CN109822295B - High-precision numerical control machining method for mold surface of outer plate of magnesium-aluminum alloy automobile covering part - Google Patents
High-precision numerical control machining method for mold surface of outer plate of magnesium-aluminum alloy automobile covering part Download PDFInfo
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Abstract
The invention discloses a high-precision numerical control machining method for the profile of an outer plate die of a magnesium-aluminum alloy automobile panel, which solves the technical problems of precision reduction and incomplete typical characteristic retention caused by multiple factors such as axial clearance of a machine tool, speed reduction of the machine tool in a crossing manner, force point of a cutter, cutter abrasion, feed mode, temperature and the like. The method comprises the steps of profile process analysis, profile processing partition, island area filling and subdivision, processing partition sequencing, processing mode conversion, programming and grinding tool profile superfine processing. The invention provides a premise for completing the die cold stamping forming of the magnesium-aluminum alloy automobile panel outer plate, greatly reduces errors and distortion caused by the problems of machine tool processing spanning deceleration, machine tool axial clearance and the like, and ensures the processing precision; the invention improves the processing precision and reduces the processing distortion caused by the abrasion of the cutter; the invention realizes the completion of high-precision and high-feature fidelity manufacture of products.
Description
Technical Field
The invention relates to the technical field of mold surface processing, in particular to a high-precision numerical control processing method for a mold surface of an outer plate of a magnesium-aluminum alloy automobile panel.
Background
The main material of the automobile panel at the early stage is a steel plate, but along with the continuous pursuit of people for high-quality automobiles, the automobile panel made of new materials is continuously developed, and the requirements on high quality and the requirements on light weight, energy conservation, emission reduction and large cruising ability of automobiles are mainly met. At present, the automobile panel material which can perfectly combine the magnesium and the aluminum plate has a series of advantages of light weight, high strength, wear resistance, corrosion resistance and the like, but because of the reasons of low material elongation rate, material viscosity, deformation uncertainty and the like, the forming of the automobile panel outer plate die of the magnesium-aluminum alloy plate is slow all the time, the cold stamping forming technology cannot be broken through and widely applied by key technology all the time, and with the continuous promotion of technical attack, the forming of the automobile panel outer plate die of the magnesium-aluminum alloy plate needs ultra-accurate processing precision and perfect feature preservation degree. Magnesium-aluminum alloy automobile panel planking mould needs super accurate processing to solve its uncertain, the unable accurate cold-forming's of easy fracture scheduling problem of kick-backing, but what magnesium-aluminum alloy automobile panel planking corresponded is the high-end car, needs be high precision, consequently need constantly to study the processing method of the current high accuracy numerical control machine tool of experiment. Traditional processing mode receives the influence of multiple factors such as lathe axial clearance, lathe stride across speed reduction, cutter point of application of force, cutter wearing and tearing, feed mode, temperature, and the precision can't be higher promotes, and the damage condition also appears in the feature retention moreover, causes unable realization super accurate processing. If the cold shaping of magnadure automobile panel planking mould will realize the high accuracy, must have high accurate processing to guarantee precision and characteristic retention degree to this comes to press close to the CAE analysis more, acquires accurate experimental data, thereby solves the easy fracture of magnesium aluminum alloy panel cold work forming process, and it is uncertain to kick-back, the unable problem of guaranteeing of precision, therefore deepen the processing procedure experimental study a high accurate processing method and solve the fashioned key difficult problem of magnadure automobile panel planking mould.
Disclosure of Invention
Aiming at the defects in the background technology, the invention provides a high-precision numerical control machining method for the profile of the outer plate die of the magnesium-aluminum alloy automobile panel, and solves the technical problems of precision reduction and incomplete typical feature retention caused by multiple factors such as axial clearance of a machine tool, spanning deceleration of the machine tool, force point of a cutter, cutter abrasion, feed mode, temperature and the like.
The technical scheme of the invention is realized as follows: the high-precision numerical control machining method for the molded surface of the outer plate die of the magnesium-aluminum alloy automobile covering part comprises the following steps of: the method comprises the following steps: profile process analysis, step two: profile processing and partitioning, step three: filling and subdividing the island area, and step four: sorting the machining partitions, and step five: and changing the processing mode, and sixthly: programming, step seven: and (5) performing superfine processing on the molded surface of the grinding tool.
The first step comprises the steps of comprehensively analyzing the die according to the functional area and the shape structure of the die profile, and carding the profile characteristics of the die profile: the method comprises the steps of measuring the rolling angle, the curvature of the molded surface, the minimum R angle value and the small-area groove, analyzing the functional grade of the molded surface of the mold, corresponding the functional grade and the mold area, and performing comprehensive data analysis for the whole arrangement of the machining process.
After the step one is finished, the profile processing subarea in the step two is carried out, and a targeted programming strategy is adopted according to different rising and falling angles, profile curvatures and minimum R angle values, so that the small speed reduction spanning and the tool step distance equalization of the machine tool are realized.
Further, the profile machining partitioning principle is as follows: the product supplementing surface is independently partitioned, a round corner area at the periphery of the product supplementing surface is independently partitioned, the lower end of a round corner is partitioned into the product area, an integral slow curvature plane is independently partitioned, and an island area with the area smaller than 0.3 square meter is independently partitioned; each partition adopts a separate profile programming mode.
After the second step is finished, island region filling and subdivision in the third step are carried out, wherein the island region filling and subdivision comprises convex island treatment and concave island treatment, when the convex island treatment is carried out, an elliptical and circular island protection region is manufactured by outwards extending 20mm in the shape of the outermost boundary of the island, and the protection region is processed as an independent region; when the concave island is processed, the molded surface of the island is leveled, so that a machine tool can perform linear crossing processing when the area is processed for the first time, and then the machine tool starts to perform re-processing according to the independent area from the upper round angle of the concave island.
Further, after the third step is completed, the machining subarea sorting of the fourth step is performed:
1) the upper die and the lower die are arranged correspondingly, namely the processing areas of the upper die and the lower die are arranged correspondingly;
2) firstly, processing a peripheral fillet of the molded surface of the outer non-product;
3) secondly, processing all outer round corner outer areas;
4) processing a region with larger curvature and a large corner angle or a vertical surface;
5) processing an island region;
6) and processing a flat area of the profile of the key product.
The processing mode conversion of the fifth step comprises inclined shaft processing and contour line processing, wherein the inclined shaft processing adopts the corner turning function of a main shaft of a numerical control machine tool, an included angle of about 25 degrees is formed between the stress direction of the center of the cutter and the molded surface of the mold, and an angle area which is 10-15 degrees away from the center point of the cutter is used as a cutting point for cutting; the contour line processing adopts a Z-shaped feed mode, and a cutter processing track is compiled for a profile with large fluctuation and a vertical surface in a normal projection mode, so that the processing step distance in the unit surface area of the profile is ensured to be uniform and qualified.
After the machining program of the molded surface of the mold in the step six is compiled into the machining program of the molded surface of the mold to be machined in the step one, according to the partition mode of the step two and the step three, the sequencing mode of the step four and the machining mode of the step five, wherein the attention principle in the programming process is as follows: all the profiles are processed by adopting cutters with the same diameter, the same material and the same manufacturer batch number to process the upper die and the lower die of the same die, and the cutter with the diameter of phi 30 is preferably selected; the machining error caused by the problem of the cutter is reduced; when a narrow slot region is encountered, the diameter of the cutter is degraded and other requirements are unchanged.
Further, the machining process of the molded surface of the die adopts a simultaneous machine tool, two same numerical control machines are adopted to machine the upper die and the lower die of the same die at the same time, or the starting point and the ending point of the time with the same temperature are selected to machine the upper die and the lower die of the same die in the same equipment, and the machining time is generally preferably carried out at night with the temperature tending to be stable.
The superfinishing of the mold surface in the step seven is to perform high-speed and large-feed micro light cutting on the mold by using a high-precision machine tool after the mold surface is completely processed, and specifically comprises the following steps:
1) the ultra-precision machining rotating speed is set, the ultra-precision machining is high-speed light cutting, and the rotating speed is 8000-;
2) the superfinishing step distance is 0.3-0.5mm, a slant shaft processing mode is selected, and meanwhile Z-shaped feed is carried out on the vertical surface of the die, and return-shaped feed is carried out on the plane of the die.
The invention has the beneficial effects that:
1) the machining method is tested and improved by researching the reason of the machining error generated when the high-precision mold surface is required, so that a systematic machining method system is formed, the problem of the surface distortion and the typical characteristic distortion caused by the machining error of the mold surface when the high-precision requirement is met is solved, the machining precision of the mold surface is ensured, the ultra-high-precision machining requirement of the mold of the magnesium-aluminum alloy automobile covering part outer plate is met, and the premise is provided for completing the mold cold stamping forming of the magnesium-aluminum alloy automobile covering part outer plate;
2) through comprehensive analysis such as profile analysis, profile partition sorting and the like, errors and distortion caused by problems of machine tool machining spanning deceleration, machine tool axial clearance and the like are greatly reduced, and machining precision is guaranteed;
3) by means of processing modes such as inclined axis processing, contour line processing and the like, processing errors caused by the problem of the center point of the cutter are solved, processing precision is improved, and processing distortion caused by cutter abrasion is reduced;
4) through the simultaneous machining, the machining distortion caused by the external temperature change is solved, and the high-precision and high-characteristic-fidelity manufacturing of the product is realized.
Drawings
In order to illustrate the embodiments of the invention more clearly, the drawings that are needed in the description of the embodiments will be briefly described below, it being apparent that the drawings in the following description are only some embodiments of the invention, and that other drawings may be derived from those drawings by a person skilled in the art without inventive effort.
FIG. 1 is a process flow diagram of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without any inventive step, are within the scope of the present invention.
Embodiment 1, a high-precision numerical control machining method for a mold surface of an outer plate of a magnesium-aluminum alloy automobile panel, as shown in fig. 1, comprises the following steps: the method comprises the following steps: profile process analysis, step two: profile processing and partitioning, step three: filling and subdividing the island area, and step four: sorting the machining partitions, and step five: and changing the processing mode, and sixthly: programming, step seven: and (5) performing superfine processing on the molded surface of the grinding tool.
The first step comprises the steps of comprehensively analyzing the die according to the functional area and the shape structure of the die profile, and carding the profile characteristics of the die profile: the method comprises the steps of measuring the relief angle, the curvature of a molded surface, the minimum R angle value and a small-area groove, and analyzing the functional grade of the molded surface of the mold. And the functional grade corresponds to the mould area so as to comprehensively control the profile information of the mould and perform comprehensive data analysis for the integral arrangement of the processing technology.
After the step one is finished, the profile processing subarea in the step two is carried out according to the profile process analysis result, and aiming at the problems of machine tool crossing deceleration and tool step imbalance caused by different relief angles, profile curvatures and minimum R angle values in the processing process, a targeted programming strategy is adopted to realize small quantity of machine tool crossing deceleration and tool step equalization.
Further, the profile machining partitioning principle is as follows: the product supplementing surface is independently partitioned, a fillet area at the periphery of the product supplementing surface is independently partitioned, the lower end of a fillet is partitioned into the product area, and an integral slow-curvature plane is independently partitioned, wherein the area of the island area is smaller than 0.3 square meter and is independently partitioned, and the island area smaller than 0.3 square meter comprises a small-area island and a raised island; each partition adopts a separate profile programming mode.
And after the second step is completed, island area filling and subdivision in the third step are carried out, wherein the island area filling and subdivision comprises convex island treatment and concave island treatment, so that the problem of speed reduction crossing of a machine tool is solved. The surmounting deceleration means is a condition that when a turning or the like is encountered during high-speed cutting in a machine tool machining process, the turning is decelerated to ensure accuracy, and this causes a change in cutting force to cause a slight deformation in profile quality. When the raised island is processed, an elliptical or circular island protection area is manufactured by outwards expanding 20mm in the shape of the outermost boundary of the island, and the protection area is processed as an independent area; when the concave island is processed, the molded surface of the island is leveled, so that a machine tool can perform linear crossing processing when the area is processed for the first time, and then the machine tool starts to perform re-processing according to the independent area from the upper round angle of the concave island.
And further, after the third step is completed, the fourth step of processing partition sequencing is performed, wherein the processing partition sequencing mainly solves the problems of processing errors and typical characteristic distortion caused by factors such as axial clearance of a machine tool, tool wear, area overlapping and the like. The processing subarea sequencing specifically comprises the following steps:
1) the upper die and the lower die are arranged correspondingly, namely the processing areas of the upper die and the lower die are arranged correspondingly;
2) firstly, processing a peripheral fillet of the molded surface of the outer non-product;
3) secondly, processing all outer round corner outer areas;
4) processing a region with larger curvature and a large corner angle or a vertical surface;
5) processing an island region;
6) and processing a flat area of the profile of the key product.
By utilizing the processing sequencing mode, the processing area can be correspondingly eliminated, and the key features are preferentially processed, so that the distortion of the key features is reduced, the profile distortion of a large plane area caused by lapping or machine tool crossing deceleration is eliminated, and the optimal processing effect is achieved
And the processing mode of the step five is changed, so that the problems of tool path peak and trough errors caused by the stress problem of the tool and tool path unevenness caused by uneven profile are mainly solved, the service life of the tool is prolonged, and the processing distortion caused by tool abrasion in the processing process is reduced. The processing mode conversion mainly comprises inclined shaft processing and contour line processing, wherein the inclined shaft processing mainly solves errors caused by cutter stress and tool path wave crest and trough errors, and the contour line processing mainly solves the problems of processing step width difference and precision distortion caused by large profile fluctuation. The contour line processing adopts a Z-shaped feed mode, and a cutter processing track is compiled for a profile with large fluctuation and a vertical surface in a normal projection mode, so that the processing step distance in the unit surface area of the profile is ensured to be uniform and qualified.
The inclined shaft machining adopts the rotation angle function of a main shaft of a numerical control machine tool, an included angle of about 25 degrees is formed between the stress direction of the center of the cutter and the molded surface of the mold, and an angle area which is 10-15 degrees away from the center point of the cutter is used as a cutting point for cutting. In the conventional machining process of a machine tool, the center of a cutter is generally perpendicular to a machined profile, but the center point of the cutter is only a moving linear speed and a rotating linear speed is not available during machining, so that the center point of the cutter is always in a state of digging the profile of a mold and is subjected to higher pressure, fine indentation is easily caused on the profile of the machined mold, and the area of the center point of the cutter is slightly subjected to cold work hardening, so that the profile of the machined mold has obvious tool path wave crests and wave troughs and slight machining distortion. And inclined axis processing adopts contained angle formula processing, and the cutter stress point is the outside of cutter and not cutter center, therefore all cutting points all are the combination of cutter removal linear velocity and cutter rotation linear velocity in the course of working, consequently can reduce profile resistance by a wide margin, promote the machining precision, reduce crest trough distortion. Meanwhile, the service life of the cutter can be greatly prolonged, so that the process of machining the whole molded surface is ensured to be summarized, the abrasion loss of the cutter is greatly reduced, and the abrasion error of the cutter is also greatly reduced.
And after the step six mould profile processing program is compiled into the step one, processing program compilation is carried out on the processed mould profile according to the partition mode of the step two and the step three, the sorting mode of the step four and the processing mode of the step five. The attention principle in the programming process is as follows: all the profiles are processed by adopting cutters with the same diameter, the same material and the same manufacturer batch number to process the upper die and the lower die of the same die, and the cutter with the diameter of phi 30 is preferably selected; the machining error caused by the problem of the cutter is reduced; when a narrow slot region is encountered, the diameter of the cutter is degraded and other requirements are unchanged.
Further, the mold surface machining process adopts simultaneous machine tool machining, and the simultaneous machine tool machining is a machining measure for avoiding the influence of environmental temperature. The upper die and the lower die of the same die are machined by two same numerical control machines at the same time, or the upper die and the lower die of the same die are machined by the same equipment at the same starting point and the ending point of the same time with the same temperature, and the machining time is generally preferably conducted at night with the temperature tending to be stable.
And seventhly, performing the ultra-precision machining on the molded surface of the die by using a high-precision machine tool to perform high-speed and large-feed micro light cutting on the die after the molded surface of the die is completely machined, so that the precision of the molded surface of the die is greatly improved, the surface roughness of the machined molded surface is reduced, the machining precision and continuity are ensured to the maximum extent, and the typical characteristics are protected from distortion. The method specifically comprises the following steps:
1) the ultra-precision machining rotating speed is set, the ultra-precision machining is high-speed light cutting, and the rotating speed is 8000-;
2) the superfinishing step distance is 0.3-0.5mm, a slant shaft processing mode is selected, and meanwhile Z-shaped feed is carried out on the vertical surface of the die, and return-shaped feed is carried out on the plane of the die.
After the processing by the method is finished, the maximum error of the molded surface is 0.07mm, the surface roughness is about 1.6, and the requirement of ultrahigh precision of the magnesium-aluminum alloy automobile panel outer plate die is met. The invention solves the problem of high-precision processing of the forming die of the magnesium-aluminum alloy plate with the magnesium content of below 6 percent and the thickness of 0.4-4 mm.
Nothing in this specification is intended to be exhaustive of all conventional and well known techniques.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents, improvements and the like that fall within the spirit and principle of the present invention are intended to be included therein.
Claims (5)
1. The high-precision numerical control machining method for the molded surface of the outer plate die of the magnesium-aluminum alloy automobile covering part is characterized by comprising the following steps of: the method comprises the following steps: profile process analysis, step two: profile processing and partitioning, step three: filling and subdividing the island area, and step four: sorting the machining partitions, and step five: and changing the processing mode, and sixthly: programming, step seven: performing superfine processing on the molded surface of the die;
the first step comprises the steps of comprehensively analyzing the die according to the functional area and the shape structure of the die profile, and carding the profile characteristics of the die profile: the method comprises the steps of (1) analyzing the functional grade of the molded surface of the die, corresponding the functional grade to the die area, and performing comprehensive data analysis for the overall arrangement of the processing technology;
the profile processing partitioning principle comprises the following steps: the product supplementing surface is independently partitioned, a round corner area at the periphery of the product supplementing surface is independently partitioned, the lower end of a round corner is partitioned into the product area, an integral slow curvature plane is independently partitioned, and an island area with the area smaller than 0.3 square meter is independently partitioned; each partition adopts a separate profile programming mode;
after the second step is finished, island region filling and subdivision in the third step are carried out, wherein the island region filling and subdivision comprises convex island treatment and concave island treatment, when the convex island treatment is carried out, an elliptical and circular island protection region is manufactured by outwards extending 20mm in the shape of the outermost boundary of the island, and the protection region is processed as an independent region; when the concave island is processed, the profile of the island is leveled, so that a machine tool performs linear crossing processing in the primary processing area, and then the island is processed again according to an independent area from the upper fillet of the concave island;
the processing mode conversion of the fifth step comprises inclined shaft processing and contour line processing, wherein the inclined shaft processing adopts the corner turning function of a main shaft of a numerical control machine tool, an included angle of 25 degrees is formed between the stress direction of the center of the cutter and the molded surface of the mold, and an angle area which is 10-15 degrees away from the center point of the cutter is used as a cutting point for cutting; the contour line processing adopts a Z-shaped feed mode, and a cutter processing track is compiled for a profile with large fluctuation and a vertical surface in a normal projection mode;
the processing process of the mold surface adopts a simultaneous machine tool to process, two same numerical control machines are adopted to process the upper mold and the lower mold of the same mold at the same time, or the starting point and the stopping point of the time with the same temperature are selected to process the upper mold and the lower mold of the same mold in the same equipment, and the processing time is selected at night when the temperature tends to be stable.
2. The high-precision numerical control machining method for the mold surface of the outer plate of the magnesium-aluminum alloy automobile panel according to claim 1, characterized by comprising the following steps of: and after the step one is finished, performing the profile machining subarea of the step two, and adopting a targeted programming strategy according to different undulation angles, profile curvatures and minimum R angle values.
3. The high-precision numerical control machining method for the mold surface of the magnesium-aluminum alloy automobile panel outer plate according to claim 1 or 2, wherein the machining method comprises the following steps: after the third step is completed, the processing subarea sorting of the fourth step is carried out:
the upper die and the lower die are arranged correspondingly, namely the processing areas of the upper die and the lower die are arranged correspondingly;
firstly, processing a peripheral fillet of the molded surface of the outer non-product;
secondly, processing all outer round corner outer areas;
processing a region with larger curvature and a large corner angle or a vertical surface;
processing an island region;
and processing a flat area of the profile of the key product.
4. The high-precision numerical control machining method for the mold surface of the outer plate of the magnesium-aluminum alloy automobile panel according to claim 3, characterized by comprising the following steps of: after the step one, processing the molded surface of the processed die according to the partition mode of the step two and the step three, the sorting mode of the step four and the processing mode of the step five, wherein the attention principle in the programming process is as follows: all the profiles are processed by adopting cutters with the same diameter, the same material and the same manufacturer batch number to process the upper die and the lower die of the same die, and a cutter with the diameter of phi 30 is selected; the machining error caused by the problem of the cutter is reduced; when a narrow slot region is encountered, the diameter of the cutter is degraded and other requirements are unchanged.
5. The high-precision numerical control machining method for the mold surface of the outer plate of the magnesium-aluminum alloy automobile panel according to claim 4, wherein the machining method comprises the following steps: the superfinishing of the mold surface in the step seven is to perform high-speed and large-feed micro light cutting on the mold by using a high-precision machine tool after the mold surface is completely processed, and specifically comprises the following steps:
1) the ultra-precision machining rotating speed is set, the ultra-precision machining is high-speed light cutting, and the rotating speed is 8000-;
2) the superfinishing step distance is 0.3-0.5mm, a slant shaft processing mode is selected, and meanwhile Z-shaped feed is carried out on the vertical surface of the die, and return-shaped feed is carried out on the plane of the die.
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| CN115600487B (en) * | 2022-09-02 | 2024-02-02 | 南京天洑软件有限公司 | Method and device for designing mold surface of automobile windshield glass based on convolutional neural network |
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