CN111338296B - Five-axis machine tool geometric error compensation method for improving curve integral tool path fairing - Google Patents

Five-axis machine tool geometric error compensation method for improving curve integral tool path fairing Download PDF

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CN111338296B
CN111338296B CN202010155886.2A CN202010155886A CN111338296B CN 111338296 B CN111338296 B CN 111338296B CN 202010155886 A CN202010155886 A CN 202010155886A CN 111338296 B CN111338296 B CN 111338296B
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CN111338296A (en
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付国强
饶勇建
陶春
谢云鹏
鲁彩江
高宏力
郭亮
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Southwest Jiaotong University
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Abstract

The invention provides a five-axis machine tool geometric error compensation method for improving the fairing of a curved surface integral tool path, which comprises the following steps: obtaining an optimized tool posture and a compensation processing code of a planned tool position point by applying a group intelligent optimization algorithm; setting the optical compliance index redundancy and the optical compliance algebra allowable value, and setting the initial value of i as 1; calculating the smoothness index of the ith cutter location point, and judging whether to calculate a new cutter location point; obtaining a fairing algebra and judging whether to optimize a new knife location point; optimizing the new knife location point by applying a group intelligent optimization algorithm; inserting the optimized new knife location point into the optimized knife location point file, and updating the optimized knife location point file; and comparing the number n of the cutter positions with i, and if i is greater than n, outputting a compensation processing code file. Through the design, the invention can effectively solve the technical problem of realizing geometric error compensation of the curved surface planning tool position point and the curved surface overall tool path by considering the quality requirement of the curved surface overall tool path.

Description

Five-axis machine tool geometric error compensation method for improving curve integral tool path fairing
Technical Field
The invention belongs to the technical field of numerical control machining error compensation, and particularly relates to a five-axis machine tool geometric error compensation method for improving the smooth of a curved surface integral tool path.
Background
Five-axis machine tools have been widely used for machining complex parts in various fields such as aerospace, aviation, navigation, automobiles, national defense and the like. Five-axis machining is also one of the important indicators for the state advanced manufacturing level. The machining accuracy of a five-axis machine tool is affected by many factors, wherein geometric errors and thermal errors are one of the main error sources and account for about 60% of the total manufacturing errors. Geometric error compensation becomes an economic and effective important means for improving five-axis milling precision.
The existing machine tool error compensation function or error compensation technology improves the position accuracy or the size accuracy of a machine tool to a certain extent, but the texture accuracy of a machined curved surface is not considered, in the error compensation process, random adjustment of machining codes or the position and the posture of a cutter without constraint can cause irregular change of the texture appearance of a workpiece curved surface, and can cause texture change, and the texture appearance of the workpiece directly influences the physical performance of the workpiece and even the fatigue life, such as the optical performance of an aspheric surface reflector, the pneumatic performance of an impeller and the like. International standard ISO1302 makes specifications on product surface characteristics including surface roughness, texture, waviness and the like, and currently, researches on texture morphology mostly focus on optimizing process conditions (such as a tool path form, cutting depth, feed amount and the like), and researches on irregular changes of curved surface texture morphology caused by changing motion amount of a motion axis due to error compensation in five-axis machine tool machining are few. In addition, the existing geometric error compensation technology can realize error compensation of the planning cutter contact for processing the curved surface, but after the error compensation at the planning cutter contact, large-angle mutation of a rotating shaft may exist between the poses of adjacent cutters. Large-angle sudden change can cause large nonlinear error, singular problems and even collision, thereby influencing the processing quality of the curved surface. There are also few relevant studies on this problem.
Disclosure of Invention
Aiming at the defects in the prior art, the geometric error compensation method for the five-axis machine tool for improving the smoothness of the curved surface integral tool path, which is provided by the invention, can effectively solve the technical problem of realizing geometric error compensation of a curved surface planning tool position point and the curved surface integral tool path by considering the quality requirement of the curved surface integral tool path.
In order to achieve the above purpose, the invention adopts the technical scheme that:
the scheme provides a five-axis machine tool geometric error compensation method for improving the fairing of a curved surface integral tool path, which comprises the following steps:
s1, according to a five-axis machine tool geometric error model, tool attitude optimization is carried out on the planned tool location point of the curved surface integral tool path by utilizing a group intelligent optimization algorithm to obtain an optimized tool attitude and a compensation processing code, and an optimized tool location point file and a compensation processing code file;
s2, setting the smoothness index redundancy S according to the processing precision and the curved surface texture of the five-axis machine toolmaxAllowable sum-of-light algebra value gmaxSetting the initial value of i as 1 and the smooth algebra of the planning tool location point as 0;
s3, calculating the smoothness index S of the ith cutter location point according to the rotation angles of the rotation shafts of the ith cutter location point and the (i + 1) th cutter location pointiAnd judging the optical compliance index siWhether or not greater than the smoothness index redundancy SmaxIf yes, go to step S4, otherwise, go to step S7;
s4, calculating the cutter position of the new cutter location point
Figure BDA0002404014410000021
And initial tool pose To nAnd based on the tool position of the new tool location
Figure BDA0002404014410000023
And initial tool pose To nCalculating to obtain the fairing algebra g of the new knife location pointnAnd judging the fairing number g of the new knife location pointnWhether it is greater than the smooth algebra allowable value gmaxIf yes, go to step S7, otherwise, go to step S5; (ii) a
S5, according to the geometric error model of the five-axis machine tool, tool posture optimization is carried out on the new planned tool location point of the curved surface integral tool path by utilizing a group intelligent optimization algorithm to obtain an optimized new tool location point and a compensation machining code;
s6, inserting the optimized new tool location point into the optimized tool location point file, updating the optimized tool location point file, inserting the compensation processing code of the optimized new tool location point into the compensation processing code file, updating the compensation processing code file, and returning to the step S3;
and S7, enabling i to be i +1, obtaining the number n of the tool positions in the tool position file, judging whether the value of i is greater than the number n of the tool positions, if so, completing the compensation of the geometric error of the five-axis machine tool, outputting a compensation machining code file as a geometric error compensation result, and if not, returning to the step S3.
The invention has the beneficial effects that: the method optimizes the tool posture of the planning tool location point representing the curved surface texture, establishes the tool path fairing strategy by considering the integral tool path fairing degree of the curved surface, reduces the influence of geometric errors and simultaneously ensures the integral texture quality of the curved surface of the workpiece, and can further improve the machining precision of a five-axis machine tool and the surface quality of the workpiece.
Further, the smoothness index S of the ith tool location in the step S3iThe expression of (c) is as follows:
si＝|αi-αi+1|+|γi-γi+1|
wherein alpha isiThe rotation angle of the first rotating shaft, gamma, representing the ith knife positioniIndicating the angle of rotation of the second axis of rotation for the ith tool position.
The beneficial effects of the further scheme are as follows: the method utilizes the rotation angle of the rotating shaft to calculate and obtain the smoothness index of the ith tool location point, can improve the calculation precision, and provides good conditions for the geometric error compensation of the five-axis machine tool.
Still further, the step S4 includes the steps of:
s401, acquiring the cutter position of a new cutter position point according to the cutter position and the cutter gesture of the ith cutter position point and the (i + 1) th cutter position point
Figure BDA0002404014410000032
And initial tool pose To n；
S402, calculating a fairing algebra g of a new cutter location point according to the fairing algebra of the ith cutter location point and the (i + 1) th cutter location pointn；
S403, judging the fairing g of the new knife location pointnWhether it is greater than the smooth algebra allowable value gmaxIf so, the process proceeds to step S7, otherwise, the process proceeds to step S5.
The beneficial effects of the further scheme are as follows: the invention uses the fairing g of a new knife location pointnAllowed value g of degree of coincidencemaxAnd (4) comparing to judge whether to optimize and insert a new cutter position, so that the influence of geometric errors is reduced and the quality of the integral texture of the curved surface of the workpiece is ensured.
Still further, the new tool position of the tool location point in step S401
Figure BDA0002404014410000041
The expression of (c) is as follows:
Figure BDA0002404014410000042
the initial tool attitude To nThe expression of (a) is as follows:
Figure BDA0002404014410000044
wherein the content of the first and second substances,
Figure BDA0002404014410000045
center position of tool, T, representing newly inserted tool siteo nRepresenting the initial tool pose of the newly inserted tool site,
Figure BDA0002404014410000047
the tool position of the ith tool position is shown,
Figure BDA0002404014410000048
representing the tool pose for the ith tool location.
Still further, the fairing number g of the new knife location point in the step S402nThe expression of (a) is as follows:
gn＝max(gi,gi+1)+1
wherein, giIndicates the number of fairing steps at the ith knife-edge position, and max indicates the larger value.
Still further, the step S6 includes the steps of:
s601, inserting the optimized new knife location point into an optimized knife location point file, and updating the optimized knife location point file, wherein the insertion position is between the ith knife location point and the (i + 1) th knife location point;
s602, inserting the optimized compensation machining code of the new tool location point into a compensation machining code file, and updating the compensation machining code file, wherein the insertion position is between the compensation machining code of the ith tool location point and the compensation machining code of the (i + 1) th tool location point;
s603, return to step S3.
The beneficial effects of the further scheme are as follows: the invention further optimizes the tool posture of the planned tool location point, and effectively improves the machining precision of the five-axis machine tool and the surface quality of the workpiece.
Still further, the swarm intelligence optimization algorithm in the step S1 and the step S5 is any one of a particle swarm optimization algorithm, a chicken swarm optimization algorithm or an ant swarm optimization algorithm.
Further, when the swarm intelligence optimization algorithm is used in step S1 and step S5, the tool position error is selected as a fitness function for compensating the geometric error of the five-axis machine tool according to the geometric error model of the five-axis machine tool.
The beneficial effects of the further scheme are as follows: and selecting the position error of the cutter as a fitness function to ensure that the position error of the cutter is minimum, and ensuring the quality of the curved surface cutter path while compensating the error.
Still further, when the tool pose optimization is performed on the planned tool location point of the curved-surface overall tool path in the step S1 and the step S5, the tool position is kept unchanged.
The beneficial effects of the further scheme are as follows: when the tool posture optimization is carried out on the planned tool location point of the whole curved surface tool path, the position of the tool is kept unchanged, the optimization precision can be improved, and the error is reduced.
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FIG. 1 is a flow chart of the method of the present invention.
Fig. 2 is a schematic diagram of a mouse-type workpiece in this embodiment.
Fig. 3 is a schematic diagram illustrating a smooth effect of a curved surface tool path of a part of the mouse-shaped workpiece in the embodiment.
Fig. 4 is a schematic diagram of processing codes of a part of a curved surface tool path of a mouse-shaped workpiece after uncompensated tool path and tool path fairing compensation in the embodiment.
FIG. 5 is a diagram illustrating workpiece error comparison before and after compensation in this embodiment.
Detailed Description
The following description of the embodiments of the present invention is provided to facilitate the understanding of the present invention by those skilled in the art, but it should be understood that the present invention is not limited to the scope of the embodiments, and it will be apparent to those skilled in the art that various changes may be made without departing from the spirit and scope of the invention as defined and defined in the appended claims, and all matters produced by the invention using the inventive concept are protected.
Examples
As shown in fig. 1, the present invention provides a five-axis machine tool geometric error compensation method for improving curve overall tool path fairing, which can effectively solve the technical problem of realizing geometric error compensation of a curve planning tool location point and a curve overall tool path by considering the quality requirement of the curve overall tool path, in this embodiment, as shown in fig. 2, a SmartCNC500_ DRTD five-axis machine tool is used for processing the workpiece as an example to explain the five-axis machine tool geometric error compensation method for improving curve overall tool path fairing, and the implementation method thereof is as follows:
s1, according to a five-axis machine tool geometric error model, tool attitude optimization is carried out on the planned tool location point of the curved surface integral tool path by utilizing a group intelligent optimization algorithm to obtain an optimized tool attitude and a compensation processing code, and an optimized tool location point file and a compensation processing code file;
in the embodiment, a chicken swarm algorithm in a swarm intelligent optimization algorithm is applied, and a five-axis machine tool geometric error model is combined to optimize the tool posture of the planned tool position of the curved surface integral tool path, so that the optimized tool posture and the compensation processing code of the planned tool position are obtained, and an optimized tool position file and a compensation processing code file are obtained; when the group intelligent optimization algorithm is applied, the comprehensive cutter position error is selected according to the machine tool geometric error model to serve as a fitness function for compensating the geometric error of the five-axis machine tool, the cutter attitude optimization is only carried out on the planned cutter position point of the whole curved surface cutter path in the optimization process, and the cutter position is kept unchanged.
S2, setting the smoothness index redundancy S according to the processing precision and the curved surface texture of the five-axis machine toolmaxAllowable sum-of-light algebra value gmaxSetting the initial value of i as 1 and the smooth algebra of the planning tool location point as 0;
s3, calculating the smooth index S of the ith cutter location point according to the rotation angles of the rotation axes of the ith cutter location point and the (i + 1) th cutter location pointiAnd determining the smoothness index siWhether or not greater than the smoothness index redundancy SmaxIf yes, go to step S4, otherwise, go to step S7; smoothness index s of ith tool location pointiThe expression of (a) is as follows:
si＝|αi-αi+1|+|γi-γi+1|
wherein alpha isiThe rotation angle of the first rotating shaft, gamma, representing the ith knife positioniA second rotation axis rotation angle representing the ith tool location;
s4, calculating the cutter position of the new cutter location point
Figure BDA00024040144100000715
And initial tool pose To nAnd based on the tool position of the new tool location
Figure BDA00024040144100000713
And initial tool pose To nCalculating to obtain the fairing algebra g of the new knife location pointnAnd judging the fairing number g of the new knife location pointnWhether it is greater than the smooth algebra allowable value gmaxIf yes, go to step S7, otherwise, go toGo to step S5; the realization method comprises the following steps:
s401, acquiring the cutter position of a new cutter position point according to the cutter position and the cutter gesture of the ith cutter position point and the (i + 1) th cutter position point
Figure BDA0002404014410000071
And initial tool pose To n；
Tool position of new tool location point
Figure BDA0002404014410000073
The expression of (a) is as follows:
Figure BDA0002404014410000074
initial tool pose To nThe expression of (a) is as follows:
Figure BDA0002404014410000076
wherein the content of the first and second substances,
Figure BDA0002404014410000077
the center position of the cutter of the newly inserted cutter point is shown,
Figure BDA0002404014410000078
the initial tool pose of the newly inserted tool site is represented,
Figure BDA0002404014410000079
the tool position of the ith tool location is shown,
Figure BDA00024040144100000710
representing the tool posture of the ith tool location point;
s402, calculating a fairing algebra g of a new cutter location point according to the fairing algebra of the ith cutter location point and the (i + 1) th cutter location pointn；
Fairing generation of new knife positiongnThe expression of (a) is as follows:
gn＝max(gi,gi+1)+1
wherein, giRepresenting the fairing algebra of the ith knife location point, and max represents a larger value;
s403, judging the fairing g of the new knife location pointnWhether it is greater than the smooth algebra allowable value gmaxIf yes, go to step S7, otherwise, go to step S5;
s5, according to the five-axis machine tool geometric error model, carrying out tool attitude optimization on the new planned tool location point of the curved surface overall tool path by using a group intelligent optimization algorithm to obtain an optimized new tool location point and a compensation processing code;
s6, inserting the optimized new knife location point into the optimized knife location point file, updating the optimized knife location point file, inserting the compensation processing code of the optimized new knife location point into the compensation processing code file, updating the compensation processing code file, and returning to the step S3, wherein the implementation method comprises the following steps:
s601, inserting the optimized new knife location point into the optimized knife location point file, and updating the optimized knife location point file, wherein the insertion position is between the ith knife location point and the (i + 1) th knife location point;
s602, inserting the optimized compensation machining code of the new tool location point into a compensation machining code file, and updating the compensation machining code file, wherein the insertion position is between the compensation machining code of the ith tool location point and the compensation machining code of the (i + 1) th tool location point;
s603, returning to the step S3;
and S7, enabling i to be i +1, obtaining the number n of the tool positions in the tool position file, judging whether the value of i is greater than the number n of the tool positions, if so, completing the compensation of the geometric error of the five-axis machine tool, outputting a compensation machining code file as a geometric error compensation result, and if not, returning to the step S3.
In this embodiment, the swarm intelligence optimization algorithm in step S1 and step S5 is any one of a particle swarm optimization algorithm, a chicken swarm optimization algorithm, or an ant swarm optimization algorithm.
In this embodiment, when the swarm intelligence optimization algorithm is used in steps S1 and S5, the tool position error needs to be selected according to the geometric error model of the five-axis machine tool as the fitness function for compensating the geometric error of the five-axis machine tool.
In this embodiment, when the tool pose optimization is performed on the planned tool location of the curved overall tool path in step S1 and step S5, the position of the tool is kept unchanged.
In this embodiment, fig. 3 is a schematic diagram illustrating a fairing effect of a curved surface tool path of a part of a mouse-shaped workpiece, fig. 3(a) is a planned tool location point, fig. 3(b) is an optimized planned tool location point, fig. 3(c) is a relatively enlarged view, and fig. 3(d) is a faired tool location point. FIG. 4 shows the machining codes of the workpiece after the uncompensated and smooth compensation of the tool path, and the compensated machining codes of the newly added tool location points of the smooth processing are shown in the box. In order to verify the effectiveness of the geometric error compensation method of the five-axis machine tool for improving the curve integral tool path fairing, an ideal machining code and a workpiece machining code after tool path fairing compensation are respectively adopted to machine a workpiece on the five-axis numerical control machine tool, then two workpiece errors are measured, and fig. 5 is a comparison graph of errors before and after compensation, and as can be seen from fig. 5, the geometric error is reduced by adopting the method of the invention. In summary, the geometric error compensation method for the five-axis machine tool for improving the overall cutter path smoothness of the curved surface can greatly improve the machining precision and ensure the texture and the appearance of the workpiece.

Claims (6)

1. The geometric error compensation method of the five-axis machine tool for improving the smooth curve of the whole curved surface cutter path is characterized by comprising the following steps of:
s1, according to a five-axis machine tool geometric error model, tool attitude optimization is carried out on the planned tool location point of the curved surface integral tool path by utilizing a group intelligent optimization algorithm to obtain an optimized tool attitude and a compensation processing code, and an optimized tool location point file and a compensation processing code file;
s2, setting the smoothness index redundancy S according to the processing precision and the curved surface texture of the five-axis machine toolmaxAllowable sum-of-light algebra value gmaxAnd setting the initial value of i to 1 toAnd the smooth algebra of the planning tool location point is 0;
s3, calculating the smoothness index S of the ith cutter location point according to the rotation angles of the rotation shafts of the ith cutter location point and the (i + 1) th cutter location pointiAnd judging the optical compliance index siWhether or not greater than the smoothness index redundancy SmaxIf yes, go to step S4, otherwise, go to step S7;
the smoothness index S of the ith tool location point in the step S3iThe expression of (a) is as follows:
si＝|αi-αi+1|+|γi-γi+1|
wherein alpha isiFirst rotation angle of axis gamma representing ith tool positioniA second rotation axis rotation angle representing the ith tool location;
s4, calculating the cutter position of the new cutter location point
Figure FDA0003623017250000011
And initial tool pose
Figure FDA0003623017250000012
And based on the tool position of the new tool location point
Figure FDA0003623017250000013
And initial tool pose
Figure FDA0003623017250000014
Calculating to obtain the fairing algebra g of the new knife location pointnAnd judging the fairing number g of the new knife location pointnWhether it is greater than the smooth algebra allowable value gmaxIf yes, go to step S7, otherwise, go to step S5;
tool position of the new tool location point
Figure FDA0003623017250000015
The expression of (a) is as follows:
Figure FDA0003623017250000016
the initial tool pose
Figure FDA0003623017250000017
The expression of (a) is as follows:
Figure FDA0003623017250000021
wherein the content of the first and second substances,
Figure FDA0003623017250000022
the center position of the cutter of the newly inserted cutter point is shown,
Figure FDA0003623017250000023
the initial tool pose of the newly inserted tool site is represented,
Figure FDA0003623017250000024
the tool position of the ith tool location is shown,
Figure FDA0003623017250000025
representing the tool posture of the ith tool location point;
the fairing g of the new knife position pointnThe expression of (a) is as follows:
gn＝max(gi,gi+1)+1
wherein, giRepresenting the fairing algebra of the ith knife location point, and max represents a larger value;
s5, according to the five-axis machine tool geometric error model, carrying out tool attitude optimization on the new planned tool location point of the curved surface overall tool path by using a group intelligent optimization algorithm to obtain an optimized new tool location point and a compensation processing code;
s6, inserting the new optimized tool location into the optimized tool location file, updating the optimized tool location file, inserting the compensation processing code of the new optimized tool location into the compensation processing code file, updating the compensation processing code file, and returning to the step S3;
and S7, enabling i to be i +1, obtaining the number n of the tool positions in the tool position file, judging whether the value of i is greater than the number n of the tool positions, if so, completing the compensation of the geometric error of the five-axis machine tool, outputting a compensation machining code file as a geometric error compensation result, and if not, returning to the step S3.
2. The method for compensating geometric errors of a five-axis machine tool for improving the smoothness of a curved-surface integral tool path according to claim 1, wherein the step S4 comprises the following steps:
s401, acquiring the cutter position of a new cutter position point according to the cutter position and the cutter gesture of the ith cutter position point and the (i + 1) th cutter position point
Figure FDA0003623017250000026
And initial tool pose
Figure FDA0003623017250000027
S402, calculating to obtain a new smooth order generation g of the knife location point according to the smooth order generation of the ith knife location point and the (i + 1) th knife location pointn；
S403, judging the fairing g of the new knife location pointnWhether it is greater than the allowable value g of optical order numbermaxIf so, the process proceeds to step S7, otherwise, the process proceeds to step S5.
3. The method for compensating geometric errors of a five-axis machine tool for improving the smoothness of a curved-surface integral tool path according to claim 1, wherein the step S6 comprises the following steps:
s601, inserting the optimized new knife location point into an optimized knife location point file, and updating the optimized knife location point file, wherein the insertion position is between the ith knife location point and the (i + 1) th knife location point;
s602, inserting the optimized compensation machining code of the new tool location point into a compensation machining code file, and updating the compensation machining code file, wherein the insertion position is between the compensation machining code of the ith tool location point and the compensation machining code of the (i + 1) th tool location point;
s603, the process returns to step S3.
4. The method for compensating geometric error of a five-axis machine tool for improving the fairing of a curved surface overall tool path according to claim 1, wherein the swarm intelligence optimization algorithm in the steps S1 and S5 is any one of a particle swarm optimization algorithm, a chicken swarm optimization algorithm or an ant swarm optimization algorithm.
5. The method for compensating geometric errors of a five-axis machine tool for improving the smoothness of a curved-surface overall tool path according to claim 1, wherein when a swarm intelligence optimization algorithm is used in the steps S1 and S5, a tool position error is selected according to a geometric error model of the five-axis machine tool as a fitness function for compensating the geometric errors of the five-axis machine tool.
6. The method for compensating geometric errors of a five-axis machine tool for improving the smoothness of a curved-surface overall tool path according to claim 1, wherein the tool position is kept unchanged when tool pose optimization is performed on the planned tool location point of the curved-surface overall tool path in steps S1 and S5.
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