CN112548676A - 一种叠层材料振动钻削状态自适应监测方法 - Google Patents
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Abstract
本发明公开了一种叠层材料振动钻削状态自适应监测方法,在加工过程中监测与进给方向相同的主轴负载功率及扭矩值大小,依据钻头加工材料划分钻削加工状态,并根据试验库数据设定判断钻削状态改变时两个监测对象的参照阈值,以达到对钻削过程自适应状态监测的目的。本方法通过加工系统中的监测模块对加工过程进行监测,采用本方法可以实时自动判断加工过程,为加工过程监控、参数自适应加工提供技术基础,以改善加工过程。
Description
技术领域
本发明涉及叠层结构钻削加工状态监测领域,尤其涉及一种叠层材料振动钻削状态自适应监测方法。
背景技术
为了实现更轻的整体重量和更高的结构强度,碳纤维环氧树脂基复合材料(CFRP)与金属材料的叠层结构在飞机结构件上得到了大量的使用。这些叠层结构经常需要通过钻削的方法制备装配孔,满足装配需求。目前,一架大型飞机需要的制孔数量通常在百万以上,而结构件中装配孔的数量占据了很大一部分。如何优化制孔质量,提高制孔效率成为了飞机制造中关注的焦点之一。
随着加工装备和工艺的升级,振动加工方法在金属材料钻削中已经得到了广泛的使用,其良好的断屑效果显著提高了制孔孔壁质量、优化了孔直线度与圆度并降低了出口毛刺。然而在叠层结构加工领域中,由于使用的加工参数较为保守,振动钻削方法并没有解决其加工效率低的问题。究其本质原因,是由于叠层结构中碳纤维复合材料、钛合金及铝合金等材料间巨大的性能差异导致。因为在钻削不同材料时使用了同样的加工参数,为避免较大的加工缺陷,所选择的加工参数进给速度较低,因此加工时间较长,加工效率较低。
在专利《叠层结构制孔在线监测自适应加工方法》(申请号201410504645.9)中利用超声波测厚的方法,在加工时确定刀具底端位置与材料分界面距离,以实现钻削过程中根据加工材料确定加工参数。然而在实际使用中,当叠层结构中材料数量较多或者厚度较大时,超声波传感器难以获得钻削过程中钻头的加工状态。而在专利《一种碳纤维复合材料与金属材料叠层装配制孔方法与装置》(申请号200910187487.8)中则是提前输入材料厚度,使用位置传感器获得刀具位置信息,以实现加工参数的改变,但当加工变厚度曲面零件时,该方法可行性较差,难以实现制孔的高效性,加工质量也难以保证。
发明内容
本发明所要解决的技术问题是针对背景技术中所涉及到的缺陷,提供一种叠层材料振动钻削状态自适应监测方法。
本发明为解决上述技术问题采用以下技术方案:
一种叠层材料振动钻削状态自适应监测方法,包括如下步骤:
步骤1),建立钻削信号数据库:
步骤1.1),统计各种叠层材料,形成集合N;
步骤1.2),针对集合N中的每种叠层材料,采集其在以下三种加工状态:钻头头部开始进入叠层材料至钻头头部全部进入叠层材料时、钻头头部完全在叠层材料内时、钻头头部开始钻出叠层材料至钻头头部全部钻出叠层材料时;所述加工状态包含主轴功率和扭矩值;
步骤1.3),对于集合N中的任意两种叠层材料M1、M2,将其相叠,采集钻头头部从叠层材料M1中开始钻出进入叠层材料M2中到钻头头部从M1中完全钻出进入叠层材料M2时加工状态并录入钻削信号数据库;
步骤1.4),对于每一种加工状态,设置其对应的钻头头部加工参数并录入钻削信号数据库;
步骤2),对于待加工的叠层结构:
步骤2.1),获取待加工的叠层结构中各个叠层材料的次序后和钻削信号数据库进行匹配,获得钻头将依次进行的各个准加工状态及其对应的加工参数;
步骤2.2),采用钻头对待加工的叠层结构进行加工,并实时采集钻头的加工状态;
步骤2.3),将钻头的实时加工状态和钻头将依次进行的各个准加工状态进行匹配,如果实时加工状态的主轴功率、准加工状态的主轴功率之间差值的绝对值小于预设的功率误差阈值或者实时加工状态的扭矩值、准加工状态的扭矩值之间差值的绝对值小于预设的扭矩误差阈值,则依照该准加工状态的加工参数对待加工的叠层结构进行加工。
本发明采用以上技术方案与现有技术相比,具有以下技术效果:
本发明在使用振动钻削工艺加工叠层结构时,依据加工过程监测信号的改变确定实际加工状态,采用的阈值比较方法来源于基础试验库,参照信息准确可靠,能够为加工过程监控、参数自适应加工提供技术基础,以改善加工过程。
附图说明
图1是本发明的叠层结构振动钻削制孔自适应监测方法实施的结构示意图;
图2是本发明钻头在钻削两层叠加材料过程中不同钻削位置的示意图。
具体实施方式
下面结合附图对本发明的技术方案做进一步的详细说明:
本发明可以以许多不同的形式实现,而不应当认为限于这里所述的实施例。相反,提供这些实施例以便使本公开透彻且完整,并且将向本领域技术人员充分表达本发明的范围。在附图中,为了清楚起见放大了组件。
本发明公开了一种叠层材料振动钻削状态自适应监测方法,实施的结构示意图如图1所示,具体包括如下步骤:
步骤1),建立钻削信号数据库:
步骤1.1),统计各种叠层材料,形成集合N;
步骤1.2),针对集合N中的每种叠层材料,采集其在以下三种加工状态:钻头头部开始进入叠层材料至钻头头部全部进入叠层材料时、钻头头部完全在叠层材料内时、钻头头部开始钻出叠层材料至钻头头部全部钻出叠层材料时;所述加工状态包含主轴功率和扭矩值;
步骤1.3),对于集合N中的任意两种叠层材料M1、M2,将其相叠,采集钻头头部从叠层材料M1中开始钻出进入叠层材料M2中到钻头头部从M1中完全钻出进入叠层材料M2时加工状态并录入钻削信号数据库,如图2所示;
步骤1.4),对于每一种加工状态,设置其对应的钻头头部加工参数并录入钻削信号数据库;
步骤2),对于待加工的叠层结构:
步骤2.1),获取待加工的叠层结构中各个叠层材料的次序后和钻削信号数据库进行匹配,获得钻头将依次进行的各个准加工状态及其对应的加工参数;
步骤2.2),采用钻头对待加工的叠层结构进行加工,并实时采集钻头的加工状态;
步骤2.3),将钻头的实时加工状态和钻头将依次进行的各个准加工状态进行匹配,如果实时加工状态的主轴功率、准加工状态的主轴功率之间差值的绝对值小于预设的功率误差阈值或者实时加工状态的扭矩值、准加工状态的扭矩值之间差值的绝对值小于预设的扭矩误差阈值,则依照该准加工状态的加工参数对待加工的叠层结构进行加工。
本技术领域技术人员可以理解的是,除非另外定义,这里使用的所有术语(包括技术术语和科学术语)具有与本发明所属领域中的普通技术人员的一般理解相同的意义。还应该理解的是,诸如通用字典中定义的那些术语应该被理解为具有与现有技术的上下文中的意义一致的意义,并且除非像这里一样定义,不会用理想化或过于正式的含义来解释。
以上所述的具体实施方式,对本发明的目的、技术方案和有益效果进行了进一步详细说明,所应理解的是,以上所述仅为本发明的具体实施方式而已,并不用于限制本发明,凡在本发明的精神和原则之内,所做的任何修改、等同替换、改进等,均应包含在本发明的保护范围之内。
Claims (1)
1.一种叠层材料振动钻削状态自适应监测方法,其特征在于,包括如下步骤:
步骤1),建立钻削信号数据库:
步骤1.1),统计各种叠层材料,形成集合N;
步骤1.2),针对集合N中的每种叠层材料,采集其在以下三种加工状态:钻头头部开始进入叠层材料至钻头头部全部进入叠层材料时、钻头头部完全在叠层材料内时、钻头头部开始钻出叠层材料至钻头头部全部钻出叠层材料时;所述加工状态包含主轴功率和扭矩值;
步骤1.3),对于集合N中的任意两种叠层材料M1、M2,将其相叠,采集钻头头部从叠层材料M1中开始钻出进入叠层材料M2中到钻头头部从M1中完全钻出进入叠层材料M2时加工状态并录入钻削信号数据库;
步骤1.4),对于每一种加工状态,设置其对应的钻头头部加工参数并录入钻削信号数据库;
步骤2),对于待加工的叠层结构:
步骤2.1),获取待加工的叠层结构中各个叠层材料的次序后和钻削信号数据库进行匹配,获得钻头将依次进行的各个准加工状态及其对应的加工参数;
步骤2.2),采用钻头对待加工的叠层结构进行加工,并实时采集钻头的加工状态;
步骤2.3),将钻头的实时加工状态和钻头将依次进行的各个准加工状态进行匹配,如果实时加工状态的主轴功率、准加工状态的主轴功率之间差值的绝对值小于预设的功率误差阈值或者实时加工状态的扭矩值、准加工状态的扭矩值之间差值的绝对值小于预设的扭矩误差阈值,则依照该准加工状态的加工参数对待加工的叠层结构进行加工。
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