CN110103079A - The on-line monitoring method of tool wear in a kind of micro- milling process - Google Patents
The on-line monitoring method of tool wear in a kind of micro- milling process Download PDFInfo
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- CN110103079A CN110103079A CN201910523349.6A CN201910523349A CN110103079A CN 110103079 A CN110103079 A CN 110103079A CN 201910523349 A CN201910523349 A CN 201910523349A CN 110103079 A CN110103079 A CN 110103079A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
- B23Q17/00—Arrangements for observing, indicating or measuring on machine tools
- B23Q17/09—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool
- B23Q17/0952—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool during machining
- B23Q17/0957—Detection of tool breakage
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Abstract
The invention discloses a kind of on-line monitoring methods of tool wear in micro- milling process, its step includes: micro- Milling Force Model that 1 foundation includes tool wear, according to the coefficient of waste in micro- Milling Force peg model of each milling experiment measurement, while recording corresponding cutter wear area；The series of discrete data point of 2 coefficients of waste and cutter wear area obtained according to experiment, the relational expression of the coefficient of waste Yu cutter wear area is fitted using numerical method；3, according to the relationship of micro- Milling Force, the coefficient of waste and wear area, obtain the direct mapping relations of micro- Milling Force Yu tool wear area, to realize the on-line monitoring of tool wear in micro- milling process.The present invention can be predicted tool wear using on-line monitoring method/technology, avoid tool failure, to promote processing efficiency and processing quality.
Description
Technical field
The present invention relates to micro- Milling Process field, the on-line monitoring side of tool wear in specifically a kind of micro- milling process
Method.
Background technique
With the adjustment of Industry Structure, numerically-controlled machine tool is at present just towards high-precision, high-speed and high-efficiency, flexibility and intelligence
The direction of change is developed.The processing of many key components and parts, aviation hair in high-end precision manufactureing field, such as modern national defense equipment
The processing of motivation blade, retarder, crankshaft type component etc., since its structure is complicated, material workability is poor, required precision
Height, when processing such part using traditional numeric-control machine, geometric accuracy is poor with surface integrity, and quality is difficult to ensure.
Micro- milling because the diversity with rapidoprint and be able to achieve the advantage of complex three-dimensional Machining of Curved Surface it is fine with it is super
Precision instrument processing and other fields have wide practical use.However micro- milling cutter is discontinuously cut under ultrahigh rotating speed, cutter
It galls damage rapidly and is difficult to monitor, seriously affect machining accuracy and product quality, the on-line monitoring that cutter galls damage is always micro-
The difficult point of Milling Processes control.
In tool wear monitoring technical aspect, researchers represent the mill of blade using rake face or tool flank wear
Damage degree, and based on this, establish the micro- Milling Force Model for considering tool wear, anticipation tool wear degree, prediction knife
Has remaining life.But it is urgently to be resolved that in the actual production process, there are still some problems:
Firstly, since precision machine tool main shaft high speed rotation and micro- milling cutter diameter is small, the state of wear of cutter itself is difficult to reality
When measure；Secondly, existing micro- Milling Force Model still lacks direct mapping relations between Milling Force and tool abrasion, it can not
Tool wear degree is judged by the micro- Milling Force of real-time monitoring.
Summary of the invention
Present invention place in order to overcome the deficiencies of the prior art, provides a kind of on-line monitoring of tool wear in micro- milling process
Method, to predict tool wear using on-line monitoring method/technology, avoid tool failure, to promote processing efficiency
And processing quality.
To achieve the above object, the invention provides the following technical scheme:
In a kind of micro- milling process of the present invention the characteristics of on-line monitoring method of tool wear the following steps are included:
Step 1 establishes micro- Milling Force Model comprising tool wear, according to micro- Milling Force mark of each milling experiment measurement
The coefficient of waste in cover half type, while recording corresponding cutter wear area；
The series of discrete data point of step 2, the coefficient of waste and cutter wear area that are obtained according to experiment, using numerical value
Method fits the relational expression of the coefficient of waste Yu cutter wear area；
Step 3, according to the relationship of micro- Milling Force, the coefficient of waste and wear area, obtain micro- Milling Force and tool wear face
Long-pending direct mapping relations, to realize the on-line monitoring of tool wear in micro- milling process.
The characteristics of on-line monitoring method of tool wear, lies also in a kind of micro- milling process of the present invention, utilizes formula
(1) micro- Milling Force Model F comprising tool wear in establishment step 1:
F=KwFC (1)
In formula (1), KwFor the coefficient of waste, FCFor the micro- Milling Force Model for not considering tool wear.
The micro- Milling Force Model for not considering tool wear is the Milling Force meter established according to micro- milling mechanical characteristics
Calculate model.
After cutter wear area is one procedure of every completion in the step 1, put down when cutter is stood upside down by measuring end
Eroded area on face and obtain.
Any one discrete data point is by measuring the abrasion system demarcated after micro- Milling Force of every procedure in the step 2
Number and the tool wear area of measurement form.
It is the relational expression that the coefficient of waste Yu cutter wear area are fitted using formula (2) in the step 2:
Sw=f (Kw) (2)
In formula (2), SwFor cutter wear area, f () indicates the function of mapping relations.
In the step 3, the direct mapping relations of micro- Milling Force and wear area are obtained using formula (3):
F=g (Sw) (3)
In formula (3), g () represents the function of mapping relations.
Compared with prior art, the beneficial effects of the present invention are:
1, the present invention can by monitoring micro- milling force estimation cutting-tool wear state and prediction cutter remaining life on-line, into
And to guarantee that processing quality provides feasible theoretical method.
2, tool abrasion is defined with according to the wear area on micro- milling cutter end plane in the present invention, and traditionally
Indicate that abrasion loss is compared using the abrasion length in flank or rake face, it more being capable of comprehensive characterization cutter using wear area
Actual wear state.
3, the present invention can obtain the direct direct mapping relations of micro- Milling Force and tool abrasion, are not only to monitor on-line
Cutting-tool wear state provides feasible technical backstopping, is also analysis Cutting Tool Failure Mechanism, tool life, optimization milling
It cuts parameter, promote the theoretical foundation that processing efficiency has established science.
Detailed description of the invention
Fig. 1 is the micro- cutter wear schematic diagram of the present invention；
Fig. 2 is the schematic diagram that the present invention establishes micro- Milling Force and tool wear area mapping relations；
Fig. 3 is the flow chart of on-line monitoring method of the present invention.
Specific embodiment
In the present embodiment, the on-line monitoring method of tool wear in a kind of micro- milling process is using theoretical and experiment phase
In conjunction with method, it is determined that it is fine cut during micro- Milling Force and tool abrasion quantitative relationship.Firstly, establishing comprising abrasion
Micro- Milling Force Model of coefficient；Secondly, obtaining the wear area and micro- Milling Force and the coefficient of waste of micro- milling cutter by experiment
Mapping relations；Finally, obtaining micro- Milling Force and tool wear area according to the relationship of micro- Milling Force, the coefficient of waste and wear area
Direct mapping relations, thus can not be according to Milling Force Dynamic Signal online evaluation cutter when overcoming Classical forecast tool wear
The shortcomings that abrasion, repeats the drawbacks of peace loading, unloading cutter causes cumulative errors, improves because of nothing when avoiding measurement tool wear
Method prediction tool wear and the deficiency that leads to tool failure, reduce processing quality.Specifically, as shown in figure 3, this method packet
Include following steps:
(1) micro- Milling Force Model comprising tool wear is established, is demarcated according to micro- Milling Force of each milling experiment measurement
The coefficient of waste in model, while recording corresponding cutter wear area, comprising the following steps:
1) according to micro- milling the characteristics of establishes micro- Milling Force Model comprising tool wear factor:
I) according to micro- Milling Theory, the Milling Force Model F comprising undetermined parameter is established using formula (1)C:
FC=(Ft,Fr)=f (h, K (Kmt,Kmr,Ket,Ker)) (1)
In formula (1), Ft、FrRespectively tangential, radial cutting force；H is momentary cutting thick；Kmt、KmrRespectively tangential, diameter
To cutting coefficient；Ket、KerRespectively tangential, radial cutting sword coefficient.
A) in micro- milling process, the caused dimensional effect that strongly reduces of rounded cutting edge radius will lead to effective rake change
Phenomena such as negative rake and minimum thickness of cut.In Milling Force Model, it is thick for cutting to embody the parameter of micro- milling dimensional effect
Spend h:
In formula (2), D is milling cutter diameter, N be the number of teeth,It is helical angle, r for angle between teeth, βeFor cutting edge blunt round radius, hmin
For minimum thickness of cut, apIt is cutting width, f for cutting depth, btIt is the speed of mainshaft for per tooth feeding, n.
B) during the cutting process, when momentary cutting thick h is less than minimum thickness of cut, cutting process will not be generated and be cut
It cuts, on the interface that blade and material are formed, friction and the plough effect of cutting can replace cutting process and intermittently occur.Therefore,
Need to consider respectively cutting and plough to cut phenomenon when establishing Milling Force Model:
It should be pointed out that during establishing micro- Milling Force Model, by considering different micro- milling feature or ginseng
Number, can establish different micro- Milling Force Models.If formula (4) are a kind of thickness of cutting model:
In formula (4), θ is cutter tooth cutting angle.
Micro- Milling Force analytic modell analytical model is can be obtained into formula (4) substitution formula (5).The Milling Force of actual measurement is usually at right angle
(the F indicated under coordinate systemx,Fy), it is therefore desirable to Milling Force is converted using formula (5):
In addition to the micro- milling feature of correlation or parameter enumerated in embodiment, it can also be examined in establishing micro- Milling Force Model
Considering such as cutter bounce, point of a knife track, other modeling patterns may refer to document；Such as:
1. Zhu Kun roc, Li Kexuan, Mei Tao, the micro- milling force modeling progress mechanical engineering journal of Shi Yungao, 2016,52
(17):20-34.http://www.cjmenet.com.cn/Jwk_jxgcxb/CN/10.3901/JME.2016.17.020；
2.B.Boswell,M.N.Islam,I.J.Davies.International Journal
ofAdvancedManufacturing Technology,2018,94(1-4):789-806.https://doi.org/
10.1007/s00170-017-0912-y；
3.D.Carou,E.M.Rubio,J.Herrera,C.H.Lauro,J.P.Davim.Latest advances
inthemicro-milling oftitanium alloys:areview.ProcediaManufacturing,2017,13:
275-282.https://doi.org/10.1016/j.promfg.2017.09.071。
II) in cutting process, tool wear can significantly affect cutting process, with the increase of tool abrasion, act on
Milling Force on forward and backward knife face also increases with it, therefore needs to consider the influence of tool wear when establishing Milling Force Model.By
It is present on entire blade in abrasion, using only " size " on a certain scale (as utilized rake face or tool flank wear, figure
1) degree of wear of Lai Daibiao blade often loses authenticity.Therefore, the wear area on blade is defined as cutter mill here
Damage amount, and utilize coefficient of waste KwTo reflect tool wear to the influence degree of Milling Force:
F=KwFC (6)
It needs to be noted that the abrasion of cutter is a concept of space, for the ease of characterization, uses project to micro- milling here
Tool wear area on knife end plane represents tool abrasion, sees Fig. 1.In addition, with the micro- milling cutter schematic diagram of two teeth in Fig. 1
For (milling cutter can be other numbers of teeth such as monodentate, 3 teeth), wear area elder generation independent measurement on each tooth of milling cutter/calculate
Come, then the average abrasion area of two teeth is defined as to the abrasion loss of milling cutter, naturally it is also possible to individually calculate each tooth
Wear area, while Milling Force corresponding on the tooth individually being calculated.
2) the micro- milling force data obtained according to experiment is demarcated the parameter in micro- Milling Force Model, while being recorded per together
The corresponding tool wear area of process.
(2) the series of discrete data point of the coefficient of waste and cutter wear area obtained according to experiment, using numerical value side
Method fits the relational expression of the coefficient of waste Yu cutter wear area, comprising the following steps:
1) data point of the coefficient of waste and wear area is drawn out.
2) model appropriate is selected to fit the coefficient of waste and wear area relational expression according to data distribution rule:
Sw=f (Kw) (7)
In formula (7), SwFor cutter wear area, f () represents the function of mapping relations.
It needs to be noted that according to data fitting function relational expression, there are many forms.Assuming that data point is (Kw1,Sw1),
(Kw2,Sw2),…(Kwi,Swi), for example be fitted using exponential function, then Sw=aexp (bKw+ c), wherein a, b, c are to be wait be fitted
Number；Polynomial curve-fit is such as used, by taking cubic polynomial as an example, thenWherein a, b, c, d
For to fitting coefficient.Actual conditions are selected according to data distribution rule, then select fitting effect most when meeting many kinds of function rule
Excellent.
(3) according to the relationship of micro- Milling Force, the coefficient of waste and wear area, micro- Milling Force and tool wear area are obtained
Direct mapping relations, to realize the on-line monitoring of tool wear in micro- milling process, as shown in Figure 2, comprising the following steps:
1) relationship between micro- Milling Force and the relationship of the coefficient of waste:
F=u (Kw) (8)
In formula (8), u () is the mapping relations function of micro- Milling Force and the coefficient of waste.
2) convolution (7) and formula (8) determine that the direct mapping of micro- Milling Force and tool wear area is closed using formula (9)
System:
F=g (Sw) (9)
It should be pointed out that micro- Milling Force is periodically variable value related with milling cutter position, and the cutter mill surveyed
Damaging area is a determining numerical value.In order to both make directly to correspond to, here with last second in per pass manufacturing procedure before
In 10 periods (selection in time and period is not unique, within the period before milling cutter exits workpiece, and the milling period
Can choose other amount of cycles such as 12 periods, 15 periods) statistical value (root-mean-square value RMS) of micro- Milling Force is used as micro- milling
Cutting the indicated value of power, (statistical value has root-mean-square value, variance, mean value, the coefficient of skewness and a set-back coefficient etc. in time domain, even frequency
Corresponding statistical value in domain, can choose that wherein feature is apparent one or more groups of to characterize micro- Milling Force), and substituted into formula
(8) and in formula (9) mapping relations between micro- Milling Force and tool wear area are characterized.
Present invention may determine that the quantitative relationship of micro- Milling Force and tool abrasion, when overcoming Classical forecast tool wear
Can not be according to Milling Force Dynamic Signal online evaluation tool wear the shortcomings that, repeats peace loading, unloading when avoiding measurement tool wear
The drawbacks of cutter causes cumulative errors is carried, improving leads to tool failure because of unpredictable tool wear, reduces processing quality
Deficiency, to monitor micro- milling force estimation cutting-tool wear state and prediction cutter remaining life on-line, and then to guarantee processing matter
Amount provides feasible theoretical method.
Claims (7)
1. the on-line monitoring method of tool wear in a kind of micro- milling process, which comprises the following steps:
Step 1 establishes micro- Milling Force Model comprising tool wear, according to micro- Milling Force calibration mold of each milling experiment measurement
The coefficient of waste in type, while recording corresponding cutter wear area；
The series of discrete data point of step 2, the coefficient of waste and cutter wear area that are obtained according to experiment, using numerical method
Fit the relational expression of the coefficient of waste Yu cutter wear area；
Step 3, according to the relationship of micro- Milling Force, the coefficient of waste and wear area, obtain micro- Milling Force and tool wear area
Direct mapping relations, to realize the on-line monitoring of tool wear in micro- milling process.
2. the on-line monitoring method of tool wear in a kind of micro- milling process according to claim 1, which is characterized in that benefit
With micro- Milling Force Model F comprising tool wear in formula (1) establishment step 1:
F=KwFC (1)
In formula (1), KwFor the coefficient of waste, FCFor the micro- Milling Force Model for not considering tool wear.
3. the on-line monitoring method of tool wear in a kind of micro- milling process according to claim 2, which is characterized in that institute
That states does not consider that micro- Milling Force Model of tool wear is the Milling Force computation model established according to micro- milling mechanical characteristics.
4. the on-line monitoring method of tool wear in a kind of micro- milling process according to claim 1, which is characterized in that institute
After stating cutter wear area in step 1 and being one procedure of every completion, pass through the abrasion on measurement end plane when cutter is stood upside down
Region and obtain.
5. the on-line monitoring method of tool wear in a kind of micro- milling process according to claim 1, which is characterized in that institute
Stating any one discrete data point in step 2 is by measuring the coefficient of waste demarcated after micro- Milling Force of every procedure and measurement
Tool wear area composition.
6. the on-line monitoring method of tool wear in a kind of micro- milling process according to claim 2, which is characterized in that institute
It states in step 2, is the relational expression for fitting the coefficient of waste Yu cutter wear area using formula (2):
Sw=f (Kw) (2)
In formula (2), SwFor cutter wear area, f () indicates the function of mapping relations.
7. the on-line monitoring method of tool wear in a kind of micro- milling process according to claim 1, which is characterized in that institute
It states in step 3, obtains the direct mapping relations of micro- Milling Force and wear area using formula (3):
F=g (Sw) (3)
In formula (3), g () represents the function of mapping relations.
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Cited By (10)
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| CN110842648A (en) * | 2019-11-28 | 2020-02-28 | 南京科技职业学院 | Online cutter wear prediction and monitoring method |
| CN111007800A (en) * | 2019-12-20 | 2020-04-14 | 常州先进制造技术研究所 | Universal method for wear prediction and machining parameter optimization of flat-head micro-milling cutter |
| CN112372372A (en) * | 2020-12-07 | 2021-02-19 | 哈尔滨理工大学 | Efficient milling cutter accumulated friction wear boundary identification and verification method |
| CN112756925A (en) * | 2021-01-26 | 2021-05-07 | 福州大学 | ADC12 aluminum alloy high-speed milling cutter surface bonding abrasion degree evaluation method based on bonding effect |
| CN112873050A (en) * | 2021-02-05 | 2021-06-01 | 武汉理工大学 | Spherical polishing cutter wear degree prediction method, equipment and storage medium |
| CN113199304A (en) * | 2021-04-27 | 2021-08-03 | 中国科学院合肥物质科学研究院 | Tool changing monitoring method based on extended Kalman filtering and cutting force model |
| CN113927368A (en) * | 2021-09-23 | 2022-01-14 | 苏州大学 | Micro milling cutter cutting edge wear monitoring method based on cutting force coefficient curve inflection point identification |
| CN114119501A (en) * | 2021-11-05 | 2022-03-01 | 苏州大学 | Method and system for measuring non-deformed cutting thickness of micro-milling |
| CN114273974A (en) * | 2021-12-14 | 2022-04-05 | 中国科学院合肥物质科学研究院 | Vibration signal-based tool runout parameter online estimation method in high-speed milling |
| CN116011263A (en) * | 2023-03-27 | 2023-04-25 | 南昌新宝路航空科技有限公司 | Cutter service life prediction method and numerical control cutter scheduling method and system |
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| CN110842648A (en) * | 2019-11-28 | 2020-02-28 | 南京科技职业学院 | Online cutter wear prediction and monitoring method |
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| CN112372372B (en) * | 2020-12-07 | 2022-09-02 | 哈尔滨理工大学 | Efficient milling cutter accumulated friction wear boundary identification and verification method |
| CN112372372A (en) * | 2020-12-07 | 2021-02-19 | 哈尔滨理工大学 | Efficient milling cutter accumulated friction wear boundary identification and verification method |
| CN112756925A (en) * | 2021-01-26 | 2021-05-07 | 福州大学 | ADC12 aluminum alloy high-speed milling cutter surface bonding abrasion degree evaluation method based on bonding effect |
| CN112873050A (en) * | 2021-02-05 | 2021-06-01 | 武汉理工大学 | Spherical polishing cutter wear degree prediction method, equipment and storage medium |
| CN113199304A (en) * | 2021-04-27 | 2021-08-03 | 中国科学院合肥物质科学研究院 | Tool changing monitoring method based on extended Kalman filtering and cutting force model |
| CN113927368A (en) * | 2021-09-23 | 2022-01-14 | 苏州大学 | Micro milling cutter cutting edge wear monitoring method based on cutting force coefficient curve inflection point identification |
| CN113927368B (en) * | 2021-09-23 | 2023-03-07 | 苏州大学 | Micro milling cutter cutting edge wear monitoring method based on cutting force coefficient curve inflection point identification |
| CN114119501A (en) * | 2021-11-05 | 2022-03-01 | 苏州大学 | Method and system for measuring non-deformed cutting thickness of micro-milling |
| CN114119501B (en) * | 2021-11-05 | 2023-03-17 | 苏州大学 | Method and system for measuring non-deformed cutting thickness of micro-milling |
| CN114273974A (en) * | 2021-12-14 | 2022-04-05 | 中国科学院合肥物质科学研究院 | Vibration signal-based tool runout parameter online estimation method in high-speed milling |
| CN116011263A (en) * | 2023-03-27 | 2023-04-25 | 南昌新宝路航空科技有限公司 | Cutter service life prediction method and numerical control cutter scheduling method and system |
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