CN113468663B - Machining method and design system for micro-texture on surface of stamping die - Google Patents
Machining method and design system for micro-texture on surface of stamping die Download PDFInfo
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Abstract
The invention discloses a processing method and a design system of a micro-texture on the surface of a stamping die, which are used for acquiring three-dimensional point cloud data of the stamping die; calculating to obtain the characteristic parameters of the three-dimensional topography of the surface of the stamping die according to the three-dimensional point cloud data; carrying out boundary characteristic division according to the three-dimensional morphology characteristic parameters, and determining the boundary characteristic division parameters of the surface of the stamping die; obtaining a friction wear area division parameter according to the boundary characteristic division parameter and the three-dimensional shape characteristic parameter; obtaining die stamping simulation data, carrying out orthogonal polynomial regression design on stamping die performance parameters and micro-texture design parameters, and determining the corresponding relation between the performance parameters and the micro-texture parameters; dividing parameters according to the friction and wear area, and combining the corresponding relation between the performance parameters and the micro-texture parameters to obtain the micro-texture processing design parameters of the surface of the stamping die; and processing the micro texture on the surface of the stamping die according to the micro texture processing design parameters. The surface friction characteristic and the material flow of the stamping die processed by the method are actively optimized.
Description
Technical Field
The invention relates to the field of stamping die design and manufacture, in particular to a processing method and a design system of a micro-texture on the surface of a stamping die.
Background
Stamping is an important process in automobile production, the quality of a stamped and formed part is determined by a stamping die, and the surface characteristics of the stamping die have important influence on the service life of the die and the quality of the formed part. In the working process, the contact area of the stamping die is large, and in addition, the deformation of the plate is accompanied with huge deformation force in the flanging process, so that severe friction is easy to occur between the concave-convex die and the plate, the die is easy to wear due to long-time friction, and the service life of the die is shortened. And if the structure of part of the die is unreasonable, the plate material in the area is abnormal in flow, so that the problems of thinning, folding, resilience, poor uniformity and the like of the plate material occur.
The existing die surface treatment technologies mainly comprise carburizing, nitriding, chromium plating, laser cladding, TD, PVD, CVD and the like, and the traditional die surface strengthening technologies are mainly used for improving the surface hardness of a die and further prolonging the service life of the die, and cannot optimize the frictional wear characteristic of the surface of the die, improve the material flow condition in the stamping forming process and improve the quality of a formed part.
The conventional mold surface treatment technology has various disadvantages: the waste gas combustion of the carburizing technology influences the environment, and the treated die is easy to have the problems of surface intergranular oxidation and the like; the nitriding technology is easy to generate a loose and porous surface compound layer, and the brittleness is high; the waste liquid of the chromium plating technology can pollute the environment and is not suitable for high-strength plates; in the laser cladding technology, residual stress can be generated in a cladding layer in the cooling process, and special materials are lacked to adapt to all dies; deformation exists in TD coating treatment, and secondary heating in the later period easily causes deformation or cracking of a formed part; the heat resistance of a plating layer of the PVD physical vapor deposition technology is generally poor, and the cost is high; the CVD chemical vapor deposition reaction temperature is high, so that the mould is easy to deform, and the interface of a deposition layer is easy to diffuse.
In recent years, the micro-texture technology is developed rapidly, the tribology performance between friction pairs can be improved, the micro-texture technology is applied to the fields of tool antifriction, mechanical seal, bearing lubrication and the like, and the micro-texture technology has a wide application prospect in the field of die surface treatment. The processing of micro-pits and micro-raised textures is carried out on the complex curved surface of the stamping die, the micro-textures which are adaptive to the specific type, specific morphology, specific distribution and specific parameters of the region are processed in the specific curved surface region, the friction characteristic distribution and the material flow property of the surface of the die can be actively controlled and optimized, the service life of the die is prolonged, the quality of a formed part is improved, and the problems of plate thinning, wrinkling, resilience, poor uniformity and the like are avoided or reduced.
At present, in the research field, due to the lack of simulation stamping equipment, a stamping simulation test is difficult to develop, so the research results of the microtexture technology in the field of die surface treatment are less, and the actual stamping production of the microtextured die is not developed although the stamping equipment is not lacked in the actual production. Meanwhile, the automation and intelligence level of processing design in the field of mold surface treatment is low, the design process and the design method are more traditional, the design efficiency is not high, and an intelligent design system capable of improving the mold surface treatment efficiency is lacked.
Disclosure of Invention
Aiming at the defects in the prior art, the invention aims to provide a processing method and a design system of a micro texture on the surface of a stamping die, and the friction characteristic and the material flow of the processed surface of the stamping die are actively optimized.
In order to achieve the purpose, the invention is realized by the following technical scheme:
in a first aspect, an embodiment of the present invention provides a method for processing a microtexture on a surface of a stamping die, including:
carrying out three-dimensional scanning on the stamping die to obtain the integral three-dimensional point cloud data of the stamping die;
calculating to obtain the characteristic parameters of the three-dimensional topography of the surface of the stamping die according to the three-dimensional point cloud data;
dividing boundary characteristics according to the three-dimensional feature characteristic parameters, and determining the boundary condition of each area on the surface of the stamping die;
dividing friction wear areas of all areas on the surface of the stamping die according to the boundary characteristic dividing condition and the three-dimensional shape characteristic parameters;
obtaining die stamping simulation data, carrying out orthogonal polynomial regression design on stamping die performance parameters and micro-texture design parameters in a simulation result, and determining the corresponding relation between the performance parameters and the micro-texture parameters;
according to the dividing condition of the friction and wear area on the surface of the stamping die, combining the corresponding relation of the performance parameter and the micro-texture parameter, carrying out micro-texture design on each friction and wear area to obtain the micro-texture processing design parameter on the surface of the stamping die; and processing the micro texture on the surface of the stamping die according to the micro texture processing design parameters.
As a further implementation mode, the stamping die is repeatedly scanned for multiple times, normal vectors of all points are calculated through a normal vector calculation algorithm, and curvatures of all points are calculated through a curvature calculation algorithm; and fitting the calculation result to obtain the curvature and normal vector data of each point on the surface of the stamping die.
As a further implementation mode, a laser scanning device emits a laser spot or linear laser to the stamping die by a triangular distance measurement method, the distance from the surface of the stamping die to the laser scanning device is measured, and the three-dimensional point cloud data of the whole stamping die is obtained.
In a further embodiment, the boundary features are identified and divided to obtain abrupt and gradual boundaries of each region of the surface of the press mold.
As a further implementation mode, according to boundary characteristics and three-dimensional morphology parameters of each region, a male die and a female die are separated to divide a friction wear region, and firstly, according to a stamping model input in advance, the surface of the die is divided into a contact region and a non-contact region; secondly, dividing a contact area into a fillet area, a vertical area and other areas according to each abrupt change boundary and a gradual change boundary of the surface of the die and the curvature and normal vector of each point; and finally, classifying the fillet area according to the curvature of the fillet area and the normal vector parameter.
As a further implementation mode, the fillet area and the vertical surface area of the male die are processed with micro-convex textures, the fillet area and the vertical surface area of the female die are processed with micro-concave textures, and reasonable micro-texture parameters are respectively set for each level of the fillet area and the vertical surface area of the male die and the female die according to the corresponding relation of comprehensive performance parameters and micro-texture parameters.
The embodiment of the invention also provides a processing design system of the micro texture on the surface of the stamping die, which comprises:
the data acquisition system is used for acquiring three-dimensional point cloud data of the whole stamping die;
the three-dimensional feature parameter calculation system is used for calculating and obtaining three-dimensional feature parameters of the surface of the stamping die according to the three-dimensional point cloud data;
the boundary characteristic dividing system is used for dividing boundary characteristics according to the three-dimensional morphology characteristic parameters and determining boundary characteristic dividing parameters of all areas on the surface of the stamping die;
the friction and wear area division expert system is used for dividing the friction and wear area of each area on the surface of the stamping die according to the boundary characteristic division parameter and the three-dimensional shape characteristic parameter to obtain a friction and wear area division parameter;
the stamping simulation calculation system is used for acquiring stamping simulation data of the die, carrying out orthogonal polynomial regression design on stamping die performance parameters and micro-texture design parameters in a simulation result, and determining the corresponding relation between the performance parameters and the micro-texture parameters;
and the micro-texture design expert system is used for carrying out micro-texture design on each friction and wear area according to the friction and wear area division parameters and combining the corresponding relation between the performance parameters and the micro-texture parameters to obtain the micro-texture processing design parameters of the surface of the stamping die.
As a further implementation manner, the three-dimensional feature parameter calculation system includes a normal vector calculation module and a curvature calculation module, the normal vector calculation module is used for calculating normal vectors of the regions on the surface of the stamping die, and the curvature calculation module is used for calculating curvatures of the regions on the surface of the stamping die.
As a further embodiment, the frictional wear area division expert system includes:
the friction wear area division knowledge base is used for receiving and storing expert knowledge of the division of the friction wear area on the surface of the stamping die;
the friction wear area division database is connected with the knowledge base and the interpretation mechanism and is used for storing data, states, known facts and reasoning facts related to the division of the friction wear area of the die;
the inference machine is used for solving the current problem according to the three-dimensional morphology characteristic parameters and the boundary characteristic parameter data and the knowledge in the knowledge base and the inference strategy of forward inference to obtain friction wear area division parameter data;
the explaining mechanism is connected with the inference machine and the system interface and is used for explaining the solving process;
the knowledge acquisition mechanism is connected with the inference machine and the knowledge base and is used for modifying and perfecting the knowledge base;
and the system interface is connected with the knowledge base and used for realizing the bidirectional information exchange with a user or a design system.
As a further embodiment, the microtexture design expert system comprises:
the microtexture design knowledge base is used for receiving and storing microtexture design expert knowledge;
the microtexture design database is connected with the knowledge base and the interpretation mechanism and is used for storing data, states, known facts and reasoning facts related to microtexture design;
the inference machine is used for solving the current problem according to the friction wear area division parameters, the performance parameters and the micro-texture parameter corresponding relation data, knowledge in a knowledge base and an inference strategy of forward inference to obtain micro-texture design parameter data;
the explaining mechanism is connected with the inference machine and the system interface and is used for explaining the solving process;
the knowledge acquisition mechanism is connected with the inference machine and the knowledge base and is used for modifying and perfecting the knowledge base;
and the system interface is connected with the knowledge base and used for realizing the bidirectional information exchange with a user or a design system.
The beneficial effects of the above-mentioned embodiment of the present invention are as follows:
(1) the micro-pit texture can store abrasive dust and lubricating oil, reduce friction, resist abrasion, reduce the friction force on the surface of the die, effectively improve the lubricating property of the die and promote the material to flow; the micro-convex texture can increase the friction coefficient of a contact interface, promote the material flow and reduce the maximum reduction rate of the plate. According to the surface structure characteristics of the stamping die, the micro-texture which is adaptive to the specific type, specific morphology, specific distribution and specific parameters of the area is processed in different areas, the friction characteristic distribution and the material flow property of the surface of the die can be actively controlled and optimized, the friction reducing and wear resisting effects and the material flow improving effects of the micro-texture are maximized, the service life of the die is prolonged, the quality of a formed part is improved, and the problems of plate thinning, wrinkles, resilience, poor uniformity and the like are avoided or reduced.
(2) The invention realizes the characteristic adaptive processing of the micro-texture on the surface of the die through an intelligent design system, converts the three-dimensional point cloud data of the die into the micro-texture processing parameters with characteristic adaptation by means of seven modules such as a data acquisition system, a soft CPU system, a three-dimensional appearance characteristic parameter calculation system, a boundary characteristic division system, a friction and wear area division expert system, a stamping simulation calculation system, a micro-texture design expert system and the like, can greatly improve the design efficiency, liberates a designer from repetitive labor, simultaneously can store the design experience in the system and improve the standardization level of the die design.
(3) The micro-texture is processed on the surface of the stamping die, the dimension of the micro-texture is in a micron order, the influence on the overall appearance of the surface of the stamping die is avoided, and compared with other die surface processing methods, the influence on the shape precision, the size precision and the position precision of the stamping surface can be controlled to the minimum degree.
Drawings
The accompanying drawings, which are incorporated in and constitute a part of this specification, are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification, illustrate exemplary embodiments of the invention and together with the description serve to explain the invention and not to limit the invention.
FIG. 1 is a diagram of a friction wear zone division expert system in accordance with one or more embodiments of the present invention;
FIG. 2 is a microtexture design expert system component diagram in accordance with one or more embodiments of the present invention;
FIG. 3 is a diagram of a friction wear zone partitioning expert system knowledge base in accordance with one or more embodiments of the present invention;
FIG. 4 is a flow diagram of inference engine reasoning in accordance with one or more embodiments of the present invention;
FIG. 5 is a block diagram of a microtexture design expert system knowledge base in accordance with one or more embodiments of the invention;
FIG. 6 is a soft CPU data flow diagram in accordance with one or more embodiments of the present invention;
FIG. 7 is a flow diagram of a normal vector calculation algorithm in accordance with one or more embodiments of the present invention;
FIG. 8 is a flow diagram of a curvature calculation algorithm in accordance with one or more embodiments of the present invention;
FIG. 9 is a flow diagram of a frictional wear area determination in accordance with one or more embodiments of the present disclosure;
FIG. 10 is a graphical depiction of a topographical feature of an exemplary frictional wear area in accordance with one or more embodiments of the present invention;
FIG. 11 is a flow diagram of a design of an orthogonal polynomial regression experiment to determine a correspondence between performance parameters and microtexture parameters in accordance with one or more embodiments of the present disclosure;
FIG. 12 is a general flow diagram of a design system according to one or more embodiments of the invention;
FIG. 13(a) is a drawing punch frictional wear zone division of the present invention according to one or more embodiments;
FIG. 13(b) is a drawing die frictional wear zone division of the present invention according to one or more embodiments;
FIG. 14 is a flow diagram of a method of processing according to one or more embodiments of the invention.
Detailed Description
The first embodiment is as follows:
the embodiment provides a processing method of a micro-texture on the surface of a stamping die, which comprises the following steps:
carrying out three-dimensional scanning on the stamping die to obtain the integral three-dimensional point cloud data of the stamping die;
calculating three-dimensional feature characteristic parameters such as curvature, normal vector and the like of each area on the surface of the stamping die according to the three-dimensional point cloud data;
dividing boundary characteristics according to the three-dimensional feature characteristic parameters, and determining the boundary condition of each area on the surface of the stamping die;
dividing friction wear areas of all areas on the surface of the stamping die according to the boundary characteristic dividing condition and the three-dimensional shape characteristic parameters;
carrying out die stamping simulation, carrying out orthogonal polynomial regression design on the performance parameters of the stamping die and the design parameters of the microtexture in the simulation result, and determining the corresponding relation between the performance parameters capable of reflecting the service life of the die and the quality of a formed part and the microtexture parameters;
and according to the dividing condition of the friction and wear area on the surface of the stamping die, combining the corresponding relation of the performance parameter and the micro-texture parameter, carrying out micro-texture design on each friction and wear area, and obtaining the micro-texture processing design parameter on the surface of the stamping die.
And (3) processing micro texture with specific parameters on the surface of the stamping die by a proper processing method (such as laser etching processing).
Specifically, as shown in fig. 14, the method includes the following steps:
(1) the laser three-dimensional scanner (or other equipment suitable for scanning large-area complex curved surfaces) emits laser spots or linear lasers to the stamping die by a triangular distance measurement method (or other suitable methods), and a plurality of detectors measure the distance from the surface of the stamping die to the laser three-dimensional scanner to obtain the integral three-dimensional point cloud data of the stamping die. The three-dimensional point cloud data is imported into the design system through the data acquisition system in an STL format and then transmitted to the three-dimensional feature characteristic parameter calculation system to obtain characteristic parameters such as curvatures, normal vectors and the like of different areas through program calculation. And repeating the scanning for 3-6 times, after point cloud data of each time is imported, calculating normal vectors of all points through an algorithm shown in fig. 7, calculating curvatures of all points through an algorithm shown in fig. 8, and finally fitting all calculation results to obtain more accurate curvatures and normal vector data of all points on the surface of the stamping die.
(2) And transmitting the three-dimensional feature parameter data such as curvature, normal vector and the like obtained from the three-dimensional feature parameter calculation system to a boundary feature division system, and identifying and dividing boundary features to obtain all abrupt and gradual change boundaries of the surface of the stamping die. The mutation boundary is a normal vector mutation point, and different normal planes exist on two sides of the mutation boundary, so that normal vectors on the two sides are different; the gradual change boundary is a curvature mutation point, and the two sides of the gradual change boundary have the same normal plane, so the normal vectors are the same, but the curvatures of the two sides are different.
The method for determining the mutation boundary comprises the following steps: determining adjacent triangular meshes and adjacent vertexes of each point, calculating a normal vector of each point according to the normal vector weighted average of the adjacent triangular meshes, calculating a normal included angle between each point and the adjacent vertexes, taking the maximum value as a normal angle of the point, summing and averaging the normal angles of each point to serve as a threshold, comparing the normal angle of each point with the threshold, setting the threshold according to the characteristics to be extracted after preliminarily extracting the characteristic points, obtaining all normal vector mutation points of the three-dimensional point cloud data, wherein the set of the normal vector mutation points in the same region is a mutation boundary.
The gradual change boundary determining method comprises the following steps: determining adjacent triangular meshes and adjacent vertexes of each point, calculating a normal vector of each point according to the normal vector weighted average of the adjacent triangular meshes, calculating the curvature of each point, determining the curvature change expectation and the standard deviation of each point and the adjacent vertexes of each point, comparing the curvature change expectation and the standard deviation of each point with a threshold value set according to needs, acquiring all curvature mutation points of the three-dimensional point cloud data, and after the determined mutation boundary points are eliminated, the set of the residual curvature mutation points in the same region is the gradual change boundary.
(3) And transmitting three-dimensional feature parameter data such as curvature and normal vector and the like obtained in the three-dimensional feature parameter calculation system and boundary feature division parameter data obtained in the boundary feature division system to a friction and wear region division expert system, and dividing the male die and the female die into friction and wear regions according to the boundary features and the three-dimensional feature parameters of the regions.
Firstly, dividing the surface of a die into a contact area and a non-contact area according to a stamping model input in advance, wherein the contact area is an area on the surface of the die, which is in contact with a plate material in the stamping process, and the non-contact area is an area on the surface of the die, which is not in contact with the plate material in the stamping process.
Secondly, dividing a contact area into a fillet area, a vertical surface area and other areas according to each abrupt change boundary, a gradual change boundary and the curvature and normal vector of each point on the surface of the die, wherein the fillet area is generally an area surrounded by the two gradual change boundaries, the curvature of the fillet area is generally kept unchanged in the fillet area at the same level, and the normal vector direction of the fillet area is continuously changed; the vertical surface area is an area surrounded by two gradual change boundaries or an area surrounded by two abrupt change boundaries or an area surrounded by an abrupt change boundary and a gradual change boundary, the curvature of the vertical surface area is zero, and the direction of a normal vector is kept unchanged; the areas other than the fillet area and the facade area are other areas.
And finally, classifying the fillet area into 1-5 grades according to the curvature of the fillet area and the normal vector parameter, wherein the minimum curvature of the 1 grade is the most gentle, the rise and fall of the curved surface are smaller, the maximum curvature of the 5 grade is the most steep, and the rise and fall of the curved surface are larger. The friction and wear area determination flowchart is shown in fig. 9, and the typical morphology and feature division of the friction and wear area is shown in fig. 10.
(4) An orthogonal polynomial regression design experiment is applied to the processed stamping die, actual stamping is carried out, the relationship between performance parameters such as the friction coefficient, the abrasion loss, the plate thinning rate and the like, which can reflect the service life of the die and the quality of a formed part, and microtexture parameters such as the shape, the height (micro-protrusion), the depth (micro-pit), the diameter, the transverse and longitudinal spacing, the height-diameter ratio (micro-protrusion), the depth-diameter ratio (micro-pit), the area occupancy, the connectivity coefficient and the like, is obtained, and a flow chart of the corresponding relationship between the performance parameters and the microtexture parameters is obtained through the orthogonal polynomial regression experiment design and is shown in fig. 11.
The performance parameters and the microtexture parameters are imported through a data acquisition system in a numerical relationship mode and then transmitted to a microtexture design expert system. And receiving the friction and wear area division parameters transmitted by the friction and wear area division expert system, and the corresponding relation between the comprehensive performance parameters and the micro-texture parameters, and designing the micro-texture parameters of each friction and wear area to obtain the micro-texture design parameters.
The specific design criteria are as follows: the micro-convex texture is processed in the convex die fillet area and the convex die elevation area, and the reasonable parameters of shape, height, diameter, transverse and longitudinal spacing, height-diameter ratio, area occupancy and the like are respectively set for the fillet area and the convex die elevation area of 1-5 levels according to the corresponding relation of comprehensive performance parameters and micro-texture parameters, so that the friction of each fillet area and each convex die elevation area is optimally increased, the capability of driving the plate to flow is optimized, the plate thinning rate is optimally reduced, and the best effects of prolonging the service life of a die and optimizing the forming performance of the plate are achieved.
And processing micro-pit textures in the fillet area and the vertical face area of the female die, and respectively setting parameters such as reasonable shape, depth, diameter, transverse and longitudinal spacing, depth-diameter ratio, area occupancy, connectivity coefficient and the like for the fillet area and the vertical face area of 1-5 levels according to the corresponding relation of comprehensive performance parameters and micro-texture parameters, so that the friction of each fillet area and vertical face area is optimally reduced, the capability of driving the plate to flow is optimized, the plate thinning rate is optimally reduced, the service life of the die is prolonged, and the optimal effect of optimizing the forming performance of the plate is achieved.
(5) And transmitting and exporting micro-texture parameter data such as the shape, the height (micro-protrusion), the depth (micro-pit), the diameter, the transverse and longitudinal spacing, the height-diameter ratio (micro-protrusion), the depth-diameter ratio (micro-pit), the area occupancy, the connectivity coefficient and the like of the micro-texture obtained in the micro-texture design expert system, determining laser processing parameters such as the optimal laser power, the optimal repetition frequency, the optimal scanning speed and the like according to the micro-texture design parameters, selecting a reasonable laser (nanosecond/picosecond/femtosecond), and processing the surface of the die (or selecting a proper processing method except the laser processing).
Example two:
the embodiment provides a system for processing and designing micro-texture on the surface of a stamping die, which comprises:
the data acquisition system is used for acquiring three-dimensional point cloud data of the whole stamping die;
the three-dimensional feature parameter calculation system is used for calculating and obtaining three-dimensional feature parameters of the surface of the stamping die according to the three-dimensional point cloud data;
the boundary characteristic dividing system is used for dividing boundary characteristics according to the three-dimensional morphology characteristic parameters and determining boundary characteristic dividing parameters of all areas on the surface of the stamping die;
the friction and wear area division expert system is used for dividing the friction and wear area of each area on the surface of the stamping die according to the boundary characteristic division parameter and the three-dimensional shape characteristic parameter to obtain a friction and wear area division parameter;
the stamping simulation calculation system is used for acquiring stamping simulation data of the die, carrying out orthogonal polynomial regression design on stamping die performance parameters and micro-texture design parameters in a simulation result, and determining the corresponding relation between the performance parameters and the micro-texture parameters;
and the micro-texture design expert system is used for carrying out micro-texture design on each friction and wear area according to the friction and wear area division parameters and combining the corresponding relation between the performance parameters and the micro-texture parameters to obtain the micro-texture processing design parameters of the surface of the stamping die.
Furthermore, the data acquisition system is an entrance end of the design system, all original data enter the design system from the data acquisition system, and the three-dimensional point cloud data are imported into the design system through the data acquisition system, temporarily stored and transmitted to other modules for operation.
Furthermore, the three-dimensional feature parameter calculation system is used for calculating and describing three-dimensional feature parameters of the surface of the stamping die and mainly comprises a normal vector calculation module and a curvature calculation module. The system is operated in a mode that three-dimensional point cloud data of the surface of the stamping die in an STL format transmitted by a data acquisition system is received, the curvature and normal vector of each region of the surface of the stamping die are obtained according to a specific program algorithm, and the curvature and normal vector data are temporarily stored and then transmitted to a boundary characteristic division system. In the present embodiment, the normal vector calculation employs a normal vector calculation algorithm as shown in fig. 6, and the curvature calculation employs a curvature calculation algorithm as shown in fig. 7.
Further, the boundary characteristic dividing system is used for dividing the boundary characteristics of the die, mainly receiving data transmitted by the three-dimensional feature characteristic parameter calculating system, determining a sudden change boundary and a gradual change boundary on the surface of the die according to a specific die boundary characteristic dividing algorithm process and two three-dimensional feature parameters of curvature and normal vector, temporarily storing the boundary characteristic dividing parameters and transmitting the parameters to the friction and wear area dividing expert system.
Furthermore, the friction wear area division expert system is used for dividing the friction wear area, the system contains rich expert knowledge for dividing the friction wear area on the surface of the stamping die, can receive three-dimensional feature parameters transmitted by the three-dimensional feature parameter calculation system and boundary feature division parameters transmitted by the boundary feature division system, automatically completes a series of inference designs according to the parameters to obtain the division parameters of the friction wear area, and transmits the data to the microtexture design expert system after temporary storage.
Furthermore, as shown in fig. 1, the expert system for dividing the friction and wear area includes a knowledge base for dividing the friction and wear area, a database for dividing the friction and wear area, an inference engine, an interpretation mechanism, a knowledge acquisition mechanism, and a system interface, where the knowledge acquisition mode of the knowledge base is non-automatic acquisition, that is, the knowledge editing software is used to input the expert knowledge and practical experience in the field into the knowledge base; the expression mode of the knowledge base is a generative knowledge expression mode, namely facts and rules of the knowledge base are expressed through a knowledge expression method of a generative system, and the structure of the knowledge base is shown in FIG. 3.
The database is a working memory area of the friction wear area division expert system, which stores data about problems, states, known facts, reasoning facts, and the like. The inference engine is a group of programs for coordinating and controlling the friction and wear area division expert system, and solves the current problem according to the input three-dimensional feature parameter data and the boundary feature parameter data, knowledge in the knowledge base and the inference strategy of forward inference to obtain the friction and wear area division parameter data, and the inference engine reasoning flow chart is shown in fig. 4.
The interpretation mechanism is used for interpreting the solving process and answering the questions of the user. The knowledge acquisition mechanism is used for serving a knowledge base, is mainly responsible for modifying and perfecting the knowledge base, detects and maintains the integrity and consistency of the knowledge base, and mainly comprises modules such as knowledge editing software and the like. The system interface is an information transmission link of the friction wear area division expert system and the design system, is used for finishing bidirectional information exchange between the expert system and the whole design system, and can realize information modification of the expert system by a user.
Further, the stamping simulation calculation system is used for receiving the three-dimensional point cloud data transmitted by the data acquisition system, constructing a die stamping model on the basis of the three-dimensional point cloud data, developing die stamping simulation, developing orthogonal polynomial regression design on performance parameters of a stamping die and design parameters of the microtexture in a simulation result, obtaining the relationship between the performance parameters, such as friction coefficient, abrasion loss, plate thinning rate and the like, which can reflect the service life of the die and the quality of a formed part, and the parameters, such as height, depth, diameter, area rate and the like of the microtexture, and importing the data of the corresponding relationship between the performance parameters and the microtexture parameters, which are obtained through calculation, into the data acquisition system.
Furthermore, the microtexture design expert system is used for reasonably designing microtexture processing technological parameters such as microtexture shape, height (micro-protrusion), depth (micro-pit), diameter, transverse and longitudinal spacing, height-diameter ratio (micro-protrusion), depth-diameter ratio (micro-pit), area occupancy, connectivity coefficient and the like, contains rich microtexture design expert knowledge, can receive friction and wear area division parameter data transmitted by the friction and wear area division expert system and performance parameter and microtexture parameter corresponding relation data imported by a user through the data acquisition system, automatically completes a series of inference designs according to the parameters to obtain microtexture design parameters, and exports the design system after the data are temporarily stored.
Furthermore, the micro texture design expert system comprises six modules, namely a micro texture design knowledge base, a micro texture design database, an inference machine, an explanation mechanism, a knowledge acquisition mechanism, a system interface and the like, and the construction diagram of the expert system is shown in fig. 2; the knowledge acquisition mode of the knowledge base is non-automatic acquisition, namely, expert knowledge and practical experience in the field are input into the knowledge base by using knowledge editing software; the expression mode of the knowledge base is a production type knowledge expression mode, namely the facts and the rules of the knowledge base are expressed through a knowledge expression method of a production type system, and the structural composition of the knowledge base is shown in a figure 5 (when performance parameters only consider friction coefficients, abrasion loss and plate thinning rate).
The database is the working storage area of the microtexture design expert system, storing data about problems, states, known facts, reasoning facts, etc. The inference engine is a set of programs for coordinating and controlling the micro-texture design expert system, the current problem is solved according to the input friction wear area division parameter data and the corresponding relation data of the performance parameters and the micro-texture parameters by using knowledge in the knowledge base and according to the inference strategy of forward inference to obtain the micro-texture design parameter data, and the inference engine reasoning flow chart is also shown in figure 4.
The interpretation mechanism is used for interpreting the solving process and answering the questions of the user. The knowledge acquisition mechanism is used for serving a knowledge base, is mainly responsible for modifying and perfecting the knowledge base, detects and maintains the integrity and consistency of the knowledge base, and mainly comprises modules such as knowledge editing software and the like. The system interface is an information transmission link between the microtexture design expert system and the design system, so that the two-way information exchange between the expert system and the whole design system is completed, and the information modification of the expert system by a user can be realized.
Further, the system also comprises a soft CPU, the soft CPU is a software system similar to a computer hardware CPU, as shown in fig. 6, and mainly comprises a conversion module, a production module, and an operation module, the instruction executed by the system is a formula from a database, and the operand is from the database or other modules of a design system.
In this embodiment, a three-dimensional scanning is performed on the stamping die, and the three-dimensional point cloud data of the whole stamping die is obtained and imported into the design system through the data acquisition system.
And according to the imported three-dimensional point cloud data, developing die stamping simulation in a stamping simulation calculation system to obtain corresponding relation data of the performance parameters and the microtexture parameters, and further transmitting the corresponding relation data of the performance parameters and the microtexture parameters to a microtexture design expert system. Meanwhile, characteristic parameter data of curvatures, normal vectors and the like of different areas are obtained in the three-dimensional feature parameter calculation system through program calculation, the three-dimensional feature parameter data are transmitted to the boundary feature dividing system to complete the division of abrupt change boundaries and gradual change boundaries, the boundary feature dividing parameter data and the three-dimensional feature parameter data are transmitted to the friction wear area dividing expert system together, and the friction wear area of the surface of the die is divided. And transmitting the obtained friction and wear area division parameter data to a micro-texture design expert system, integrating the initially introduced performance parameters such as friction coefficients and the like and the corresponding relation data of the micro-texture parameters, deducing the micro-texture parameters required by each area according to different performance parameters required by different friction and wear areas, and obtaining micro-texture processing design parameter data. And exporting the obtained micro-texture parameter data to a design system, determining a processing method and technological parameters required by processing the micro-texture with specific parameters, and processing on the surface of the die.
Example three:
in the embodiment, a stamping die with a simple structure for the air outlet valve of the automobile inner box cover is selected for example analysis, and a micro-convex texture and a micro-concave texture with reasonable parameters are processed on the surface of the stamping die, wherein the processing method comprises the following steps:
(1) three-dimensional point cloud data of a box cover air outlet valve stamping die used in an automobile is obtained through a handheld laser three-dimensional scanner, and is guided into a design system through a data obtaining system in an STL format, and then is transmitted to a three-dimensional feature characteristic parameter calculating system to obtain characteristic parameters such as curvatures, normal vectors and the like of different areas through program calculation.
(2) And transmitting the three-dimensional feature parameter data of the stamping die of the box cover air outlet valve for the automobile, such as curvature, normal vector and the like obtained in the three-dimensional feature parameter calculation system to a boundary feature division system, and obtaining all abrupt and gradual change boundaries on the surface of the concave-convex die only by considering the drawing convex die and the drawing concave die which are actually contacted with the workpiece.
(3) And transmitting three-dimensional feature parameter data such as curvature and normal vector and the like obtained in the three-dimensional feature parameter calculation system and boundary feature division parameter data obtained in the boundary feature division system to a friction and wear region division expert system, and dividing the male die and the female die into friction and wear regions according to the boundary features and the three-dimensional feature parameters of the regions.
Firstly, dividing the surface of a die into a contact area and a non-contact area according to a stamping model input in advance, wherein the contact area is an area on the surface of the die, which is in contact with a plate material in the stamping process, and the non-contact area is an area on the surface of the die, which is not in contact with the plate material in the stamping process. And secondly, dividing the contact area into a fillet area, a vertical surface area and other areas according to the abrupt change boundary and the gradual change boundary of the surface and the curvature and normal vector of each point. Considering only the contact area on the drawing punch, drawing die, which is actually in contact with the workpiece, the frictional wear area division diagram is shown in fig. 13(a) and 13 (b).
(4) The three-dimensional point cloud data transmitted by the data acquisition system is received by the stamping simulation calculation system, a die stamping model is constructed on the basis of the three-dimensional point cloud data, die stamping simulation is carried out, orthogonal polynomial regression design is carried out on performance parameters of a stamping die and design parameters of the microtexture in a simulation result, the relation between the performance parameters, such as friction coefficient, abrasion loss, plate thinning rate and the like, which can reflect the service life of the die and the quality of a formed part, and the parameters, such as height, depth, diameter, area rate and the like of the microtexture is obtained, and the corresponding relation data of the performance parameters and the microtexture parameters is led into a microtexture design expert system through the data acquisition system. And receiving the friction and wear area division parameters transmitted by the friction and wear area division expert system, and the corresponding relation between the comprehensive performance parameters and the micro-texture parameters, and designing the micro-texture parameters of each friction and wear area to obtain the micro-texture design parameters.
Reasonable parameters of the microtexture of the drawing convex die of the gas outlet valve of the tank cover for the automobile interior are as follows: the texture shape is volcano-crater-shaped, the height is 5-30, the diameter is 50-150, the transverse spacing and the longitudinal spacing are both 200-500, the height-diameter ratio is 1/30-3/5, and the area occupancy is 5-20%; reasonable parameters of the microtexture of the drawing female die of the box cover air outlet valve used in the automobile are as follows: the texture is in the shape of a round micro-pit, the depth direction is hemispherical, the depth is 5-50, the diameter is 50-300m, the curvature radius of the texture is 40-80m, the transverse spacing and the longitudinal spacing are both 200-500, the depth-diameter ratio is 1/60-1, and the area occupancy is 5-20%.
(5) The method comprises the following steps of transmitting and exporting micro-texture parameter data such as the shape, the height (micro-protrusion), the depth (micro-pit), the diameter, the transverse and longitudinal spacing, the height-diameter ratio (micro-protrusion), the depth-diameter ratio (micro-pit), the area occupancy, the connectivity coefficient and the like of a micro-texture to be processed on the surface of a stamping die of a gas outlet valve of a box cover for an automobile, which is obtained from a micro-texture design expert system, selecting a picosecond laser to process, and determining the optimal laser processing parameter range according to the micro-texture design parameters as follows: wavelength of 1064nm, power of 1-50W, pulse repetition frequency of 1-200kHz, scanning speed of 50-500mm/s, switching light delay of 50-300s, pulse width of 5-15ps, processing repetition frequency of 2-10 times, current of 5-30A, and ambient temperature of 10-35 ℃.
The above description is only a preferred embodiment of the present application and is not intended to limit the present application, and various modifications and changes may be made by those skilled in the art. Any modification, equivalent replacement, improvement and the like made within the spirit and principle of the present application shall be included in the protection scope of the present application.
Claims (8)
1. A processing method of micro texture on the surface of a stamping die is characterized by comprising the following steps:
acquiring three-dimensional point cloud data of the whole stamping die;
calculating to obtain the characteristic parameters of the three-dimensional topography of the surface of the stamping die according to the three-dimensional point cloud data;
carrying out boundary characteristic division according to the three-dimensional morphology characteristic parameters, and determining boundary characteristic division parameters of all areas on the surface of the stamping die;
dividing friction wear areas of all areas on the surface of the stamping die according to the boundary characteristic dividing parameters and the three-dimensional shape characteristic parameters to obtain friction wear area dividing parameters;
obtaining die stamping simulation data, carrying out orthogonal polynomial regression design on stamping die performance parameters and micro-texture design parameters in a simulation result, and determining the corresponding relation between the performance parameters and the micro-texture parameters;
according to the friction and wear area division parameters, combining the corresponding relation of the performance parameters and the micro-texture parameters, carrying out micro-texture design on each friction and wear area to obtain the micro-texture processing design parameters of the surface of the stamping die; processing the micro texture on the surface of the stamping die according to the micro texture processing design parameters;
the three-dimensional feature parameters comprise curvatures and normal vectors, the surface of the stamping die is repeatedly scanned for multiple times, normal vectors of all points are calculated through a normal vector calculation algorithm, and curvatures of all points are calculated through a curvature calculation algorithm; fitting the calculation result to obtain the curvature and normal vector data of each point on the surface of the stamping die;
identifying and dividing boundary characteristics to obtain a sudden change boundary and a gradual change boundary of the surface of the stamping die;
according to the boundary characteristics and three-dimensional morphology parameters of each region, a male die and a female die are separated to divide a friction wear region, and firstly, the surface of a die is divided into a contact region and a non-contact region according to a pre-input stamping model; secondly, dividing a contact area into a fillet area, a vertical area and other areas according to each abrupt change boundary and a gradual change boundary of the surface of the die and the curvature and normal vector of each point; and finally, classifying the fillet area according to the curvature of the fillet area and the normal vector parameter.
2. The method as claimed in claim 1, wherein the laser scanning device emits a laser spot or a linear laser to the stamping die by a triangulation method, and the distance from the surface of the stamping die to the laser scanning device is measured to obtain the three-dimensional point cloud data of the stamping die as a whole.
3. The method for processing the micro-texture on the surface of the stamping die as claimed in claim 1, wherein a die stamping model is constructed, die stamping simulation is carried out, orthogonal polynomial regression design is carried out on the performance parameters of the stamping die and the design parameters of the micro-texture in the simulation result, and the corresponding relation between the performance parameters capable of reflecting the service life of the die and the quality of a formed part and the parameters of the micro-texture is obtained.
4. The method for processing the micro-texture on the surface of the stamping die as claimed in claim 3, wherein the convex die fillet area and the vertical face area are processed with micro-convex texture, the concave die fillet area and the vertical face area are processed with micro-concave texture, and reasonable micro-texture parameters are respectively set for each level of the fillet area and the vertical face area of the convex die and the concave die according to the corresponding relationship between the comprehensive performance parameters and the micro-texture parameters.
5. A processing design system for micro texture on the surface of a stamping die is characterized by comprising:
the data acquisition system is used for acquiring three-dimensional point cloud data of the whole stamping die;
the three-dimensional feature parameter calculation system is used for calculating and obtaining three-dimensional feature parameters of the surface of the stamping die according to the three-dimensional point cloud data;
the boundary characteristic dividing system is used for dividing boundary characteristics according to the three-dimensional morphology characteristic parameters and determining boundary characteristic dividing parameters of all areas on the surface of the stamping die;
the friction and wear area division expert system is used for dividing the friction and wear area of each area on the surface of the stamping die according to the boundary characteristic division parameter and the three-dimensional shape characteristic parameter to obtain a friction and wear area division parameter;
the stamping simulation calculation system is used for acquiring stamping simulation data of the die, carrying out orthogonal polynomial regression design on stamping die performance parameters and micro-texture design parameters in a simulation result, and determining the corresponding relation between the performance parameters and the micro-texture parameters;
and the micro-texture design expert system is used for carrying out micro-texture design on each friction and wear area according to the friction and wear area division parameters and combining the corresponding relation between the performance parameters and the micro-texture parameters to obtain the micro-texture processing design parameters of the surface of the stamping die.
6. The machining design system for the micro-texture on the surface of the stamping die as claimed in claim 5, wherein the three-dimensional topographic characteristic parameter calculating system comprises a normal vector calculating module and a curvature calculating module, the normal vector calculating module is used for calculating normal vectors of all areas on the surface of the stamping die, and the curvature calculating module is used for calculating the curvature of all areas on the surface of the stamping die.
7. The system of claim 6, wherein the expert system for dividing frictional wear area comprises:
the friction wear area division knowledge base is used for receiving and storing expert knowledge of the division of the friction wear area on the surface of the stamping die;
the friction wear area division database is connected with the knowledge base and the interpretation mechanism and is used for storing data, states, known facts and reasoning facts related to the division of the friction wear area of the die;
the inference machine is used for solving the current problem according to the three-dimensional morphology characteristic parameters and the boundary characteristic parameter data and the knowledge in the knowledge base and the inference strategy of forward inference to obtain friction wear area division parameter data;
the explaining mechanism is connected with the inference machine and the system interface and is used for explaining the solving process;
the knowledge acquisition mechanism is connected with the inference machine and the knowledge base and is used for modifying and perfecting the knowledge base;
and the system interface is connected with the knowledge base and used for realizing the bidirectional information exchange with a user or a design system.
8. The system of claim 6, wherein the microtexture design expert system comprises:
the microtexture design knowledge base is used for receiving and storing microtexture design expert knowledge;
the microtexture design database is connected with the knowledge base and the interpretation mechanism and is used for storing data, states, known facts and reasoning facts related to microtexture design;
the inference machine is used for solving the current problem according to the friction wear area division parameters, the performance parameters and the micro-texture parameter corresponding relation data, knowledge in a knowledge base and an inference strategy of forward inference to obtain micro-texture design parameter data;
the explaining mechanism is connected with the inference machine and the system interface and is used for explaining the solving process;
the knowledge acquisition mechanism is connected with the inference machine and the knowledge base and is used for modifying and perfecting the knowledge base;
and the system interface is connected with the knowledge base and used for realizing the bidirectional information exchange with a user or a design system.
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