CN110928233B - Machining path optimization method for machining deformation control of large-scale integral structure part - Google Patents
Machining path optimization method for machining deformation control of large-scale integral structure part Download PDFInfo
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- 238000000034 method Methods 0.000 title claims abstract description 46
- 238000005457 optimization Methods 0.000 title claims abstract description 20
- 238000003754 machining Methods 0.000 title claims description 49
- 238000012545 processing Methods 0.000 claims abstract description 45
- 238000005452 bending Methods 0.000 claims abstract description 17
- 230000008859 change Effects 0.000 claims abstract description 16
- 230000008569 process Effects 0.000 claims abstract description 8
- 238000012163 sequencing technique Methods 0.000 claims abstract description 5
- 238000005520 cutting process Methods 0.000 claims description 11
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- 238000010586 diagram Methods 0.000 description 4
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- 238000005266 casting Methods 0.000 description 1
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- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
- G05B19/19—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by positioning or contouring control systems, e.g. to control position from one programmed point to another or to control movement along a programmed continuous path
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- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
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Abstract
The invention discloses a processing path optimization method facing to large-scale integral structure part processing deformation control, which comprises the steps of firstly carrying out unit division on an area to be cut in a blank, secondly calculating the influence value of initial internal stress contained in each unit on the bending deformation of a part along the length direction, then sequencing all the units from large to small according to the influence values on the premise of meeting constraint conditions, obtaining a unit sequencing result, namely a global optimal processing path, searching a starting point with stable deflection on a curve on a change curve of the processing path, and setting a procedure at a process path corresponding to the starting point to cut the part deformation to ensure the part precision. The invention can greatly reduce the final deformation of the parts and improve the manufacturing precision of the parts in batch.
Description
Technical Field
The invention relates to the technical field of machining, in particular to a machining path optimization method for machining deformation control of large-scale integral structural parts.
Background
Large-scale integral structure parts are widely adopted on modern airplanes, have the structural characteristics of large overall dimension and thin wall, and have extremely low rigidity when not assembled with other parts. Forgings and castings are common blanks for manufacturing large integral structural parts, and the large amount of initial residual stress with high amplitude in the blanks is released and rebalanced in the machining process, so that the parts with weak rigidity are subjected to large bending and twisting machining deformation.
At present, various methods and technological measures can effectively reduce the machining deformation of large-scale integral structural parts. Through searching relevant documents at home and abroad, the academic paper 'machining deformation control technology for large aluminum alloy wing integral panels' of forest and earthquake et al in aeronautical manufacturing technology 2013,421(1/2): 146-. The academic paper "Investigation on Deformationof Single-side Stringer Parts Based on thin Initial reactive Stress" published by Yinfei Yang et al in Journal of Material Processing Technology 2019(271), P623-633 reduces part Deformation by increasing blank thickness and adjusting part position in the blank, not only increasing blank cost, but also increasing Processing time. The academic paper of "the current situation of thin-wall part milling path" of Wangxiang et al in aeronautical Manufacturing Technology 2013,434(14):98-100 and the literature of "the machining sequence on the residual stress distribution and machining quality: analysis and improvement using numerical simulations" of Cerutti X et al in International Journal of Advanced machining Technology 2016,83(1-4): 489-. The method includes the steps of firstly listing several machining path schemes, then carrying out simulation on several machining working conditions, and finally comparing finite element simulation results to obtain the optimal scheme. The implementation of the method does not significantly increase the processing time and the blank cost, so the method is widely applied to actual production. However, the machining path schemes that can be implemented without considering the minimum cutting unit volume are theoretically infinite, and the method cannot simulate and compare all schemes, so that the method cannot give a globally optimal solution, and the implementation effect is influenced.
Disclosure of Invention
The invention aims to solve the technical problems that the processing time is increased, the blank cost is increased, a global optimal solution cannot be given and the like in the conventional processing deformation control method, and provides a processing path optimization method for processing deformation control of large-scale integral structural parts.
The invention adopts the following technical scheme for solving the technical problems:
a machining path optimization method for large-scale integral structure part machining deformation control comprises the following steps:
step 1), after the position of a known part in a blank and the initial internal stress distribution of the blank are known, performing unit division on an area to be cut in the blank;
step 2), calculating the influence value of the initial internal stress contained in each unit on the bending deformation of the part along the length direction;
step 3), sequencing all units from large to small according to the influence values of the units on the premise of meeting preset constraint conditions to obtain a global optimal processing path;
step 4), calculating the bending deflection of the parts after the units are cut off one by one according to the optimal processing path through a theoretical formula or a finite element, drawing a change curve of the deflection along with the processing path, and searching a starting point with stable deflection on the change curve;
and 5) setting a working procedure at the process path corresponding to the starting point to cut the deformation of the part and ensure the precision of the part.
As a further optimization scheme of the machining path optimization method for the machining deformation control of the large-scale integral structure part, when a region to be cut in a blank is divided into units in the step 1), the length, the width and the height of each unit are respectively equal to N times of the feeding amount, the cutting width and the cutting depth value of each tooth of cutting machining, and N is a natural number which is more than or equal to 1.
As a further optimization scheme of the machining path optimization method for the machining deformation control of the large-scale integral structure part, when the blank is a part with a uniform section and the stress of the blank is uniformly distributed on each section, the unit length is equal to the length of the part.
As a further optimization scheme of the machining path optimization method for the machining deformation control of the large-scale integral structure part, the specific steps of the step 2) are as follows:
n units are counted in the area to be cut, the average value of the initial internal stress of any unit i along the length direction is sigma (i), the cross-sectional area of the unit i perpendicular to the length direction is A (i), the cross-sectional center coordinate is y (i), and the centroid coordinate of the part is shown in the specificationIs YaxisThe elastic modulus of the material is E, the length of the part is L, and the moment of inertia of the part to the self centroid is I; the influence value of the initial internal stress contained in the unit i on the bending deformation in the length direction is W (i):
as a further optimization scheme of the machining path optimization method for the machining deformation control of the large-scale integral structure part, the preset constraint conditions in the step 3) are as follows: material can only be removed in the up-down direction and only the cells exposed at the surface can be removed, the cells inside.
As a further optimization scheme of the machining path optimization method for the machining deformation control of the large-scale integral structure part, the specific steps of searching for the starting point with stable deflection on the change curve in the step 4) are as follows:
the deflection value at each processing path node on the deflection change curve is w (j), the deflection value at the curve end point is w (n), the design tolerance of the part is delta, the processing node which meets the following conditions is found out from the deflection change curve from the end point to the front, namely the starting point with stable deformation:
|W(j)-w(n)|≥Δ，j＝1，2，...n。
compared with the prior art, the invention adopting the technical scheme has the following technical effects:
1. the method does not increase the cost of the blank, and can calculate the global optimal solution of the feasible processing path according to the initial stress distribution condition;
2. a method for acquiring a stable point of bending deformation deflection is provided, and the purpose of controlling the deformation of parts can be achieved by combining special procedures.
Drawings
FIG. 1 is a flow chart of an implementation of the machining path optimization method for the machining deformation control of large-scale integral structural parts according to the invention;
FIG. 2 is a flow chart of a global optimal machining path determination method of the present invention;
FIG. 3 is a schematic diagram comparing a blank and a part in an embodiment of the invention;
FIG. 4 is a schematic diagram illustrating division of a blank unit according to an embodiment of the present invention;
FIG. 5 is a schematic diagram of a stable starting point of deformation in the processing procedure according to an embodiment of the present invention;
fig. 6 is a schematic diagram illustrating a flexible clamping technique applied in a special process according to an embodiment of the present invention.
In the figure, 1-blank, 2-part, 3-initial internal stress distribution of the blank, 4-section unit, 5-change curve of deflection along with the processing path, 6-processing stage of special process, 7-positioning block for flexible clamping and 8-stress-free clamping block for flexible clamping.
Detailed Description
The technical scheme of the invention is further explained in detail by combining the attached drawings:
the present invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. In the drawings, components are exaggerated for clarity.
As shown in fig. 1, the invention discloses a machining path optimization method for large-scale integral structure part machining deformation control, which comprises the following steps:
step 1), after the position of a known part in a blank and the initial internal stress distribution of the blank are known, unit division is carried out on an area to be cut in the blank, the length, the width and the height of each unit are respectively equal to N times of the feeding amount, the cutting width and the cutting depth of each tooth of cutting processing, N is a natural number which is more than or equal to 1, and when the blank is a part with an equal section and the stress of the blank is uniformly distributed on each section, the unit length is equal to the length of the part;
step 2), calculating the influence value of the initial internal stress contained in each unit on the bending deformation of the part along the length direction, so that n units are totally arranged in the region to be cut, the average value of the initial internal stress of any unit i along the length direction is sigma (i), the cross-sectional area of the unit i perpendicular to the length direction is A (i), and the cut-off area is A (i)The coordinate of the center of the surface is Y (i), and the coordinate of the centroid of the part is YaxisThe elastic modulus of the material is E, the length of the part is L, and the moment of inertia of the part to the self centroid is I; the influence value of the initial internal stress contained in the unit i on the bending deformation in the length direction is W (i):
step 3), sequencing all units from large to small according to the influence values of the units on the premise of meeting preset constraint conditions to obtain a global optimal processing path; the preset constraint conditions are as follows: the material can be removed only in the up-down direction, and only the cells exposed at the surface are removed, and the cells inside can be removed
Step 4), calculating the bending deflection of the parts after the units are cut off one by one according to the optimal processing path through a theoretical formula or a finite element, drawing a change curve of the deflection along with the processing path, and searching a starting point with stable deflection on the change curve;
the deflection value at each processing path node on the deflection change curve is w (j), the deflection value at the curve end point is w (n), the design tolerance of the part is delta, the processing node which meets the following conditions is found out from the deflection change curve from the end point to the front, namely the starting point with stable deformation:
|w(j)-w(n)|≥Δ，j＝1，2，...n (2)
and 5) setting a working procedure at the process path corresponding to the starting point to cut the deformation of the part and ensure the precision of the part.
A typical T-shaped edge strip structure as shown in fig. 3 is taken as an example for illustration:
step 1): dividing the blank and the part in the figure 3 into blank units according to the cross section, and dividing the parts except the part in the blank cross section into units like the units in the figure 4;
step 2): according to the initial internal stress distribution 4 of the blank in the figure 4 and a formula (1), respectively calculating the influence value of the initial internal stress contained in each unit on the bending deformation along the length direction;
step 3): according to the division condition of the blank units in the step 1) and the influence value of each unit pair on bending deformation along the length direction calculated in the step 2), performing unit sorting to obtain a globally optimal processing path, wherein the sorting method is as shown in fig. 2:
step 3.1), inputting the influence value of the initial internal stress contained in each unit on the bending deformation along the length direction;
step 3.2), listing all the remaining units of the current processing node;
step 3.3), judging whether the number of the units is 0, if so, outputting a processing path, and then finishing screening; if the number of the units is not 0, executing the step 3.4);
step 3.4), screening units meeting the process constraint conditions, namely units exposed on the upper surface and the lower surface;
step 3.5), searching a unit with the largest influence value of the initial internal stress on bending deformation along the length direction in the units screened in the step 3.4) as a unit for removing the node of the current processing path;
step 3.6), switching to unit screening of the next processing path node;
step 3.7), repeating the steps 3.2) to 3.6) until the unit screening of all processing path nodes is completed.
Step 4): according to the optimal processing path obtained in the step 3), the bending deflection of the parts after the units are cut off one by one according to the optimal processing path is calculated through a theoretical formula or a finite element, and a curve of the deflection along with the change of the processing path is drawn, wherein the result is a curve shown in fig. 5. And searching from the end point to the front in a deformation curve in the machining process according to the design tolerance of the part, and finding out a first machining path node with the difference between the deformation amount and the final deformation amount being more than or equal to the final deformation tolerance as a starting point for machining stable deformation.
And step 5): and (3) according to the global optimal processing path obtained in the step 3), actually processing the part, and arranging a special process in the processing stage shown in the figure 5 from the stable deformation starting point calculated in the step 4), cutting off the deformation, and finishing the final processing of the part.
The special procedure at the processing stage of fig. 5 may use a flexible clamping technique as shown in fig. 6, which includes a positioning block and a stress-free clamping block. The flexible clamping technology can adopt the existing mature commercial products, and the related operations are conveniently carried out; and can also be realized by adopting a plug gasket mode.
It will be understood by those skilled in the art that, unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the prior art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
The above-mentioned embodiments, objects, technical solutions and advantages of the present invention are further described in detail, it should be understood that the above-mentioned embodiments are only illustrative of the present invention and are not intended to limit the present invention, and any modifications, equivalents, improvements and the like made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (5)
1. A machining path optimization method for large-scale integral structure part machining deformation control is characterized by comprising the following steps:
step 1), after the position of a known part in a blank and the initial internal stress distribution of the blank are known, performing unit division on an area to be cut in the blank;
step 2), calculating the influence value of the initial internal stress contained in each unit on the bending deformation of the part along the length direction;
step 3), sequencing all units from large to small according to the influence values of the units on the premise of meeting preset constraint conditions to obtain a global optimal processing path;
step 4), calculating the bending deflection of the parts after the units are cut off one by one according to the optimal processing path through a theoretical formula or a finite element, drawing a change curve of the deflection along with the processing path, and searching a starting point with stable deflection on the change curve;
the specific steps for finding the starting point of stable deflection on the change curve are as follows:
the deflection value at each processing path node on the deflection change curve is w (j), the deflection value at the curve end point is w (n), the design tolerance of the part is delta, the processing node which meets the following conditions is found out from the deflection change curve from the end point to the front, namely the starting point with stable deformation:
|w(j)-w(n)|≥Δ，j＝1,2,…n；
and 5) setting a working procedure at the process path corresponding to the starting point to cut the deformation of the part and ensure the precision of the part.
2. The machining path optimization method for the machining deformation control of the large-scale integral structure part according to claim 1, wherein when the area to be cut in the blank is divided into units in the step 1), the length, the width and the height of each unit are respectively equal to N times of the feeding amount, the cutting width and the cutting depth of each tooth of the cutting machining, and N is a natural number which is greater than or equal to 1.
3. The method for optimizing the machining path for the machining deformation control of the large-scale integral structure part according to claim 2, wherein when the blank is a part with a uniform section and the stress of the blank is uniformly distributed on each section, the unit length is equal to the length of the part.
4. The method for optimizing the machining path for the machining deformation control of the large-scale integral structural part according to claim 1, wherein the specific steps of the step 2) are as follows:
n units are counted in the area to be cut, the average value of the initial internal stress of any unit i along the length direction component is sigma (i), the cross-sectional area of the unit i perpendicular to the length direction is A (i), the cross-sectional center coordinate is Y (i), and the centroid coordinate of the part is Y (i)axisThe elastic modulus of the material is E, the length of the part is L, and the moment of inertia of the part to the self centroid is I; the cell i contains an initial internal stress pairThe influence value of the longitudinal bending deformation is W (i):
5. the method for optimizing the machining path for the machining deformation control of the large-scale integral structural part according to claim 1, wherein the preset constraint conditions in the step 3) are as follows: the material can only be removed in the up-down direction and the interior cells can only be removed after the cells exposed at the surface are removed.
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