CN112051802A - Automatic numerical control machining process method for aero-engine split-structure casing type parts - Google Patents
Automatic numerical control machining process method for aero-engine split-structure casing type parts Download PDFInfo
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- 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
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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 provides an automatic numerical control machining process method for parts of a casing of an aircraft engine split structure. Firstly, determining a technological process mainly comprising milling and turning, then developing machine tool configuration and machine tool functions, secondly, selecting a cutter handle adaptive to part structure and material characteristics, optimizing a clamp structure, verifying a numerical control process and optimizing by adopting a simulation technology after completing numerical control process optimization, subsequently verifying on site, counting the service life of a cutter to realize a cutter management function, finally carrying out mass production, and curing the process to form a typical characteristic processing template; the automatic numerical control machining process method changes the mode of manual control machining processes of manual measurement, manual tool feeding and the like of the traditional numerical control machining of parts of the aircraft engine, realizes the integrated application of multiple advanced technical means such as online measurement, automatic tool changing, tool damage monitoring, tool life management, tool feeding mistake proofing, virtual simulation machining and the like, and improves the machining efficiency of numerical control equipment.
Description
Technical Field
The invention relates to the technical field of aerospace manufacturing, in particular to an automatic numerical control machining process method for parts of a casing of an aircraft engine split structure.
Background
The casing part is a core part of an aeroengine, and is a most main bearing part in the aeroengine, the manufacturing quality of the casing part directly influences the service performance and the service life of the aeroengine, particularly, the open casing has a complex structure, the processing content is concentrated, the design of a numerical control processing technology is very complex, dozens of cutters are needed for one process of most parts, hundreds of processing steps are arranged, and due to the difference of the technical level of personnel and inconsistent understanding of the process, the programming quality and the processing efficiency of the casing part are lower, the processing cost is high, and the casing part is always the bottleneck problem in the aeroengine manufacturing industry.
An automatic numerical control processing technology is a method for realizing product process design by applying advanced technologies such as high-efficiency numerical control processing, stability control of a processing process, guarantee of processing technical indexes and the like. The main advantages are that in batch production, the human factor quality risk is reduced, the product quality stability is improved, the production cost is reduced, the production period is shortened, the production balance is ensured, and the economic benefit is remarkable. The application in the fields of food and beverage manufacturing, plastic products, chip manufacturing, electronic circuit boards, automobile manufacturing, electric appliance manufacturing and the like has achieved remarkable effects. However, the aircraft engine product has complex process, high precision requirement, large processing difficulty, relatively discrete working procedures, high design difficulty of the automatic numerical control processing technology and long debugging period, only realizes the automation of the numerical control processing procedure at present, and does not form the automation of the whole manufacturing process.
Disclosure of Invention
Aiming at the defects of the prior art, the invention provides an automatic numerical control machining process method for parts such as a casing of an aircraft engine split structure, which comprises the following steps:
step 1: determining a numerical control processing machine tool to be adopted according to a processing drawing of a to-be-processed split structure casing part, and making an automatic numerical control processing technological scheme mainly based on milling and turning;
step 2: generating a process model of the casing part with the split structure to be processed through CAD/CAM software;
and step 3: according to a processing drawing of a to-be-processed split-structure casing part, a numerical control processing program is compiled by adopting CAD/CAM software, and the numerical control processing program is subjected to post-processing;
and 4, step 4: carrying out initialization configuration on the numerical control machine tool in simulation software, and completing the configuration of an automatic processing unit to form a machine tool structure tree;
and 5: according to the requirements of the automatic numerical control machining process, additional machine tool functions for realizing the automatic numerical control machining process are developed in simulation software, wherein the additional machine tool functions comprise: the device comprises a part coordinate detection function, a spindle cutting power self-adaptive control function, a complex logic judgment function, a function integration application, an external program calling function and an on-machine measurement function;
the part coordinate detection function is used for detecting the coordinate value of the casing part and preventing the calling error of a machining coordinate system;
the spindle cutting power self-adaptive control function can be used for self-adaptively monitoring the spindle power and reducing the wear rate of a cutter by automatically adjusting the feeding speed of the spindle;
the complex logic judgment function is used for judging whether the input values of the compensation values of the three coordinate axes of the x axis, the y axis and the z axis are correct or not;
the function integration application is used for managing cutter information in the machining process, and the management comprises monitoring, counting and storing functions;
the external program calling function is used for calling an external program to realize the minimum occupation of the running memory;
the on-machine measurement function is used for on-line measurement of the machining characteristic size in the numerical control machining process;
step 6: selecting a cutter and a cutter handle for simulation machining in simulation software according to the structure and material characteristics of the part of the split-structure casing to be machined;
and 7: designing a clamp model through three-dimensional modeling software, and carrying out simulation analysis of physical state and geometric dimension on the clamp model in simulation software to obtain a clamp model with mechanical property and geometric parameters meeting design requirements;
and 8: importing the numerical control machining program, the process model and the clamp model after post-processing into simulation software, and performing simulation optimization on the automatic numerical control machining process;
and step 9: performing on-site verification on small-batch parts, actually processing k to-be-processed split-structure case parts by adopting an optimized automatic numerical control processing technology, executing a step 10 if the processed split-structure case parts meet the technological requirements, and executing a step 8 if the processed split-structure case parts do not meet the technological requirements to perform simulation optimization on the automatic numerical control processing technology;
step 10: after the on-site verification of the small-batch parts is finished, tool life data information is led out by using a tool management system, and the life data of each tool is modified according to the actual cutting time of the tool to obtain the actual life data information of the tool;
step 11: importing the actual service life data information of the cutter into a cutter management system, and updating the cutter information in the cutter management system;
step 12: the optimized automatic numerical control machining process is adopted to carry out actual large-batch machining on the part of the casing with the split structure to be machined;
step 13: and (4) curing the machining process, namely performing process curing on the optimized automatic numerical control machining process to form the automatic numerical control machining template of the split structure type case part.
Further, when the numerical control system is a siemens control system, the part coordinate detecting function predefines a settable frame command $ P _ UIFR 2]Controlling and modifying the coordinate value of the machining program to realize the detection of the coordinate value of the casing part; the main shaft cutting POWER self-adaptive control function can be used for carrying out self-adaptive monitoring ON the main shaft POWER by calling the main shaft cutting POWER self-adaptive control function POWER _ ON (), and when the abrasion loss of a cutter is smaller than1When the feeding speed is automatically reduced, the machining is continued, and when the abrasion loss of the cutter is satisfied1＜＜2And the feeding speed v of the main shaft is less than v1Time, control masterStopping the shaft feed motion, starting to time the continuous stop time length of the main shaft feed motion, and when the continuous stop time length T is more than or equal to T1When the spindle is controlled to stop moving, wherein1A threshold value representing a first level of wear of the tool,2threshold value, v, representing the secondary wear of the tool1Indicating a spindle feed speed setting threshold; the complex logic decision function predefines a settable frame instruction $ P _ UIFR [ ]]Judging whether the input values of the compensation values of the three coordinate axes of the x axis, the y axis and the z axis are correct, and prompting input errors if the absolute value | xi | of the input compensation value is greater than 0.1; the function integration application predefines a settable framework instruction $ P _ UIFR [ ]]The automatic tool setting instruction, the tool changing stopping instruction and the prompting instruction are solidified in a numerical control machining program, so that the monitoring, counting and storing operation of tool information in the machining process is realized; the external program calling function calls the external program through an external instruction calling function, and when the machining feature X on the part of the machining casing is machinediIn time, the machining characteristics X are automatically loaded through the main programiSubroutine of (1), automatic unloading of machining features X after machining is finishediTo achieve minimum operating memory footprint, wherein XiThe method comprises the steps of (1) representing the ith feature to be machined on a split structure casing part to be machined, wherein I is 1,2, …, and I represents the total number of features to be machined on the split structure casing part to be machined; the on-line measurement function realizes the on-line measurement of the machining characteristic dimension by reading the data acquisition values of the infrared measuring head in the machining center and the numerical control vertical lathe.
The invention has the beneficial effects that:
the invention provides an automatic numerical control machining process method for parts of a split-structure case of an aero-engine, and the method comprises the following steps that 1) aiming at the problems of mixed line production, numerical control specialization and low integration degree of parts of various products, the automatic numerical control machining process method can be adopted to realize clear rough machining target and finish machining target, the organization form of numerical control machining is centralized, and the numerical control machining process level is improved; 2) aiming at the problem of long preparation period of the numerical control machining process, the efficiency of the numerical control equipment can be improved by adopting an automatic numerical control machining process method, a feed path, cutting parameters and cooling are optimized, and the machining quality and the machining efficiency are improved; 3) aiming at the problem of long production preparation period, the automatic numerical control processing method can be adopted to realize the optimization of the clamping process, shorten the auxiliary working time and improve the clamping positioning precision and efficiency; 4) aiming at the problems of manual interruption of the machining process, manual reduction of a multiplying power switch of a machine tool, manual adjustment of a numerical control program and tool changing process in numerical control machining, the automatic numerical control machining process method can be adopted to improve the cutting efficiency, reduce the human factor quality risk and reduce the manufacturing cost; 5) aiming at the quality problems of machining deformation and deviation of technical indexes, the automatic numerical control machining process method can realize a process design mode of parallel iteration of numerical control machining programming and simulation verification, and effectively improves the machining quality of products.
Drawings
FIG. 1 is a flow chart of an automatic numerical control machining process method for parts of a casing with a split structure of an aero-engine;
fig. 2 is a view of a part of a casing with a split structure in the present invention, wherein (a) is a three-dimensional view of the part of the casing, (b) is a partially enlarged view of the part of the casing clamped at position a by hydraulic clamping, fig. (c) is a front view of the part of the casing, and fig. (d) is a top view of the part of the casing;
FIG. 3 is a left side view of the split-configuration case part of the present invention;
FIG. 4 is a partial cross-sectional view of a part of a split-structure casing in the invention, taken perpendicularly to the front end face thereof, wherein (a) and (b) are process diagrams of secondary front and rear turning of an inner ring groove of the casing;
FIG. 5 is a partial front view of a part of the split case of the present invention;
FIG. 6 is a diagram of an automated numerical control machining process of the present invention;
fig. 7 is a partial programming diagram of each additional machine tool function in the present invention, in which (a) is a program diagram of a part coordinate detection function, fig. (b) is a program diagram of a spindle cutting power adaptive control function, fig. (c) is a program diagram of a complex logic judgment function, fig. (d) is a program diagram of an external program calling function, fig. (e) is a program diagram of an on-line measurement of a nc milling machine tool, and fig. (f) is a program diagram of an on-line measurement of a nc lathe;
FIG. 8 is a diagram of a tool life control machining program of the present invention;
fig. 9 is a schematic view of the optimization of the cutting process in the present invention.
Detailed Description
The invention is further described with reference to the following figures and specific examples.
As shown in fig. 1, an automatic numerical control machining process method for parts such as a split-structure casing of an aircraft engine comprises the following steps:
step 1: determining a numerical control processing machine tool to be adopted according to a processing drawing of a to-be-processed split structure casing part, and making an automatic numerical control processing technological scheme mainly based on milling and turning;
fig. 2 to 5 show part drawings of a split-structure casing to be machined, and fig. 6 shows an automatic numerical control machining process scheme designed according to the part drawings, wherein the process scheme mainly determines a process mainly based on milling and turning processes according to structural characteristics of an annular thin wall, islands, holes and the like on the side wall of the split-structure casing part, and the automatic numerical control machining process scheme mainly comprises the following steps: 1) sequentially milling the front end face, the joint face and the holes on the joint face by using a numerical control milling center; 2) roughly turning a rear groove and a front groove (such as a T-shaped groove) in sequence by using a numerical control lathe; 3) roughly milling the longitudinal installation edges on the shape and the joint surface in sequence by using a numerical control milling center; 4) finely milling a joint surface by using a numerical control milling center, milling a front end surface again, and drilling and boring holes on the joint surface; 5) using a numerical control lathe to semi-finish turn a front groove, a rear groove and finish mill the shape in turn, and then finish the front groove and the rear groove in turn; 6) drilling and boring radial holes (straight holes and inclined holes) on the joint surface again by using a numerical control milling center, and drilling and boring holes on the front and rear mounting edges;
step 2: generating a process model of the split structure casing part to be processed through CAD/CAM software UGNX;
and step 3: according to a machining drawing of a to-be-machined split-structure casing part, writing a numerical control machining program by adopting CAD/CAM software UGNX, and performing post-processing on the numerical control machining program;
and 4, step 4: initializing and configuring a numerical control machining tool in simulation software Vericut, completing the configuration of an automatic machining unit, and forming a machine tool structure tree, wherein the automatic machining unit is constructed according to the principle of positioning, clamping and machining multiple parts at one time, and finally forming an automatic machining unit mainly comprising a four-axis machining center, a five-axis machining center and a numerical control vertical lathe;
and 5: according to the requirements of the automatic numerical control machining process, additional machine tool functions for realizing the automatic numerical control machining process are developed in simulation software, wherein the additional machine tool functions comprise: the device comprises a part coordinate detection function, a spindle cutting power self-adaptive control function, a complex logic judgment function, a function integration application, an external program calling function and an on-machine measurement function;
the part coordinate detection function is used for detecting the coordinate value of the casing part and preventing the calling error of a machining coordinate system;
the spindle cutting power self-adaptive control function can be used for self-adaptively monitoring the spindle power and reducing the wear rate of a cutter by automatically adjusting the feeding speed of the spindle;
the complex logic judgment function is used for judging whether the input values of the compensation values of the three coordinate axes of the x axis, the y axis and the z axis are correct or not;
the function integration application is used for managing cutter information in the machining process, and the management comprises monitoring, counting and storing functions;
the external program calling function is used for calling an external program to realize the minimum occupation of the running memory;
the on-machine measurement function is used for on-line measurement of the machining characteristic size in the numerical control machining process;
and selecting a proper machining numerical control machine tool according to the existing conditions of enterprises, wherein the proper machining numerical control machine tool comprises a five-axis numerical control machining center and a numerical control vertical lathe. Reasonably utilizing a Siemens control system and developing the functions of a machine tool so as to meet the requirements of a numerical control machining process and improve the monitoring capability of automatic numerical control machining;
1) developing the coordinate detection function of the part and preventing the calling error of the processing coordinate system
The part coordinate detection function realizes the detection of the coordinate value of the part of the casing by predefining a settable frame instruction $ P _ UIFR [ ], reading and modifying frame components (FI, TR), controlling and modifying the coordinate value of a machining program, and the specific program is written as shown in a diagram (a) in FIG. 7;
2) the self-adaptive control function of the cutting power of the main shaft is developed to prevent the cutter from being damaged, when the cutter is slightly worn, the machining is continued by automatically reducing the feeding speed, when the cutter is worn to a certain degree and the feeding speed is reduced to a set percentage, the feeding stop of the main shaft is set to start timing, and as long as the continuous timing reaches a set standard, the main shaft stops, so that the safety of parts is ensured
The main shaft cutting POWER self-adaptive control function can be used for carrying out self-adaptive monitoring ON the main shaft POWER by calling the main shaft cutting POWER self-adaptive control function POWER _ ON (), and when the abrasion loss of a cutter is smaller than1When the feeding speed is automatically reduced, the machining is continued, and when the abrasion loss of the cutter is satisfied1＜＜2And the feeding speed v of the main shaft is less than v1When the continuous stop time length T is more than or equal to T, the feeding motion of the main shaft is controlled to stop, and the continuous stop time length of the feeding motion of the main shaft is timed1When the spindle is controlled to stop moving, wherein1A threshold value representing a first level of wear of the tool,2threshold value, v, representing the secondary wear of the tool1Representing a set threshold value of the spindle feeding speed, and adopting a spindle cutting POWER self-adaptive control function POWER _ ON () to process a 2-level radial hole of a drill bit with the diameter of 11.5 for opening a casing, wherein a specific program is written as shown in a graph (b) in FIG. 7;
3) multiple high-level instructions are combined into a composite function development application for complex logic judgment in the machining process and process monitoring
The complex logic judgment function judges whether the input value of the compensation value of the three coordinate axes of the x axis, the y axis and the z axis is correct or not by predefining a settable frame instruction $ P _ UIFR [ ], if the absolute value | xi | of the input compensation value is larger than 0.1, an input error is prompted, and a specific program is compiled as shown in a graph (c) in FIG. 7;
4) developing function integration application to realize control of machining process
The functional integration application solidifies an automatic tool setting instruction, a tool changing stopping instruction and a prompting instruction in a numerical control machining program through predefining a settable frame instruction $ P _ UIFR [ ], and realizes monitoring, counting and storing operations of tool information in the machining process;
5) developing external program calling function to solve the problem of insufficient memory of machine tool
The split casing part is complex in structure and large in program quantity, for example, 118 numerical control programs with the same outer surface are milled for the split casing, the data quantity is 9.8MB, the operating memory controlled by a machine tool is 2MB, the operating memory cannot pre-read all programs for numerical control machining at one time, and the calling of the subsection subprogram is realized by developing an external instruction calling function;
calling function of external program calls external program through external instruction, and when machining feature X on part of casingiIn time, the machining characteristics X are automatically loaded through the main programiSubroutine of (1), automatic unloading of machining features X after machining is finishediTo achieve minimum operating memory footprint, wherein XiThe method comprises the steps that the ith characteristic to be machined on a part of a split structure casing to be machined is shown, I is 1,2, …, I, I indicates the total number of the characteristic to be machined on the part of the split structure casing to be machined, a pre-machining program of an outer profile of the split casing is finely milled, the specific program is compiled as shown in a diagram (d) in FIG. 7, when the part is machined, only a current main program needs to be loaded, a subprogram related to the main program is automatically loaded at a machining position, and the subprogram is automatically unloaded after machining, so that the memory is less occupied, and the operation is reduced;
6) the on-line measurement function of a machining center and a vertical lathe is adopted
On-line measurement of the machining characteristic dimension is realized by reading data acquisition values of infrared measuring heads in a machining center and a numerical control vertical lathe in an on-machine measurement function, wherein an on-line measurement program of a numerical control milling machine tool is shown as a graph (e) in fig. 7, and an on-line measurement program of a numerical control lathe is shown as a graph (f) in fig. 7; the on-line measurement of the milled outer profile is mainly used for measuring a plurality of monitored sizes, related measurement result information is transmitted to a global variable R parameter of a machine tool in program setting, an operator can conveniently and quickly know the measurement result, meanwhile, a measurement difference value is compensated to a set tool through the variable, and the measurement result is stored in a set measurement result file at the end of the program and is used for being compared with the measurement result of a three-coordinate measuring instrument;
step 6: selecting a cutter and a cutter handle for simulation machining in simulation software according to the structure and material characteristics of the part of the split-structure casing to be machined; the method is characterized in that a TAI19 material is adopted for an open casing part, and the open casing part comprises an upper half part and a lower half part which are welded and combined, so that a cutter handle which is suitable for the structure and the material characteristics of the part is selected for machining according to the control principle of optimal quality, highest efficiency and lowest cost, the manufacturers of blades of common finish turning cutters in machining are three, the cutting parameters of the three blades are basically the same through cutting comparison, and the service life and the consumption of the cutter are still counted by one blade;
and 7: the clamp model is designed through three-dimensional modeling software, and the simulation analysis of the physical state and the simulation analysis of the geometric dimension are carried out on the clamp model in the simulation software, so that the clamp model with mechanical property and geometric parameters meeting the design requirements is obtained, in order to improve the positioning precision and the clamping efficiency, the clamp adopts a hydraulic pressing control mode, and adopts hydraulic limiting and force limiting clamping positioning design to achieve the purpose of improving repeated positioning, thereby ensuring stable clamping and accurate positioning;
and 8: the numerical control machining program, the process model and the clamp model after post-processing are introduced into simulation software, a simulation machining environment is unified, simulation optimization is carried out on an automatic numerical control machining process, a part tool changing position and automatic tool compensation are set, automatic tool changing machining is carried out, the risk that manual tool changing is prone to error is reduced, and machining efficiency is improved; setting a part detection position, and adopting an infrared measuring head and a control system to measure a circulating program, so that the characteristics of diameter, slope points and the like can be formulated for online measurement; the measuring program is programmed to realize automatic measurement in the machining process, the machining quality of the part is monitored, and the machining efficiency is improved; the cutting force, machining deformation prediction and surface roughness prediction are completed, and the numerical control program is convenient to optimize;
optimizing cutting parameters by a simulation technology, wherein the cutting parameters comprise cutting depth, step pitch, feeding speed, optimized tool advancing and retracting positions, tool changing positions and online measuring positions, and realizing quality control of a machining process; the processing scheme is changed, the feed path and the combined cutting path are optimized, the idle stroke is shortened, and the like, so that the execution program required by the turning can be optimized; the machining parameters in the execution program are solidified in a single-stage program multi-feed mode, wherein the optimization schematic diagram of the cutting machining is shown in fig. 9, a in the diagram shows the existing feed mode, and the optimization is decomposed into three feed modes shown in b, c and d, so that the problem that the cutting stability is influenced by the uneven allowance in the turning process is effectively reduced;
when a T-shaped groove is finely turned, the condition of accidental damage of a cutter often occurs, the feeding multiplying power needs to be adjusted in real time according to the change of machining power on site during machining, great obstacles are brought to automatic numerical control machining, and an enlarged view of a clamping mode after a machining scheme is continuously adjusted is shown in a graph (b) in fig. 2.
Before processing, carrying out numerical control simulation on the optimized program, and analyzing cutting parameters aiming at each section in the process of a feed track to ensure the correctness of the program; the machining force, deformation prediction and surface roughness prediction simulation analysis in the machining process are adopted, the matching of the cutting parameters and the removal amount in the machining process is optimized, and the deformation of the part is controlled.
And step 9: performing on-site verification on small-batch parts, actually processing k to-be-processed split-structure case parts by adopting an optimized automatic numerical control processing technology, executing a step 10 if the processed split-structure case parts meet the technological requirements, and executing a step 8 if the processed split-structure case parts do not meet the technological requirements to perform simulation optimization on the automatic numerical control processing technology;
when in-situ processing verification and debugging are carried out, a machining center airborne infrared measuring head and a control system are adopted for measuring circulation, diameter and slope point online measuring program compilation is completed, automatic measurement and automatic cutter compensation in the machining process are realized, the risk of manual tool feeding is reduced, the part machining quality is ensured, and the machining efficiency is improved;
step 10: after the on-site verification of the small-batch parts is finished, tool life data information is led out by using a tool management system, and the life data of each tool is modified according to the actual cutting time of the tool to obtain the actual life data information of the tool;
according to the service life of the cutter in actual machining, a cutter use balance plan and a cutter use rule of a machining program are formulated; the balance plan comprises the type and the use quota of the cutter, the cutter use rule of the processing program comprises the clamping length of the cutter, and the cutter handle corresponds to the program number information and the used technical requirement;
step 11: importing the actual service life data information of the cutter into a cutter management system, and updating the cutter information in the cutter management system; curing the types and consumption of machining tools, aiming at the characteristics of complex structure, multiple characteristics and various types of machining tools of casing parts, selecting proper machining tools according to the direct experience of using different tools accumulated in long-term machining and combining the requirements of quality and cost control, and laying a foundation for the curing of machining parameters;
a tool life control program is compiled, the service condition of the tool is automatically monitored through a system, whether the tool used for machining reaches the set life of the tool is automatically judged, the tool is forbidden by the system when the set life is reached, and a new tool is automatically called to continue machining, so that the tool life management is realized;
the tool life monitoring can be realized by setting the service life parameters of the tool, programming a tool life control program, automatically monitoring the service condition of the tool through a machine tool control system, automatically judging whether the tool used for machining reaches the set service life of the tool, namely the system forbids the tool when the set service life is reached, and automatically calling a new tool to continue machining, thereby realizing the automatic control of the tool life; the control method is mastered by researching and utilizing the service life control function of the cutter, and the control method is applied to the full-program unmanned intervention machining of typical parts; the tool life control machining program is shown in fig. 8;
step 12: the optimized automatic numerical control machining process is adopted to carry out actual large-batch machining on the part of the casing with the split structure to be machined;
step 13: the machining process is solidified, the optimized automatic numerical control machining process is subjected to process solidification to form an automatic numerical control machining template of the split-structure type case part, and the process solidification comprises numerical control machining process solidification and machine tool and clamping solidification; the processing template is used for extracting typical processing characteristics in the process and expanding the typical processing characteristics to the application of parts of the same type;
through technical research, engineering application and system perfection, the method plays a very remarkable promoting role in optimizing the numerical control machining process, improving the numerical control machining program quality and the numerical control machining quality of products, and improves the batch production capacity of the engine; taking the case as an example, a layer milling technology characterized by small cutting depth and large feed is applied to the outer contour rough milling process, so that the main stress direction of the cutter is the main shaft direction, the processing efficiency can be improved, and the machine tool precision can be better maintained.
The stability of the process is ensured by batch production and further curing process; then through experience extraction and technology accumulation, the cured process can be used as a template of parts of the same type, so that part process design with similar characteristics can be rapidly developed; the mature process is applied to the manufacturing of parts of the same type, the research and development manufacturing cost of products of the same type can be reduced, and the preparation efficiency before manufacturing is improved.
The automatic numerical control machining process method for the parts of the split-structure case can change the mode of manual control machining processes of manual measurement, manual tool feeding and the like of the traditional numerical control machining of the parts of the aero-engine, realize the integrated application of multiple advanced technical means such as online measurement, automatic tool changing, tool damage monitoring, tool service life management, tool feeding mistake proofing, virtual simulation machining and the like, improve the machining efficiency of numerical control equipment by 15-40%, effectively reduce the labor intensity of operators, improve the machining quality of products, create huge potential economic value and are difficult to measure by numerical values. The method can realize batch production mode of high-efficiency, precise, whole-process control and automatic numerical control machining of the aeroengine in China, can improve the reliability, stability and consistency of the numerical control machining process, can ensure the manufacturing quality of the aeroengine case, improves the machining efficiency and reduces the machining cost.
Claims (2)
1. An automatic numerical control machining process method for aero-engine split structure casing parts is characterized by comprising the following steps:
step 1: determining a numerical control processing machine tool to be adopted according to a processing drawing of a to-be-processed split structure casing part, and making an automatic numerical control processing technological scheme mainly based on milling and turning;
step 2: generating a process model of the casing part with the split structure to be processed through CAD/CAM software;
and step 3: according to a processing drawing of a to-be-processed split-structure casing part, a numerical control processing program is compiled by adopting CAD/CAM software, and the numerical control processing program is subjected to post-processing;
and 4, step 4: carrying out initialization configuration on the numerical control machine tool in simulation software, and completing the configuration of an automatic processing unit to form a machine tool structure tree;
and 5: according to the requirements of the automatic numerical control machining process, additional machine tool functions for realizing the automatic numerical control machining process are developed in simulation software, wherein the additional machine tool functions comprise: the device comprises a part coordinate detection function, a spindle cutting power self-adaptive control function, a complex logic judgment function, a function integration application, an external program calling function and an on-machine measurement function;
the part coordinate detection function is used for detecting the coordinate value of the casing part and preventing the calling error of a machining coordinate system;
the spindle cutting power self-adaptive control function can be used for self-adaptively monitoring the spindle power and reducing the wear rate of a cutter by automatically adjusting the feeding speed of the spindle;
the complex logic judgment function is used for judging whether the input values of the compensation values of the three coordinate axes of the x axis, the y axis and the z axis are correct or not;
the function integration application is used for managing cutter information in the machining process, and the management comprises monitoring, counting and storing functions;
the external program calling function is used for calling an external program to realize the minimum occupation of the running memory;
the on-machine measurement function is used for on-line measurement of the machining characteristic size in the numerical control machining process;
step 6: selecting a cutter and a cutter handle for simulation machining in simulation software according to the structure and material characteristics of the part of the split-structure casing to be machined;
and 7: designing a clamp model through three-dimensional modeling software, and carrying out simulation analysis of physical state and geometric dimension on the clamp model in simulation software to obtain a clamp model with mechanical property and geometric parameters meeting design requirements;
and 8: importing the numerical control machining program, the process model and the clamp model after post-processing into simulation software, and performing simulation optimization on the automatic numerical control machining process;
and step 9: performing on-site verification on small-batch parts, actually processing k to-be-processed split-structure case parts by adopting an optimized automatic numerical control processing technology, executing a step 10 if the processed split-structure case parts meet the technological requirements, and executing a step 8 if the processed split-structure case parts do not meet the technological requirements to perform simulation optimization on the automatic numerical control processing technology;
step 10: after the on-site verification of the small-batch parts is finished, tool life data information is led out by using a tool management system, and the life data of each tool is modified according to the actual cutting time of the tool to obtain the actual life data information of the tool;
step 11: importing the actual service life data information of the cutter into a cutter management system, and updating the cutter information in the cutter management system;
step 12: the optimized automatic numerical control machining process is adopted to carry out actual large-batch machining on the part of the casing with the split structure to be machined;
step 13: and (4) curing the machining process, namely performing process curing on the optimized automatic numerical control machining process to form the automatic numerical control machining template of the split structure type case part.
2. The automatic numerical control machining process method for the parts of the aircraft engine split structure casing type according to claim 1, wherein when the numerical control system is a Siemens control system, the part coordinate detection function realizes detection of the coordinate values of the casing parts by pre-defining a settable frame instruction $ P _ UIFR [ ], and controlling and modifying the coordinate values of a machining program;
the main shaft cutting POWER self-adaptive control function can be used for carrying out self-adaptive monitoring ON the main shaft POWER by calling the main shaft cutting POWER self-adaptive control function POWER _ ON (), and when the abrasion loss of a cutter is smaller than1When the feeding speed is automatically reduced, the machining is continued, and when the abrasion loss of the cutter is satisfied1＜＜2And the feeding speed v of the main shaft is less than v1When the continuous stop time length T is more than or equal to T, the feeding motion of the main shaft is controlled to stop, and the continuous stop time length of the feeding motion of the main shaft is timed1When the spindle is controlled to stop moving, wherein1A threshold value representing a first level of wear of the tool,2threshold value, v, representing the secondary wear of the tool1Indicating a spindle feed speed setting threshold;
the complex logic judgment function judges whether the input value of the compensation value of the three coordinate axes of the x axis, the y axis and the z axis is correct or not by predefining a settable frame instruction $ P _ UIFR [ ], and prompts an input error if the absolute value | xi | of the input compensation value is larger than 0.1;
the function integration application solidifies an automatic tool setting instruction, a tool changing stopping instruction and a prompting instruction in a numerical control machining program through predefining a settable frame instruction $ P _ UIFR [ ], and realizes monitoring, counting and storing operations of tool information in the machining process;
the external program calling function calls the external program through an external instruction calling function, and when the machining feature X on the part of the machining casing is machinediIn time, the machining characteristics X are automatically loaded through the main programiSubroutine of (1), automatic unloading of machining features X after machining is finishediTo achieve minimum operating memory footprint, wherein XiThe method comprises the steps of (1) representing the ith feature to be machined on a split structure casing part to be machined, wherein I is 1,2, …, and I represents the total number of features to be machined on the split structure casing part to be machined;
the on-line measurement function realizes the on-line measurement of the machining characteristic dimension by reading the data acquisition values of the infrared measuring head in the machining center and the numerical control vertical lathe.
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