CN113050544A - Ultrasonic straight-blade knife machining composite material interference inspection method - Google Patents
Ultrasonic straight-blade knife machining composite material interference inspection method Download PDFInfo
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- CN113050544A CN113050544A CN202110249119.2A CN202110249119A CN113050544A CN 113050544 A CN113050544 A CN 113050544A CN 202110249119 A CN202110249119 A CN 202110249119A CN 113050544 A CN113050544 A CN 113050544A
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- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
- G05B19/4097—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by using design data to control NC machines, e.g. CAD/CAM
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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 discloses an ultrasonic straight-blade knife processing composite material interference detection method, which comprises the following steps: the method comprises the following steps: importing a part process model into CAM software, and reading the part process model to be processed; step two: constructing an equivalent substitute cutter of the ultrasonic straight-edged knife; step three: editing a processing operation program; step four: generating a processing track, and calculating an NC code file of a numerical control processing program; step five: performing machining simulation by using the NC code file obtained in the step four; step six: carrying out interference check and judgment, detecting the intersection of the tool and the workpiece according to the simulation result of the step five, namely whether the tool and the workpiece are interfered, and determining the interference position; measuring a machining result; step seven: according to the checking result of the sixth step, positioning the program segment which generates interference, and further modifying the program segment which causes the interference; step eight: and re-executing the step five on the modified NC codes until no interference exists in machining simulation. The invention can effectively improve the interference problem of the straight-edge cutter in the processing process.
Description
Technical Field
The invention belongs to the technical field of ultrasonic auxiliary processing, in particular relates to an interference detection method for ultrasonic processing of honeycomb composite parts in the field of aerospace, and particularly relates to an interference detection method for composite materials processed by an ultrasonic straight-edged tool.
Background
With the continuous development of equipment manufacturing industry and the diversification of market demands, the application range of ultrasonic auxiliary processing in the field of mechanical processing is continuously expanded, and the processing technology is mature day by day. The method is an ideal processing technology for the curved surface forming of composite material parts in the field of aerospace. Interference is one of the serious processing problems, both in the conventional numerical control processing and in the ultrasonic-assisted processing. The workpiece interferes with the cutter or the cutter bar, wherein the interference between the workpiece and the cutter can be divided into curvature interference and cutter bottom interference; the interference of the workpiece and the cutter bar is global interference. Interference in the machining process can cause workpiece damage and cutter abrasion if the interference is small, and can cause machine tool damage if the interference is large, so that the production cost is increased, and the production efficiency is reduced. Therefore, performing interference check and interference elimination before performing machining is an indispensable link.
The tools used for ultrasonic-assisted cutting are straight-edged tools and circular disc tools, which are completely different in shape from conventional milling cutters, and the tool shapes are both thin-edged. Because the process characteristics of the thin-blade-shaped cutter during machining are different from those of the traditional cutter, the interference situation of the thin-blade-shaped cutter is different from that of the traditional cutter in the actual machining process, and engineering personnel have difficulty in process planning and interference detection. Since the current commercial CAD/CAM software does not provide the programming function for thin-edged tools, and its interference detection function. For some large and complex parts, which contain a large number of free-form surfaces and complex structures, engineers often need to carefully observe the tool path in CAD/CAM software to check interference, and the engineers need to spend a large amount of time to check interference parts, so that the repeated workload is large, the working efficiency is low, and the production efficiency and the economic benefit of enterprises are greatly influenced.
Disclosure of Invention
Aiming at the defects in the prior art, the invention provides an interference detection method for composite material processed by an ultrasonic straight-edged tool, which solves the problem of interference between a tool and a workpiece, namely over-cutting, in the processing process of the conventional ultrasonic straight-edged tool.
The invention adopts the following technical scheme:
an ultrasonic straight-blade knife processing composite material interference inspection method comprises the following steps:
the method comprises the following steps: and (4) importing a part process model into the CAM software, and reading the part process model to be processed.
Step two: and constructing an equivalent substitute cutter of the ultrasonic straight-edged cutter.
Step three: and editing the processing operation program.
Step four: and generating a machining track, and calculating an NC code file of the numerical control machining program.
Step five: and D, performing machining simulation by using the NC code file obtained in the step four.
Step six: carrying out interference check and judgment, detecting the intersection of the tool and the workpiece according to the simulation result of the step five, namely whether the tool and the workpiece are interfered, and determining the interference position; and measuring the processing result.
Step seven: and according to the checking result of the step six, positioning the program segment which generates the interference, and further modifying the program segment which causes the interference.
Step eight: and re-executing the step five on the modified NC codes until no interference condition occurs in machining simulation.
Further, the cutter shape of the ultrasonic straight-edged knife is as follows: the straight-edge cutter is a four-edge surface centrosymmetric cutter similar to a dagger structure, the front and rear blades are symmetrically distributed and can be used for processing, and the straight-edge cutter needs to rotate 180 degrees along the knife shaft for cutting after processing a certain distance so as to ensure that the two blades need to be uniformly worn.
Further, the ultrasonic straight-edged knife replaces the equivalent tool in editing the machining operation program: the straight-edged knife is a dagger type non-rotating knife, and the current commercial CAD/CAM software does not provide programming functions for such a knife. Therefore, in the second step, the ultrasonic straight-edged cutter is equivalent to a ball-end milling cutter, wherein the total length of the cutter and the length of the cutting edge in the axial direction are consistent with the length of the straight-edged cutter, and the diameter of the ball and the diameter of the cutter are equal to the thickness H of the straight-edged cutter.
Further, in editing geometric drive information, an inclination angle needs to be added to the cutter axis vector: the inclination angle is controlled between 30-40 degrees, so that a certain downward pressure is provided for the part during machining, and the part is prevented from being pulled up during high-speed cutting.
Furthermore, the machining result measured in the step six plays a guiding role in modifying the interference section program in the step seven.
Further, processing simulation is carried out by using Vericut numerical control simulation software.
Further, in the second step, for an an ancient type of spoon-head type non-rotating cutter of the ultrasonic straight-edge cutter, the cutter information includes cutter length L, cutter edge angle β, cutter thickness H and edge width b. When a machining code is edited in CAM software by combining a unique machining process of ultrasonic auxiliary machining, a proper cutter needs to be selected for equivalent replacement. The ultrasonic straight-edged cutter is equivalent to a ball-end milling cutter, wherein the total length of the cutter and the length of the cutting edge are consistent with the length of the straight-edged cutter in the axial direction, and the diameter of the ball and the diameter of the cutter take the thickness H of the straight-edged cutter.
Further, in the sixth step, an automatic-comparison function provided by Vericut is applied, the model after the simulation processing and the design model are superposed together for accurate comparison, the over-cut and under-cut positions left on the workpiece are automatically identified and displayed, and the program line of the situation is displayed. Therefore, the machined part can meet the initial setting requirement, the machining reliability is improved, and the program segment is convenient to modify subsequently.
And further, in the seventh step, the tool path with interference is translated, the normal direction of the center of the tool path section is selected as the moving direction, and the translation distance refers to an 'automatic-comparison report' list.
The invention aims at the interference problem of the straight-edge cutter in the ultrasonic auxiliary processing process; in the planning process of the machining process, the ultrasonic straight-edge cutter is equivalent to a slender milling cutter in consideration of the special cutter shape of the straight-edge cutter, so that the convenience of machining simulation is improved. The visibility is good, the generated tool path and the simulation machining result can be visually checked, and the positioning of the interference program segment and the subsequent selected modification strategy are facilitated; the flexibility of operation is good, and according to the interference condition appearing in the simulation result, an engineer can directly modify the tool path of the interference section, so that the modification operation is simple; the invention can effectively improve the interference problem of the straight-edge cutter in the processing process.
Drawings
FIG. 1 is a flow chart of the operation of a preferred embodiment of the present invention;
fig. 2 is a structural diagram of the ultrasonic straight-edge cutter in the embodiment, and the cutter information includes cutter length L, cutter edge angle β, cutter thickness H and edge width b;
FIG. 3 is an equivalent alternative schematic view of the ultrasonic straight-edged blade of the present embodiment;
fig. 4 is a schematic view showing the case where the interference occurs in the present embodiment, and the blade portion is over-cut.
Detailed Description
The invention is further illustrated by the following figures and examples.
As shown in fig. 1 to 4, the method for detecting the interference of the composite material processed by the ultrasonic straight-edged tool in the embodiment includes the following steps:
the method comprises the following steps: and (4) importing a part process model into the CAM software, and reading the part process model to be processed.
Step two: and constructing an equivalent substitute cutter of the ultrasonic straight-edged cutter.
Step three: and editing the processing operation program.
Step four: and generating a machining track, and calculating an NC code file of the numerical control machining program.
Step five: and D, performing machining simulation by using the NC code file obtained in the step four.
Step six: carrying out interference check and judgment, detecting the intersection of the tool and the workpiece according to the simulation result of the step five, namely whether the tool and the workpiece are interfered, and determining the interference position; and measuring the processing result.
Step seven: and according to the checking result of the step six, positioning the program segment which generates the interference, and further modifying the program segment which causes the interference.
Step eight: and re-executing the step five on the modified NC codes until no interference condition occurs in machining simulation.
In the present embodiment, the numerical control machining simulation software used is Vericut.
In this embodiment, Vericut is a set of powerful numerical control machining simulation software, and is composed of an NC program verification module, a machine motion simulation module, an optimized path module, a multi-axis module, a high-level machine feature module, an entity module, a CAD/CAM interface, and other modules. The simulation device can simulate the numerical control machining process of various machining equipment such as a numerical control milling machine, a numerical control lathe, a machining center, a multi-axis machine tool and the like, can simulate a tool location file, and can also simulate an NC program of CAD/CAM post-processing, the simulation process comprises program verification, analysis, machine tool simulation, optimization, model output and the like, and the simulation effect is very vivid. Importantly, the results can be stored at any stage in the simulation process and can be directly applied to the program processing technology. The analysis of the over-cut amount and the residual amount has a very accurate data report.
In the third step, the UG used in combination is specifically operated as follows: 1. creating a cutter: selecting a tool subtype as 'ball end milling cutter', and setting tool parameters: the length of the cutting edge is L, and the diameter of the ball is H; 2. creating a geometric body: selecting a geometry type of 'WORKPIECE', determining parameters such as a machine tool coordinate system, a safety distance and the like, and notably, in the subsequent simulation machining operation, setting of the machine tool coordinate system needs to be consistent with the parameters; 3. a creation process: selecting a procedure subtype 'variable profile milling'; the processing method selects a 'curved surface', the designated driving geometric body is set as a curved surface to be processed, and the cutting mode is selected to reciprocate; selecting 'appointed vector' for the projection vector, and selecting the vertical downward direction of the curved surface to be processed; the cutter shaft selects a "relative vector" which is set to be a vertically downward direction of the curved surface to be processed, and the inclination data is set to be 30 °.
The used cutter is an an ancient type of spoon-head type non-rotating cutter such as an ultrasonic straight-edge cutter, and the cutter information comprises cutter length L, cutter edge angle beta, cutter thickness H and edge width b, which are shown in FIG. 2. The straight-edged cutters are equivalent to ball-end milling cutters, wherein the total length of the cutters and the length of the cutting edges are consistent with the length of the straight-edged cutters in the axial direction, and the diameter of the ball and the diameter of the cutters are equal to the thickness H of the straight-edged cutters, as shown in fig. 3.
In step four, post-processing operation is performed on the generated tool paths. And setting a corresponding post processor according to the numerical control machine tool used for actual machining, and generating an NC code file of the numerical control machining program.
In step five, the virtual numerical control machine tool model selected in the embodiment is a five-axis gantry machine tool. In combination with Vericut used, the specific operations include: setting a control system for simulation; creating a simulation cutter; arranging a tool clamp, a cutting blank and the like; calling a numerical control program; starting simulation and analysis processing: and resetting the model to enable each configured item of information to take effect, and starting the simulation process.
Wherein, the type of the neutron in the cutter is created and the cutter is selected, and the cutter is drawn according to the structure of the straight cutter, as shown in figure 2.
And step six, measuring, comparing and analyzing the parts during and after machining, and comprehensively analyzing the machining process. Referring to the report generated by the "auto-compare" function, the modification of the interference segment program in step seven is guided.
In this embodiment, a typical interference situation occurring during the simulation is an overcutting of the blade portion, as shown in fig. 4. And measuring, comparing and analyzing the parts during and after machining, and comprehensively analyzing the machining process. The interference segment tool path is moved up as a whole here with reference to a report generated by the "auto-compare" function.
The specific embodiments described herein are merely illustrative of the spirit of the invention. Various modifications or additions may be made or substituted by those skilled in the art without departing from the spirit or ambit of the invention as defined in the appended claims.
Claims (6)
1. The method for detecting the interference of the composite material machined by the ultrasonic straight-edged tool is characterized by comprising the following steps of:
the method comprises the following steps: importing a part process model into CAM software, and reading the part process model to be processed;
step two: constructing an equivalent substitute cutter of the ultrasonic straight-edged knife;
step three: editing a processing operation program;
step four: generating a processing track, and calculating an NC code file of a numerical control processing program;
step five: performing machining simulation by using the NC code file obtained in the step four;
step six: carrying out interference check and judgment, detecting the intersection of the tool and the workpiece according to the simulation result of the step five, namely whether the tool and the workpiece are interfered, and determining the interference position; measuring a machining result;
step seven: according to the checking result of the sixth step, positioning the program segment which generates interference, and further modifying the program segment which causes the interference;
step eight: and re-executing the step five on the modified NC codes until no interference condition occurs in machining simulation.
2. The interference detection method for composite material processed by the ultrasonic straight-edged tool as claimed in claim 1, wherein the shape of the tool of the ultrasonic straight-edged tool is as follows: the four cutting edges are centrosymmetric, the front and the rear cutting edges are symmetrically distributed and can be used for processing, and after a certain distance is processed, the cutting tool needs to rotate 180 degrees along the cutter shaft to cut so as to ensure that the two cutting edges are uniformly worn.
3. The interference detection method for the composite material machined by the ultrasonic straight-edged tool as claimed in claim 1 or 2, wherein in the second step, the equivalent tool replaced by the ultrasonic straight-edged tool in the editing and machining operation program is as follows: the ultrasonic straight-edged cutter is equivalent to a ball-end milling cutter, wherein the total length of the cutter and the length of the cutting edge are consistent with the length of the straight-edged cutter in the axial direction, and the diameter of a sphere and the diameter of the cutter are equal to the thickness H of the straight-edged cutter.
4. The interference detection method for composite material processed by the ultrasonic straight-edged tool as claimed in claim 1, wherein in the third step, in editing the geometric drive information, an inclination angle is added to the tool axis vector: the inclination angle is controlled between 30-40 degrees.
5. The interference detection method for composite material machined by the ultrasonic straight-edged tool as claimed in claim 1, wherein in the fifth step, machining simulation is performed by using vericut numerical control simulation software.
6. The method for detecting the interference of the composite material machined by the ultrasonic straight-edged tool as claimed in claim 1, wherein in the seventh step, the tool path subjected to interference is translated, the normal direction of the center of the tool path is selected as the moving direction, and the translation distance refers to an automatic-comparison report list.
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Patent Citations (6)
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Application publication date: 20210629 |