CN111077849B - Self-adaptive machining method for integral impeller of five-axis numerical control machine tool - Google Patents

Self-adaptive machining method for integral impeller of five-axis numerical control machine tool Download PDF

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CN111077849B
CN111077849B CN201911267358.XA CN201911267358A CN111077849B CN 111077849 B CN111077849 B CN 111077849B CN 201911267358 A CN201911267358 A CN 201911267358A CN 111077849 B CN111077849 B CN 111077849B
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CN111077849A (en
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邱文旺
王永飞
张海洲
杨继平
陈刚
楚亚松
臧兴磊
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Beijing Power Machinery Institute
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    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • 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
    • G05B19/4097—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 using design data to control NC machines, e.g. CAD/CAM
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • 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 self-adaptive machining method for an integral impeller of a five-axis numerical control machine tool, and belongs to the technical field of numerical control machining. Firstly, placing the end face of a part to be machined in a state of being basically vertical to a main shaft of a tool of a machine tool, and then measuring and calculating the normal vector of the end face of the part to be machined and the angle to be adjusted of two rotating shafts of the machine tool on the part to be machined by utilizing a measuring head of the machine tool; adjusting the position of a rotating shaft of the machine tool according to the calculation result to enable the end face of the part to be in a state of being exactly perpendicular to the main shaft of the tool of the machine tool, and recording coordinate values of the two rotating shafts; then calling out and recording the central position of the end face of the part measured by the machine tool measuring head and the coordinate values of the height of the end face of the part on three linear axes of the machine tool; and setting the recorded coordinate values into a register of the machine tool, and finally, using the set register as zero offset to process the whole impeller part. The invention can obviously improve the machining precision and consistency of impeller parts, improves the machining quality and is suitable for automatic machining of production lines.

Description

Self-adaptive machining method for integral impeller of five-axis numerical control machine tool
Technical Field
The invention relates to a machining method of an impeller, in particular to a self-adaptive machining method for an integral impeller, and belongs to the technical field of numerical control machining.
Background
Compared with split manufacturing, the integral impeller is integrally manufactured and formed by adopting blank materials, has the advantages of short production period flow, high comprehensive working performance of parts and high reliability, and is widely applied to the industries of aviation, aerospace, automobiles, energy sources and the like.
In the field of manufacturing of integral impellers, blade machining by adopting a five-axis numerical control machine tool is still the most important machining mode. When the whole impeller is debugged at present, a commonly adopted method is that numerical control programming is firstly carried out on a single flow channel and a single blade, then when a certain blade or flow channel is machined on a machine tool, the blade or the flow channel is used as a feature to be machined, the blade or the flow channel is rotated to a specific position consistent with a programming coordinate, and then a subprogram is called for machining. The machining method has the advantages that programming workload is simplified, procedures are concise, however, in the method, a coordinate system is redefined when each blade or runner is machined, due to the influence of various factors in the impeller part, the tooling and the clamping process, certain errors exist between the redefined coordinate system and theoretical positions to a greater or lesser extent, machining accuracy of the impeller blade profile and the runner is reduced, the method needs to align circumferential runout and end runout of parts, alignment difficulty is high, efficiency is low, efficiency of the production process is reduced, the existing situation that manual alignment is involved is not suitable for an automatic production mode, and a new integral impeller machining method needs to be provided to solve the problem urgently.
Disclosure of Invention
In view of the above, the invention provides a method for adaptively processing an integral impeller of a five-axis numerical control machine tool, which realizes processing reference positioning by means of an online measuring head of the machine tool, realizes rotation of a subprogram through coordinate transformation, finally realizes adaptive processing of the integral impeller, can remarkably improve the processing precision and consistency of impeller parts, and improves the processing quality.
A self-adaptive machining method for an integral impeller of a five-axis numerical control machine tool comprises the following steps:
the method comprises the following steps: mounting a to-be-machined integral impeller part (hereinafter referred to as a 'part') so that the part is approximately positioned at the rotating center of a workbench, setting two rotating shafts of a five-axis numerical control machine tool (hereinafter referred to as a 'machine tool') to be at 0-degree positions, and enabling the end surface of the part to be perpendicular to a main shaft of a tool of the machine tool;
step two: according to the size of the part, three or more measuring points are arranged on the end surface of the part, a machine tool measuring head is called to measure the position coordinate value (comprising three linear axes) of each measuring point in a machine tool coordinate system, and the normal vector of the end surface of the part and the angle to be adjusted of two rotating shafts of the machine tool are calculated;
step three: adjusting the position of the rotating shaft of the machine tool according to the calculation result of the step two to enable the end surface of the part to be in a state of being exactly perpendicular to the main shaft of the tool of the machine tool, and recording the coordinate values of the two rotating shafts of the machine tool at the moment;
step four: calling out and recording coordinate values of the center of the end face of the part measured by the measuring head of the machine tool and the height of the end face of the part on three linear axes of the machine tool;
step five: setting the coordinate values of the two rotating shafts and the three linear shafts recorded in the third step and the fourth step into a machine tool register;
step six: and 4, using the register value set in the step five as zero offset to process the whole impeller part.
Further, the numerical control program input in the step six for machining the whole impeller part includes the following two cases:
the first case is that the input numerical control program itself contains the machining programs of all the groups of blades or runners in the integral impeller part;
the second case is a machining program that inputs the numerical control program itself containing only a single set of blades or flow channels in the overall impeller part.
Further, when the input numerical control program is in the first situation, the program is directly called by the numerical control system of the machine tool for processing; when the input numerical control program is in the second situation, the machine tool numerical control system directly calls the input numerical control program to process the first group of blades or runners, and firstly, the input numerical control program carries out coordinate transformation under a workpiece coordinate system according to the angle value between the first group of blades or runners and the group of blades or runners, and then the machine tool numerical control system calls the input numerical control program to process the other group of blades or runners.
Further, the coordinate transformation in the workpiece coordinate system is to perform coordinate transformation on a linear axis coordinate value and a rotating axis coordinate value or a cutter axis vector component coordinate value input into a numerical control program; when the input numerical control program is expressed by adopting a linear axis coordinate value and a rotating axis coordinate value format, coordinate transformation needs to be carried out aiming at three linear axis coordinate values and two rotating axis coordinate values of each row of codes; when the input numerical control program is expressed in a linear axis coordinate value and cutter axis vector component coordinate value format, coordinate transformation needs to be performed for three linear axis coordinate values and three cutter axis vector component coordinate values of each row of codes.
Further, the processing procedure in the sixth step refers to one or more numerical control procedures, which are used for finishing the processing procedures of rough milling of the flow channel, semi-finish milling of the blade profile, back chipping, bottom sweeping, semi-finish milling of the small blade, back chipping of the small blade and the like, on the basis of all the groups of blades or flow channels.
Further, the numerical control programs input in both cases are programs for turning on a blade edge following mode (also referred to as "rotating around the center of the blade", and in different numerical control systems, functions such as RTCP, RPCP, or TCPM).
Further, when the integral impeller part is machined in the sixth step, the machine tool is allowed to set a zero offset value of the rotating shaft, which is not 0 degree; and before the five-axis numerical control program interpolation is carried out by the machine tool numerical control system, the zero offset value setting conditions of the linear axis and the rotating axis can be considered, and preprocessing is carried out on each line of the called line numerical control program codes so as to calculate the actual rotation angle of the rotating axis and the actual moving distance of the linear axis or the actual position where the rotating axis and the linear axis are to reach, which correspond to the line numerical control program codes, under the machine tool coordinate system.
Has the advantages that:
1. according to the invention, by utilizing the online measuring head and the operation compensation function of the numerical control machine tool during the machining of the integral impeller part, the part clamping and aligning errors can be greatly reduced, and the machining precision and consistency of the integral impeller part are improved.
2. The processing method provided by the invention saves the manual meter-making and alignment link, can obviously improve the working efficiency, can be suitable for automatic production working conditions such as a production line and the like, and has a wide application prospect.
3. According to the method provided by the invention, a five-axis numerical control machine tool research and development enterprise can design and develop the integral impeller self-adaptive processing function module, the customized processing function of the five-axis numerical control machine tool for the integral impeller part is improved, the debugging workload of a user in the process of processing the integral impeller part is simplified, the entry threshold of a debugging process technician is reduced, and the developed five-axis numerical control machine tool is more convenient and easier to use and has more international competitiveness.
Drawings
FIG. 1 is a flow chart of steps of a self-adaptive machining method for an integral impeller of a five-axis numerical control machine tool according to the invention;
FIG. 2 is a schematic structural view of a unitary impeller component;
FIG. 3 is an axial schematic view of a five-axis numerical control machine tool;
FIG. 4 is a schematic view showing a state where an end face of a part is exactly perpendicular to a tool spindle (projection of a machine tool rotation axis structure in a machine tool coordinate system YZ plane)
FIG. 5 is a schematic diagram of the rotation transformation of the tool path trajectory of the numerical control program;
wherein, the coordinate value A corresponding to the rotation angles of the 1-pin hole, the 2-machine tool X axis, the 3-machine tool Y axis, the 4-machine tool Z axis, the 5-machine tool A axis, the 6-machine tool C axis, the 7-workbench, the 8-cutter, the 9-impeller and the 10-A axis111-Y 'axis along with A axis swinging coordinate system, 12-Z' axis along with A axis swinging coordinate system, 13-tool path track for processing the first group of blades, 14-tool path track for processing the fourth group of blades, 15-X axis of workpiece coordinate system, 16-Y axis of workpiece coordinate system, 17-Z axis of workpiece coordinate system, and 18-included angle theta between the first group of blades and the fourth group of blades.
Detailed Description
The invention is described in detail below by way of example with reference to the accompanying drawings.
The invention provides a self-adaptive machining method for an integral impeller of a five-axis numerical control machine tool, which is characterized in that numerical control machine tools with different structural forms have different swing shaft configurations.
As shown in fig. 3, it is assumed that the cradle type five-axis numerical control machine tool is configured with two rotating shafts, namely a machine tool a axis 5 and a machine tool C axis 6, wherein the machine tool C axis 6 is a continuous rotating axis, the machine tool a axis 5 is a swinging axis, the machine tool C axis 6 is mounted on the machine tool a axis 5, and the linear axes are configured with a machine tool X axis 2, a machine tool Y axis 3 and a machine tool Z axis 4 respectively.
As shown in fig. 3, a machine tool coordinate system is formed by a machine tool X-axis 2, a machine tool Y-axis 3 and a machine tool Z-axis 4; as shown in fig. 5, an X-axis 15 of the object coordinate system, a Y-axis 16 of the object coordinate system, and a Z-axis 17 of the object coordinate system constitute the object coordinate system.
The method comprises the following implementation steps as shown in the attached figure 1:
step one, a tool and an integral impeller part 9 (hereinafter referred to as 'part') are installed, the part is approximately positioned at the rotation center of a workbench 7 through visual inspection, when the part is machined on an automatic production line, a zero point positioning system (a mother plate is fixed near the rotation center of the workbench) and an automatic loading and unloading system are adopted to install the part, a machine tool A shaft 5 and a machine tool C shaft 6 are adjusted to 0-degree positions, the end face of the part is approximately positioned at the horizontal position at the moment, and normal measurement of a machine tool measuring head is ensured. In the case of large cutting force or secondary clamping, the angular position can be fixed or determined through the pin hole 1 on the part.
Step two, according to the size of the part, three or more (including three) measuring points are uniformly distributed on the end face of the part, a machine tool measuring head is called to measure the position coordinate value (including three linear axes) of each measuring point in a machine tool coordinate system, the measured data is used for calculating the unit normal vector of the end face of the part, and the unit normal vector is assumed to be (VX)1,VY1,VZ1) Based on this, the angles Δ a and Δ C to be adjusted of the two axes of rotation of the machine tool are further calculated and recorded as follows:
(1) if VX1＝0，VY10, then
ΔA＝0
ΔC＝0
(2) If VX1＝0，VY1Not equal to 0, then
ΔA＝arcsin(-VY1)
ΔC＝0
(3) If VY is1＝0，VX1Not equal to 0, then
ΔA＝arcsin(VX1)
Figure BDA0002313226990000061
(4) If VX1≠0，VY1Not equal to 0, then
ΔA＝arccos(VZ1)
Figure BDA0002313226990000062
Step three, adjusting the position of the rotating shaft of the machine tool according to the calculation result of the step two to enable the end surface of the part to be in a state of being exactly perpendicular to the main shaft of the tool of the machine tool, for the embodiment, the main shaft of the tool of the swing basket type five-axis numerical control machine tool is always in a vertical state, the fact that the end surface of the part is exactly perpendicular to the main shaft of the tool of the machine tool is the same as the fact that the end surface of the part is arranged in an exact horizontal state, specifically as shown in the attached drawing 41、C1(ii) a At this time, the position of the coordinate system swinging along with the axis a is shown by the dotted line in fig. 4, the Y 'axis 11 of the coordinate system swinging along with the axis a is always in the plane formed by the machine tool Y axis and the machine tool Z axis of the machine tool coordinate system, and the Z' axis 12 of the coordinate system swinging along with the axis a is always overlapped with the revolving shaft of the worktable 7.
Fourthly, calling out and recording position coordinate values of the center of the end face of the part measured by the machine tool measuring head and the height of the end face of the part in a machine tool coordinate system, wherein the assumed position coordinate values are X1、Y1、Z1；
Step five, recording two rotation axis coordinate values A recorded in the step three and the step four1、C1And three linear axis coordinate values X1、Y1、Z1Set to a machine register, for example, set to G54;
and step six, machining the whole impeller part by using the register G54 set in the step five as zero offset.
The numerical control program input in the step six for processing the integral impeller part comprises the following two conditions:
the first case is that the input numerical control program itself contains the machining programs of all the groups of blades or runners in the part;
the second case is a machining program that inputs the numerical control program itself containing only a single set of blades or runners in the part.
When the input numerical control program is in the first situation, the numerical control system of the machine tool directly calls the program to process; when the input numerical control program is in the second situation, the machine tool numerical control system directly calls the input numerical control program to process the first group of blades or runners, the tool path track corresponding to the numerical control program for processing the first group of blades is 13, and for other groups of blades or runners, firstly, the input numerical control program is subjected to coordinate transformation under a workpiece coordinate system according to the angle value between the group of blades or runners and the first group of blades or runners (taking the 4 th group of blades as an example, the tool path track 14 corresponding to the used numerical control program is obtained by performing coordinate transformation on the numerical control program for processing the first group of blades), and then the machine tool numerical control system calls the input numerical control program to process the blades.
In this embodiment, taking the input numerical control program as the second case as an example, assuming that the total number of the blades or the flow channel groups of the whole impeller is N, and the serial number of the blade or the flow channel group to be processed is N, the angle value θ 18 between the blade or the flow channel group and the first group of blades or the flow channels is calculated by the following formula:
Figure BDA0002313226990000071
and (3) in the workpiece coordinate system, performing coordinate transformation on the coordinate value and the rotating shaft coordinate value (or the cutter shaft vector component coordinate value) in the subprogram according to the obtained theta angle value. Fig. 5 shows a schematic diagram of the transformation of the tool path trajectory of the numerical control program for machining the first group of blades into the tool path trajectory of the numerical control program for machining the fourth group of blades by surrounding the Z-axis 17 of the workpiece coordinate system, and for the linear axis coordinate values in the numerical control code, the following formula is adopted for coordinate transformation:
Figure BDA0002313226990000081
wherein, Xa、Ya、ZaRepresenting coordinate variationsThree linear axis coordinate values, X, of any one row in the pre-change numerical control codeb、Yb、ZbAnd the coordinate values of three linear axes after the coordinate transformation of the row control code are shown.
The coordinate transformation of the rotation axis coordinate value (or the arbor vector component coordinate value) is specifically classified into the following two cases:
(1) when the input numerical control program is expressed in a linear axis coordinate value and a rotating axis coordinate value format, a specific formula for performing coordinate transformation on two rotating axis coordinate values is as follows:
Ab＝Aa
Cb＝Ca+θ
wherein A isa、CaTwo values of the coordinate of the axis of rotation, A, representing any one line of the numerical control code before coordinate transformationb、CbAnd representing the coordinate values of the two rotating shafts after the coordinate transformation of the row control code.
(2) When the input numerical control program is expressed by adopting a linear axis coordinate value format and a cutter axis vector component coordinate value format, the specific formula for carrying out coordinate transformation on the three cutter axis vector component coordinate values is as follows:
Figure BDA0002313226990000082
wherein VXa、VYa、VZaThe coordinate value of the cutter axis vector component, VX, representing any line in the numerical control code before coordinate transformationb、VYb、VZbAnd representing the coordinate value of the cutter shaft vector component after the coordinate transformation of the row control code.
The machining program of all the blade groups (flow channels) or the machining program of the single blade group (flow channel) refers to one or more numerical control programs which can finish machining procedures such as rough milling of the flow channel, semi-finish milling of the blade profile, back chipping, bottom sweeping, semi-finish milling of the small blade, back chipping of the small blade and the like aiming at all the blade groups (flow channels) or the single blade group (flow channels).
The two input numerical control programs are both programs for starting a tool tip following mode (also called as rotation around the center of a tool, and called as functions such as RTCP, RPCP or TCPM in different numerical control systems).
Step six, when the integral impeller part is machined, the machine tool allows the setting of a zero offset value of the rotating shaft, which is not 0 degrees; and before the interpolation of the five-axis numerical control program, the machine tool numerical control system can consider the zero offset value setting conditions of the linear axis and the rotating axis, and preprocess each line of the called line number control program codes so as to calculate the actual rotating angle of the rotating axis and the actual moving distance of the linear axis (or the actual positions of the rotating axis and the linear axis) corresponding to the line number control program codes in the machine tool coordinate system. It should be noted that, when the zero offset values of the axes a and C of the machine tool set before machining are not 0 degrees, as shown in fig. 4, it means that in the machining starting state, the coordinate value corresponding to the angle α 10 of the axis a of the machine tool is no longer 0, and at this time, the rotation center line of the axis C of the machine tool is no longer parallel to the axis of the tool 8, but is in the direction of the Z' axis 12 in the coordinate system swinging along the axis a, and the actual rotation angle of the rotating shaft and the actual moving distance of the linear shaft of the five-axis numerical control machine tool (or the actual positions to which the rotating shaft and the linear shaft should reach) should be calculated with this state as.
In summary, the above description is only a preferred embodiment of the present invention, and is not intended to limit the scope of the present invention. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.

Claims (7)

1. A self-adaptive machining method for an integral impeller of a five-axis numerical control machine is characterized by comprising the following steps:
the method comprises the following steps: mounting a to-be-machined integral impeller part to enable the part to be positioned at the rotating center of a workbench, setting two rotating shafts of a five-axis numerical control machine tool to be at 0-degree positions, and enabling the end surface of the part to be perpendicular to a main shaft of a machine tool cutter;
step two: according to the size of the part, three or more measuring points are arranged on the end face of the part, a machine tool measuring head is called to measure the position coordinate value of each measuring point in a machine tool coordinate system, the normal vector of the end face of the part and the angle to be adjusted of two rotating shafts of the machine tool are calculated, and the position coordinate value comprises three linear shafts;
step three: adjusting the position of the rotating shaft of the machine tool according to the calculation result of the step two to enable the end surface of the part to be in a state of being exactly perpendicular to the main shaft of the tool of the machine tool, and recording the coordinate values of the two rotating shafts of the machine tool at the moment;
step four: calling out and recording coordinate values of the center of the end face of the part measured by the measuring head of the machine tool and the height of the end face of the part on three linear axes of the machine tool;
step five: setting the coordinate values of the two rotating shafts and the three linear shafts recorded in the third step and the fourth step into a machine tool register;
step six: and 4, using the register value set in the step five as zero offset to process the whole impeller part.
2. The adaptive machining method for the integral impeller of the five-axis numerical control machine tool according to claim 1, wherein the numerical control program input in the step six for machining the integral impeller part includes the following two cases:
the first case is that the input numerical control program itself contains the machining programs of all the groups of blades in the part;
the second case is where the input numerical control program itself contains only machining programs for a single set of blades in the part.
3. The adaptive machining method for the integral impeller of the five-axis numerical control machine tool according to claim 2, characterized in that when the input numerical control program is in the first case, the program is directly called by a machine tool numerical control system to perform machining; when the input numerical control program is in the second situation, the machine tool numerical control system directly calls the input numerical control program to process the first group of blades, and firstly, the input numerical control program carries out coordinate transformation under a workpiece coordinate system according to the angle value between the first group of blades and the group of blades, and then the machine tool numerical control system calls the other groups of blades to process the blades.
4. The adaptive machining method for the integral impeller of the five-axis numerical control machine tool according to claim 3, wherein the coordinate transformation in the workpiece coordinate system is to perform coordinate transformation on a linear axis coordinate value and a rotational axis coordinate value, or an arbor vector component coordinate value, which are input to a numerical control program; when the input numerical control program is expressed by adopting a linear axis coordinate value and a rotating axis coordinate value format, coordinate transformation needs to be carried out aiming at three linear axis coordinate values and two rotating axis coordinate values of each row of codes; when the input numerical control program is expressed in a linear axis coordinate value and cutter axis vector component coordinate value format, coordinate transformation needs to be performed for three linear axis coordinate values and three cutter axis vector component coordinate values of each row of codes.
5. The adaptive machining method for the integral impeller of the five-axis numerical control machine tool according to claim 4, wherein the machining program in the sixth step is one or more numerical control programs capable of performing one or more of rough milling flow passages, semi-finish milling blade profiles, back chipping, bottom sweeping, semi-finish milling small blades, finish milling small blades and small blade back chipping machining procedures on all groups of blades or a single group of blades.
6. The adaptive machining method for the integral impeller of the five-axis numerical control machine tool according to claim 5, wherein the numerical control programs input in the sixth step are both programs for opening a tool nose following mode.
7. The adaptive machining method for the integral impeller of the five-axis numerical control machine tool according to claim 1 or 3, wherein when the integral impeller part is machined in the sixth step, the machine tool is allowed to set the rotating shaft to a zero offset value other than 0 degrees; and before the five-axis numerical control program interpolation is carried out by the machine tool numerical control system, the zero offset value setting conditions of the linear axis and the rotating axis can be considered, and preprocessing is carried out on each line of the called line numerical control program codes so as to calculate the actual rotating angle and the actual moving distance of the linear axis of the rotating axis corresponding to the line numerical control program codes or the actual positions of the rotating axis and the linear axis.
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