CN112817271A - Method for optimizing machining allowance of casting case blank based on-machine measurement - Google Patents
Method for optimizing machining allowance of casting case blank based on-machine measurement Download PDFInfo
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- G05B19/404—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 control arrangements for compensation, e.g. for backlash, overshoot, tool offset, tool wear, temperature, machine construction errors, load, inertia
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Abstract
The invention discloses a method for optimizing the machining allowance of a casting case blank based on-machine measurement, which comprises the steps of primary clamping of a workpiece, freedom degree selection of characteristic registration, on-machine measurement of characteristics, calculation of a characteristic position error matrix, allowance distribution result verification and tool path compensation. The invention has the beneficial effects that: the invention provides a margin optimization method for registering feature positions by using on-machine measurement data, aiming at the phenomenon that the characteristics of a pipe joint, a boss and the like on the outer surface of a casting casing are easy to have uneven margin during milling. The method can exert the automatic function of the five-axis numerical control machine tool to the maximum extent, reduce the frequency of manual intervention and intervention in the workpiece clamping process, and improve the overall machining efficiency of the casing on the premise of ensuring the homogenization of the machining allowance of the casting casing blank.
Description
Technical Field
The invention relates to the technical field of cast case blank allowance homogenization treatment in numerical control milling, in particular to a cast case blank machining allowance optimization method based on-machine measurement.
Background
In recent years, with the development of manufacturing technology in the field of aviation, the performance and design structure of an aircraft engine are continuously improved and improved, a new generation of high-performance engine adopts a large number of parts with complex integral thin-wall structures, and the thrust-weight ratio of the engine is obviously improved. At present, most parts of casings of aeroengines in China are precision cast blanks, and the machining characteristics are that characteristic elements in space are complex and the precision requirement is high. Therefore, the manufacturing and forming difficulty of the casing part is increased, wherein for the casting casing, the casting error caused by the thermal deformation in the casting process is often more than 1mm, which causes the problem of uneven distribution of machining allowance in the subsequent milling process of the characteristics such as bosses, pipe joints and the like on the surface of the casting casing, and the position alignment and allowance optimization of the characteristics are mainly performed by adopting a manual marking alignment mode at present, and the surface structure of the casting casing is as shown in fig. 1.
The blank of the casting machine box is formed by integral precision casting, the casting precision is difficult to control, the blank state is inconsistent, the position degree of the characteristics of a pipe joint, a boss and the like on the surface of part of the blank is greatly deviated from the theoretical position, further, the wall thickness of the pipe joint is thin due to the adoption of the traditional point location milling processing, the hole wall can penetrate under severe conditions, in the traditional processing, the processing deviation is adjusted manually by a commonly adopted method, the manual intervention degree of the method is high, the automatic function of a machine tool is not fully exerted, the part processing efficiency and the equipment utilization rate are influenced, and even the low-level quality problem can occur due to excessive manual participation.
Because casting errors of the casting process itself cause the casting errors of the features on the outer surface of the casing to exceed 1mm, currently, feature position alignment and machining allowance distribution are mainly carried out by field operators in a mode of marking and marking, so that the following problems can exist when the features such as bosses, pipe joints and the like on the surface of the casing are milled:
1. the scribing alignment precision is low, the distribution of machining allowance is uneven, and the requirement of the scribing alignment on the skill level of an operator is high;
2. the transformation of the processing coordinate system and the checking of the program need to be confirmed by process personnel, and the confirmation process is long in time consumption and low in efficiency;
3. in the alignment and machining process of the workpiece, the human intervention factors are more, and the machining risk is high.
Disclosure of Invention
The technical problem to be solved by the invention is to provide a method for optimizing the machining allowance of a casting case blank based on-machine measurement, aiming at the problems of uneven allowance distribution and the like in the feature milling machining of a casting case pipe joint, a boss and the like, the position optimal fitting calculation and the machining allowance distribution are carried out by utilizing the on-machine measurement result of the features, and then the calculated position rigid body is converted and acted on a machining tool path, so that the allowance of the part blank is more uniform.
In order to solve the technical problem, the invention provides a method for optimizing the machining allowance of a casting casing blank based on-machine measurement, which comprises the following steps of:
step 1: mounting a workpiece on a machine tool workbench, and setting a machining coordinate system according to the reference characteristics of a casing;
step 2: the position and the posture are adjusted by rotating around a fixed shaft and translating in a plane vertical to the fixed shaft, wherein the fixed shaft is a rotating shaft of the processing characteristic, and the rotating around the fixed shaft and the translating in the plane vertical to the fixed shaft are defined as two free-axis states;
and step 3: aiming at the position alignment and the allowance homogenization of the characteristics of the revolving body structure, the shape and position deviation of the characteristics can be fully and effectively reflected by arranging measuring points around the characteristics;
and 4, step 4: the minimum distance error between the measuring point and the theoretical model is used as an optimization objective function, and accurate registration of the measuring data point and the geometric model is realized under the condition of satisfying uniform distribution of allowance;
and 5: performing matrix inverse transformation A on the measurement path in the step 3-1Then measuring again to obtain a new measuring result, comparing the deviation between the actual measuring point and the theoretical model, and repeating the steps and performing iterative measurement if the deviation does not meet the requirement;
step 6: and (5) acting the position transformation matrix A meeting the allowance inspection in the step (5) on the machining cutter path, correcting and compensating the cutter path, and machining the surface characteristics of the casting case by using the compensated cutter path.
In one embodiment, the datum feature includes a datum face, a datum hole, and an angled hole.
In one embodiment, in step 3, the measurement path is post-processed and sent to a numerical control machine tool for on-machine measurement, and a result file corresponding to the theoretical measurement point can be obtained after the measurement is completed, where the data mainly includes actual coordinate values of the point.
In one embodiment, step 4 is to assume the real measuring point P obtained by on-machine measurementiHas a coordinate value of (x)i，yi，zi) Its corresponding theoretical measurement pointP′iIs (x'i，y′i，z′i) Then the distance between the measured point and the theoretical point can be expressed as:
di＝||APi-P′iif the position transformation matrix is a position transformation matrix to be solved, and the distance sum of squares is taken as a target function, a nonlinear 'least square' optimization problem is obtained:
the optimization variables are the translation (x, y) around a fixed rotation angle alpha and in a plane perpendicular to the fixed axis.
In one embodiment, the optimization variables (x, y, α) are calculated using a numerical solver, and the position transformation matrix can be expressed as:
6. the method of claim 5, wherein the calculated α is 0.295, x is 1.03, and y is-0.85.
In one embodiment, step 5 is specifically as follows: judging the distance deviation delta d between the measuring points and the surface of the theoretical model, if the distance deviation between any two points and the surface of the theoretical model is relatively uniform, namely, the distance deviation delta d is
For a set threshold, the blank allowance representing the characteristic becomes more uniform after transformation;
conversely, if the degree of uniformity of the distance deviation does not satisfy the set threshold value
Recalculating the position transformation matrix according to the measurement result of this time until the margin check meets the set threshold value
Or the repeated measurement times reach the set maximum times k.
Based on the same inventive concept, the present application also provides a computer device comprising a memory, a processor and a computer program stored on the memory and executable on the processor, the processor implementing the steps of any of the methods when executing the program.
Based on the same inventive concept, the present application also provides a computer-readable storage medium, on which a computer program is stored, which, when being executed by a processor, carries out the steps of any of the methods.
Based on the same inventive concept, the present application further provides a processor for executing a program, wherein the program executes to perform any one of the methods.
The invention has the beneficial effects that:
the invention provides a margin optimization method for registering feature positions by using on-machine measurement data, aiming at the phenomenon that the characteristics of a pipe joint, a boss and the like on the outer surface of a casting casing are easy to have uneven margin during milling. The method can exert the automatic function of the five-axis numerical control machine tool to the maximum extent, reduce the frequency of manual intervention and intervention in the workpiece clamping process, and improve the overall machining efficiency of the casing on the premise of ensuring the homogenization of the machining allowance of the casting casing blank.
Drawings
FIG. 1 is a schematic diagram of a casting gate model in the method for optimizing the machining allowance of a casting casing blank based on-machine measurement.
FIG. 2 is a schematic flow chart of the method for optimizing the machining allowance of the casting casing blank based on-machine measurement.
Fig. 3 is a schematic view of the pipe joint characteristics in the cast casing blank machining allowance optimization method based on-machine measurement according to the invention.
FIG. 4 is a schematic diagram of two free axes in the method for optimizing the machining allowance of a casting casing blank based on-machine measurement.
FIG. 5 is a schematic diagram of a measurement path in the method for optimizing the machining allowance of the casting casing blank based on-machine measurement.
FIG. 6 is a schematic diagram of the balance homogenization in the method for optimizing the machining balance of the casting casing blank based on-machine measurement.
FIG. 7 is a schematic diagram of the tool path compensation in the method for optimizing the machining allowance of the casting casing blank based on-machine measurement.
Detailed Description
The present invention is further described below in conjunction with the following figures and specific examples so that those skilled in the art may better understand the present invention and practice it, but the examples are not intended to limit the present invention.
The main steps of the blank machining allowance optimization method comprise the steps of preliminary clamping of a workpiece, freedom degree selection of feature registration, on-machine measurement of features, feature position error matrix calculation, allowance distribution result verification and tool path compensation, and the technical process is shown in figure 2.
Preliminarily clamping a workpiece: in this step, the workpiece is mounted on the machine tool table, and the operator sets the machining coordinate system based on the reference features (reference surface, reference hole, angular hole) of the casing.
Selecting the degree of freedom: the pipe joints, bosses, etc. on the surface of the casting casing are typically characterized as bodies of revolution, as shown in fig. 3. In order to uniformize the machining allowance of the characteristics, the position and the posture are adjusted mainly by rotating around a fixed shaft and translating in a plane vertical to the fixed shaft, wherein the fixed shaft is a rotating shaft of the machining characteristics, and the invention defines the rotating around the fixed shaft and the translating in the plane vertical to the fixed shaft as two free shaft states, as shown in fig. 4. Thus, when the matrix calculation is performed in the subsequent step 4, the position transformation matrix under the two free axes is calculated.
The characteristics are measured on the machine: aiming at the position alignment and the allowance homogenization of the structural features of the revolving body, the form and position deviation of the features can be fully and effectively reflected by arranging the measuring points around the features, a planning strategy for an on-machine measuring path with the measuring points uniformly distributed around the revolving body is designed by taking a pipe joint structure as an example, and the display and simulation of the measuring path are shown in fig. 5. And post-processing the measurement path, sending the post-processed measurement path to a numerical control machine tool for on-machine measurement, and obtaining a result file corresponding to the theoretical measurement point after the measurement is finished, wherein the data mainly comprises an actual coordinate value of the point.
Calculating a position transformation matrix: the minimum distance error between the measuring point and the theoretical model is used as an optimization objective function, accurate registration of the measured data point and the geometric model is realized under the condition that the allowance is uniformly distributed, and homogenization and optimization of characteristic machining allowances of a casing part pipe joint, a boss and the like are realized. Suppose an actual measurement point P obtained by on-machine measurementiHas a coordinate value of (x)i，yi，zi) Its corresponding theoretical measurement point P'iIs (x'i，y′i，z′i) Then the distance between the measured point and the theoretical point can be expressed as:
di＝||APi-P′iif the position transformation matrix is a position transformation matrix to be solved, and the distance sum of squares is taken as a target function, a nonlinear 'least square' optimization problem is obtained:
the optimized variables are the rotation angle alpha around the fixed axis and the translation (x, y) in the plane vertical to the fixed axis, and the optimized variables (x, y, alpha) can be calculated by using numerical solving tools such as Matlab and the like, so that the position transformation matrix can be expressed as:
in this example, α is calculated to be 0.295, x is calculated to be 1.03, and y is calculated to be-0.85.
Checking the allowance: performing matrix inverse transformation A on the measurement path in the step 3-1Then measuring again to obtain new measuring result, comparing the deviation between actual measuring point and theoretical model, that is, judging the distance deviation delta d between measuring point and theoretical model surface, if the distance deviation between any two points and theoretical model surface is relatively uniform, then there is new measuring result
For a set threshold, the stock allowance representing the feature becomes more uniform after the transformation. The present embodiment sets the threshold value
The process is as shown in the figure6, then executing the step 6 to perform tool path compensation; conversely, if the degree of uniformity of the distance deviation does not satisfy the set threshold value
Then according to the measurement result of this time, recalculating the position transformation matrix, and carrying out iterative measurement until the margin check meets the set threshold value
Or the number of repeated measurements reaches a set maximum number k, which is 5 in this embodiment. The present invention refers to the above-described process of repeated measurements as iterative measurements.
Tool path compensation: and (3) acting the position transformation matrix A meeting the allowance inspection in the step (5) on a machining cutter path, correcting and compensating the cutter path, and machining the pipe joint and boss characteristics on the surface of the casting casing by using the compensated cutter path to realize the uniform machining of the allowance of the part blank, wherein the cutter path compensation process is shown in fig. 7.
The above-mentioned embodiments are merely preferred embodiments for fully illustrating the present invention, and the scope of the present invention is not limited thereto. The equivalent substitution or change made by the technical personnel in the technical field on the basis of the invention is all within the protection scope of the invention. The protection scope of the invention is subject to the claims.
Claims (10)
1. A cast casing blank machining allowance optimization method based on-machine measurement is characterized by comprising the following steps:
step 1: mounting a workpiece on a machine tool workbench, and setting a machining coordinate system according to the reference characteristics of a casing;
step 2: the position and the posture are adjusted by rotating around a fixed shaft and translating in a plane vertical to the fixed shaft, wherein the fixed shaft is a rotating shaft of the processing characteristic, and the rotating around the fixed shaft and the translating in the plane vertical to the fixed shaft are defined as two free-axis states;
and step 3: aiming at the position alignment and the allowance homogenization of the characteristics of the revolving body structure, the shape and position deviation of the characteristics can be fully and effectively reflected by arranging measuring points around the characteristics;
and 4, step 4: the minimum distance error between the measuring point and the theoretical model is used as an optimization objective function, and accurate registration of the measuring data point and the geometric model is realized under the condition of satisfying uniform distribution of allowance;
and 5: performing matrix inverse transformation A on the measurement path in the step 3-1Then measuring again to obtain a new measuring result, comparing the deviation between the actual measuring point and the theoretical model, and repeating the steps and performing iterative measurement if the deviation does not meet the requirement;
step 6: and (5) acting the position transformation matrix A meeting the allowance inspection in the step (5) on the machining cutter path, correcting and compensating the cutter path, and machining the surface characteristics of the casting case by using the compensated cutter path.
2. The cast case blank machining allowance optimization method based on-machine measurement as claimed in claim 1, wherein the reference features comprise a reference surface, a reference hole and an angular hole.
3. The method for optimizing the machining allowance of the casting casing blank based on the on-machine measurement as claimed in claim 1, wherein in the step 3, the measurement path is post-processed and sent to a numerical control machine tool for on-machine measurement, and after the measurement is completed, a result file corresponding to a theoretical measurement point is obtained, wherein the data is mainly actual coordinate values of the point.
4. The method for optimizing the machining allowance of the cast casing blank based on the on-machine measurement as claimed in claim 1, wherein in the step 4, the actual measurement point P obtained by the on-machine measurement is assumediHas a coordinate value of (x)i，yi，zi) Its corresponding theoretical measurement point P'iIs (x'i，y′i，z′i) Then the distance between the measured point and the theoretical point can be expressed as:
di＝||APi-P′il, whereinA is a position transformation matrix to be solved, and then the 'sum of squares of distances' is used as an objective function, then a nonlinear 'least square' optimization problem is obtained:
the optimization variables are the translation (x, y) around a fixed rotation angle alpha and in a plane perpendicular to the fixed axis.
5. The method of claim 4, wherein the optimization variables (x, y, α) are calculated using a numerical solver, and the position transformation matrix is represented as:
6. the method of claim 5, wherein the calculated α is 0.295, x is 1.03, and y is-0.85.
7. The method for optimizing the machining allowance of the cast casing blank based on-machine measurement as claimed in claim 1, wherein the step 5 is as follows: judging the distance deviation delta d between the measuring points and the surface of the theoretical model, if the distance deviation between any two points and the surface of the theoretical model is relatively uniform, namely, the distance deviation delta d is
For a set threshold, the blank allowance representing the characteristic becomes more uniform after transformation;
on the contrary, if the distance deviation is not uniformMeet a set threshold
Recalculating the position transformation matrix according to the measurement result of this time until the margin check meets the set threshold value
Or the repeated measurement times reach the set maximum times k.
8. A computer device comprising a memory, a processor and a computer program stored on the memory and executable on the processor, characterized in that the steps of the method of any of claims 1 to 7 are implemented when the program is executed by the processor.
9. A computer-readable storage medium, on which a computer program is stored which, when being executed by a processor, carries out the steps of the method according to any one of claims 1 to 7.
10. A processor, characterized in that the processor is configured to run a program, wherein the program when running performs the method of any of claims 1 to 7.
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| CN113536488A (en) * | 2021-08-07 | 2021-10-22 | 西北工业大学 | Blank quality containment analysis and allowance optimization method based on registration algorithm |
| CN115213736A (en) * | 2022-07-22 | 2022-10-21 | 昆山西诺巴精密模具有限公司 | Cast part blank allowance homogenization processing method based on visual detection |
| CN116638061A (en) * | 2023-06-14 | 2023-08-25 | 广州市型腔模具制造有限公司 | Die casting size deformation control method for new energy automobile |
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