling plane, axle, hole.
(3) online detection and feedback
Static test is spent on the right angle lathe tools at 90 of PCBN cutter 10 by the impact force action of different sizes with the impulsive force hammer 11 of feedback system, force transducer 13 and small-sized accelerometer 12 with detection signal by the response signal of charge amplifier 14 output by A/D converter 15 conversion of signals after, by USB four-way data acquisition unit (AD8304) 16 accumulation signal is transferred among the digital control processing dynamic characterization measurement analytic system DynaCut V1.0.The flutter stability leaf lobe figure that is obtained by digital control processing dynamic characterization measurement analytic system DynaCut V1.0 emulation shows: the harmonic frequency (the corresponding speed of mainshaft) in process system master mode natural frequency is located, there is bigger stable leaf lobe, and the closer to natural frequency, the stabilization vane lobe is big more, has more to utilize to be worth.During roughing, select the speed of mainshaft, can obtain higher working (machining) efficiency corresponding to the process system resonance frequency.Make that the vibration phase between the inside and outside surface is synchronous, depth of cut can keep evenly choosing best speed of mainshaft data under this prerequisite, to reach the purpose that improves stock-removing efficiency.During finishing, avoid resonance frequency and select the speed of mainshaft to obtain suface processing quality preferably.In the finishing process because of the amount of feeding is too big, to surpass surfaceness too greatly be Ra0.4 μ m to cutting depth, notes the vibration frequency of bottom tool when dimensional accuracy is the 0.013mm requirement.For safety, High-efficient Production from now on as reference frame.
Dynamic online detection with adopt three Lu100CCD cameras with feedback system, gathered the output of a triplex row CCD in per ten seconds, realize the three-dimensional imaging of multidiameter.Camera is when work, obtain forward sight respectively, face, the rear view picture, handle the formation stereo-picture subsequently by three MicroEnable IV FULL x4 type high speed image acquisition boards, demonstrate stereo-picture by the LCD display on the industry control PC, the monitoring form surface roughness carries out whole process control crudy to process in real time.
(4) seek to approach optimum one group solution with technology intelligent comprehensive screening optimization scheme subsystem
Process intelligent comprehensively screens optimization scheme subsystem 1 and adopts the RBF neural network model to describe the multidiameter digital control processing parameter that material is austenitic stainless steel 1Cr18Ni9 and the mapping relations of performance, by thick, the accurately machined technology prediction scheme of importing previously, and the sample of existing processing instance in database input, output as learning object, by training machined parameters and result's mapping relations are carried out modeling.By based on the finite element analogy of numerical control processing technology digital control processing result data, carry out verification experimental verification simultaneously, set up three groups of finite element models, repeatedly simulation, until the numerical control processing technology process of approaching reality, thereby and carry out suitable correction and more approached optimum one group solution.
(5), adopt data mining and augment subsystem and obtain best numerical control processing technology data
Data mining with augment subsystem 6 and the roughness test figure of the multidiameter numerical control turning of austenitic stainless steel 1Cr18Ni9 handled by amphineura network structural model, in process intelligent comprehensively screens the processing three elements parameter area of optimization scheme subsystem 1 resulting optimum one group of solution, quantized machining condition by different hierarchical composition is imported as network, constantly increasing new sample continues study and improves learning accuracy, dummy model and the further match of reality processing real data are approached, thereby realize control to the multidiameter numerical control turning precision of austenitic stainless steel 1Cr18Ni9, thereby can be with best in quality, minimum cost, top efficiency, many target process influence factors of rimmer knife tool life-span are included in the model, the numerical control processing technology of the best is recorded in the middle of the existing processing instance database in the parameter database subsystem 4, for similar workpiece processing from now on provides the numerical control processing technology foundation.
(6) best numerical control processing technology data are carried out emulation, by the best digital control processing skill of emulated data result verification correctness
Simulating, verifying subsystem 7 adopts a plurality of cube arrays near the multidiameter blank of austenitic stainless steel 1Cr18Ni9 and 90 degree right angle lathe tool entities of PCBN cutter, the three-dimensional information of process before, during and after the more complete statement processing, the three-dimensional state of multi-angle display workpiece, entity need not to recomputate display body after conversion three dimensional viewing angle, the effective approximate representation entity of model simulation status.Model P2Model as for XO Y plane, is calculated its bounding box size; Calculate its zone, projecting plane in XO Y plane again, the zone is divided equally by the square length of side, obtain a cover quadrate array; Send out the crossing cover intersection point that obtains of light and P2Model along each square center, the height value of intersection point is exactly cubical height component, draws the cube group of each central spot continuously, can construct whole model.Give PC with the data transmission that the intelligent optimization subsystem is screened, further analyze, calculate correlation parameter by PC, imitation machining simulation process, carry out analysis, diagnosis, working procedure parameter optimization and the quality control of mismachining tolerance, compare the requirement of multidiameter exemplar drawing by the emulated data result and verify best digital control processing skill correctness.
Can intelligence seek to filter out the best numerical control turning processing technology that material is austenitic stainless steel 1Cr18Ni9 by system of the present invention.By actual processing behind the simulating, verifying, can reach the part processing requirement of multidiameter fully.
The concrete material parameter of table 1 austenitic stainless steel 1Cr18Ni9
Claims (8)
1. intelligent screening system based on numerical control processing technology for difficult-to-machine metal is characterized in that comprising following subsystem:
One is used to store and extract the parameter database subsystem of difficult-to-machine material digital control processing supplemental characteristic;
One is used to store and extract the fixed data source subsystem of the no variable parameter that comprises lathe parameter, experimental data, operational characteristic data;
One is used for the online detection of component processing quality and testing result is fed back to the online detection and the feedback subsystem of parameter database subsystem;
One process intelligent that is used for the data of parameter database subsystem are carried out process synthesis screening comprehensively screens the optimization scheme system;
One is used for process intelligent is comprehensively screened data mining that the data of optimization scheme system excavate and augment and augments subsystem;
One is used for data are excavated and augmented the simulating, verifying subsystem that data that subsystem excavates and augment are verified;
One is used for each subsystem is carried out application operating system mutual and that coordinate.
2. the intelligent screening system based on numerical control processing technology for difficult-to-machine metal according to claim 1 is characterized in that described parameter database subsystem is made up of following 7 databases:
1), is used to store and extract the difficult-to-machine material property database of all kinds of difficult-to-machine material intensity, rigidity, elasticity and plasticity, hardness, impact flexibility, fracture toughness, fatigue strength aspect data;
2), three elements---speed of mainshaft S, the depth of cut F during digital control processing (car, mill, bore, grind) that is used to store and extract all kinds of difficult-to-machine materials, the digital control processing of depth of cut data (car, mill, bore, grind) parameter database;
3), be used to store and extract the machine tool parameter database of aspect data such as each cutter material of lathe, geometric angle, hardness, intensity, anti-mechanical wear coefficient, red hardness parameter;
4), be used to store and extract the workpiece parameter database of aspect data such as workpiece shape, workpiece size, chipping allowance aspect parameter;
5), be used to store and extract the frock parameter database of aspect data such as frock clamp type, degree of freedom dependability parameter;
6), be used to store and extract the model parameter database of all kinds of part type supplemental characteristics;
7), be used to store and extract all kinds of existing processing instance databases of having processed parts machining process, machined parameters, process quality data.
3. the intelligent screening system based on numerical control processing technology for difficult-to-machine metal according to claim 1 is characterized in that described fixed data source subsystem is made up of following no variable parameter data:
1), lathe parameter: comprise the maximum cutting of lathe maximum machining diameter, maximum length of cut external diameter (axle class), maximum cutting external diameter (dish class), the speed of mainshaft, spindle motor power, stroke, rapid traverse speed, bearing accuracy, repetitive positioning accuracy, the reverse difference of X/Z axle, cutter turriform formula and number of cutters, tool change time (adjacent/farthest) data;
2), experimental data: comprise quiet rigidity of numerically-controlled machine and numerically-controlled machine reliability data, wherein the numerically-controlled machine reliability data is obtaining in to the simple random sampling of machine tooling example, stratified random smapling and second order sampling;
3), operational characteristic parameter: comprise by the plane of machine tooling workpiece, axle, operational characteristic parameter that the hole reflected.
4. the intelligent screening system based on numerical control processing technology for difficult-to-machine metal according to claim 1 is characterized in that described online detection and feedback subsystem comprise static online detection and feedback system and dynamic online detection and feedback system; The online detection of described static test and feedback system by the impulsive force hammer, the two channel charge amplifiers that are arranged at force transducer on the impulsive force hammer, are arranged at small-sized accelerometer on the cutter, be connected with small-sized accelerometer with force transducer, USB four-way data acquisition unit AD8304, A/D converter that two channel charge amplifiers are connected with industry control form; Described dynamic online detection and feedback system adopt three digital cameras to obtain the three-dimensional imaging of taking thing, demonstrate stereo-picture by the industry control PC.
5. the intelligent screening system based on numerical control processing technology for difficult-to-machine metal according to claim 1, it is characterized in that described process intelligent comprehensively screens the embedding of optimization scheme subsystem forward direction type network---RBF (Radial Basis Function) neural network is arranged, the mapping relations of difficult processing metal digital control processing parameter and performance are described with the RBF neural network model, the input of the sample of existing processing instance in the database, output as learning object, are carried out modeling by training to machined parameters and result's mapping relations.Pursuing under best in quality, minimum cost, top efficiency, all multiple goals of rimmer knife tool life-span, numerical control processing technology and cutter parameters are implemented optimization process; Then adopt the numerical control processing technology example of searching success based on the method for case-based reasoning for new workpiece, thereby and carry out suitable correction and more approached optimum one group solution.
6. the intelligent screening system based on numerical control processing technology for difficult-to-machine metal according to claim 1, it is characterized in that described data mining and augment the subsystem embedding that amphineura network structural model is arranged, the amphineura network is handled the roughness test figure of digital control processing, in described process intelligent comprehensively screens the processing three elements parameter area of the resulting optimum one group of solution of optimization scheme system, quantized machining condition by different hierarchical composition is imported as network, thereby can be with best in quality, minimum cost, top efficiency, all multiple goal influence factors of rimmer knife tool life-span are included in the model, the numerical control processing technology of the best is recorded in the middle of the existing processing instance database in the parameter database subsystem, for similar workpiece processing from now on provides the numerical control processing technology foundation.
7. the intelligent screening system based on numerical control processing technology for difficult-to-machine metal according to claim 1, it is characterized in that described simulating, verifying subsystem adopts the Cuboid2array model, this model utilizes a plurality of cube arrays near blank and cutter entity, more complete statement three-dimensional information, the three-dimensional state of multi-angle display workpiece, entity need not to recomputate display body after conversion three dimensional viewing angle, the effective approximate representation entity of model simulation status, and the simulation result data transmission shown to PC.
8. the intelligent screening system based on numerical control processing technology for difficult-to-machine metal according to claim 1 is characterized in that described application operating system is used for importing, receive the data sharing between data and each subsystem, upgrades the result of data mining.
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