CN113483716A - Curved surface part machining method based on flexible sensor - Google Patents
Curved surface part machining method based on flexible sensor Download PDFInfo
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- CN113483716A CN113483716A CN202110560301.XA CN202110560301A CN113483716A CN 113483716 A CN113483716 A CN 113483716A CN 202110560301 A CN202110560301 A CN 202110560301A CN 113483716 A CN113483716 A CN 113483716A
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B21/00—Measuring arrangements or details thereof, where the measuring technique is not covered by the other groups of this subclass, unspecified or not relevant
- G01B21/20—Measuring arrangements or details thereof, where the measuring technique is not covered by the other groups of this subclass, unspecified or not relevant for measuring contours or curvatures, e.g. determining profile
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B21/00—Measuring arrangements or details thereof, where the measuring technique is not covered by the other groups of this subclass, unspecified or not relevant
- G01B21/02—Measuring arrangements or details thereof, where the measuring technique is not covered by the other groups of this subclass, unspecified or not relevant for measuring length, width, or thickness
- G01B21/08—Measuring arrangements or details thereof, where the measuring technique is not covered by the other groups of this subclass, unspecified or not relevant for measuring length, width, or thickness for measuring thickness
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
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Abstract
The invention discloses a curved surface part processing method based on a flexible sensor, which comprises the following steps: 1) determining a preprocessed part; 2) attaching a flexible sensor on the surface of the tool clamp; the flexible sensor is provided with a plurality of sensing units; 3) placing a preprocessed part on a tool clamp; 4) fastening and connecting the preprocessed part and the tool clamp; 5) judging whether the surface of the preprocessed part has a shape difference with the inner surface of the tool clamp or not; 6) determining a preprocessed part subarea with a shape difference; 7) and the upper computer controls the processing cutter to process the subarea to be processed according to the difference degree. The invention can detect the shape difference and the thickness difference distribution of the inner surface and the outer surface of the special-shaped curved surface part relative to the standard curved surface of the tool clamp, thereby providing processing parameters for eliminating the shape difference and the thickness difference.
Description
Technical Field
The invention relates to the field of part processing, in particular to a curved surface part processing method based on a flexible sensor.
Background
For the processing of special-shaped curved surface parts, the consistency of the curved surface thickness of the parts is often difficult to ensure by the traditional mechanical processing mode. In particular, for composite materials, compared with general materials, the composite materials have lower mechanical properties such as hardness and rigidity, and the composite materials are easy to deform greatly in the machining process such as cutting, and the stress applied to the materials by the cutter head can have uncontrollable influence on the forming of final parts. In order to ensure high-precision machining of the special-shaped curved surface part, generally, uniform and consistent part thickness and an expected curved surface shape need to be ensured, so that the thickness distribution and the curved surface shape difference of the curved surface part in the machining process and the real-time contact force applied to a to-be-cut area by a tool clamp are expected to be obtained, namely, the real-time distribution force on a target curved surface contour is obtained, and the machining of the target curved surface part with ideal indexes is facilitated. Although the prior art is provided with a force sensor on a cutter for detecting the pressure of a part borne by a cutter head, the detection force of the technology is easily interfered by a plurality of factors such as the material, depth and shape variation (such as arching when the cutter head is not attached to a tool clamp) of the part, and the single-point stress of the position where the cutter head is located can be detected only in real time, so that the uniform thickness and the curved surface shape of the part are difficult to ensure at the same time.
Disclosure of Invention
The invention aims to provide a curved surface part processing method based on a flexible sensor, which comprises the following steps:
1) determining a preprocessed part; the preprocessed part has special-shaped curved surface characteristics.
2) Attaching a flexible sensor on the surface of the tool clamp; the flexible sensor is provided with a plurality of sensing units; a sensing unit corresponds to a sub-area of the preprocessed part;
the flexible sensor comprises a piezoresistive flexible sensor and a piezoresistive flexible sensor.
The flexible sensor has an elastic material with a thickness denoted as h.
The inner surface of the tool clamp is completely matched with the standard workpiece.
3) Placing the preprocessed part on a tool clamp, and enabling the inner surface of the preprocessed part to be attached to the flexible sensor; a pre-processing error gap exists between the inner surface of the pre-processing part and the flexible sensor;
4) fastening and connecting the preprocessed part and the tool clamp, and applying pressure to the flexible sensor by the inner surface of the preprocessed part; the sensing unit generates deformation after being stressed, so that an electric signal is output to an upper computer;
5) the upper computer judges whether the shape difference exists between the surface of the preprocessed part and the inner surface of the tool clamp or not on the basis of the received electric signals, if not, the part processing is finished, and if so, the step 6 is carried out); the shape difference can be expressed as that the shape difference is inconsistent with the curvature of the standard curved surface of the tool clamp, so that the deformation of the flexible sensor is inconsistent;
preferably, the method for judging whether the shape difference exists between the surface of the preprocessed part and the inner surface of the tool clamp comprises the following steps: judging whether the electric signals output by each sensing unit are equal, if so, judging that the shape difference does not exist between the preprocessed part and the inner surface of the tool clamp, and if not, judging that the shape difference exists;
when the shape difference exists between the machined part and the inner surface of the tool clamp, recording the number of repeated electric signal values, and taking the electric signal with the largest number of repeated electric signals as a reference electric signal; and the sensing unit with the electric signal not equal to the reference electric signal is a to-be-processed sensing unit.
Preferably, the method for judging whether the shape difference exists between the surface of the preprocessed part and the inner surface of the tool clamp comprises the following steps: judging whether the difference between the electric signals output by any two sensing units is larger than a preset threshold value deltamaxIf so, judging that the shape difference exists between the preprocessed part and the inner surface of the tool clamp, otherwise, judging that the shape difference does not exist;
when the shape difference exists between the machined part and the inner surface of the tool clamp, the difference value between the electric signal output by the ith sensing unit and the electric signals output by other sensing units is written into a difference value set deltaiPerforming the following steps; 1,2, …, n; n is the total number of the sensing units; judging whether each difference value set is smaller than a preset threshold value deltamaxSelecting a difference set with the most elements, and taking the electric signal output by the sensing unit corresponding to the difference set as a reference electric signal; the difference between the recording electric signal and the reference electric signal is greater than a preset threshold value deltamaxThe sensing unit of (2) is a sensing unit to be processed.
6) Determining a preprocessed part subarea with a shape difference, and recording the preprocessed part subarea as a subarea to be processed;
determining the difference degree between the sub-area to be processed and the inner surface of the tool clamp; the degree of difference includes a difference shape and a difference thickness;
the preprocessed part subarea with the shape difference is an area corresponding to the to-be-processed sensing unit.
7) The upper computer controls the processing cutter to process the subarea to be processed according to the difference degree; after the processing is finished, returning to the step 5); during the processing and after the processing is finished, the sensing unit continuously generates an electric signal under the pressure action of the preprocessed part and sends the electric signal to an upper computer.
The flexible sensor also monitors the real-time pressure of the action position of the cutter head and feeds the real-time pressure back to the upper computer, so that the upper computer adjusts and compensates the force of the cutter head on the preprocessed part during processing.
The tool clamp has the advantages that the flexible sensor of the tool clamp is flexibly and conformally attached to the special-shaped curved surface of the tool clamp, the shape difference and the thickness difference distribution of the inner surface and the outer surface of a special-shaped curved surface part relative to the standard curved surface of the tool clamp can be detected, so that processing parameters are provided for eliminating the shape difference and the thickness difference, the real-time pressure distribution of the surface of the tool clamp in the machining process of a cutter can be obtained, particularly the stress condition of a machining point where a cutter head is located can be fed back to an operator or a numerical control machine tool in real time, and the stress of the cutter head on the part during machining can be adjusted and compensated. The invention realizes the high-precision processing of the expected shape and the consistent thickness of the special-shaped curved surface part based on active shape and thickness difference distribution detection and real-time stress detection and feedback.
Drawings
FIG. 1 is a process flow diagram;
in the figure: the device comprises a preprocessed part 1, a tool clamp 2, a flexible sensor 3, a sensing unit 31, a processing cutter 4 and a fixing hole 5.
Detailed Description
The present invention is further illustrated by the following examples, but it should not be construed that the scope of the above-described subject matter is limited to the following examples. Various substitutions and alterations can be made without departing from the technical idea of the invention and the scope of the invention is covered by the present invention according to the common technical knowledge and the conventional means in the field.
Example 1:
referring to fig. 1, the method for processing a curved surface part based on a flexible sensor comprises the following steps:
1) determining a preprocessed part 1; the pre-machined part 1 has special-shaped curved surface characteristics.
2) The surface of the tool clamp 2 is coated with a flexible sensor 3; the flexible sensor 3 has several sensing units 31; one sensing unit 31 corresponds to one sub-area of the prefabricated part 1;
the flexible sensor 3 comprises a piezoresistive flexible sensor 3 and a piezoresistive flexible sensor 3.
The flexible sensor 3 is of an elastic material and has a thickness denoted h.
The inner surface of the tool clamp 2 is completely matched with a standard workpiece.
3) Placing the preprocessed part 1 on a tool clamp 2, and enabling the inner surface of the preprocessed part 1 to be attached to a flexible sensor 3; a pre-processing error gap exists between the inner surface of the pre-processing part 1 and the flexible sensor 3;
4) the pre-processing part 1 and the tool clamp 2 are connected through a fixing hole bolt to finish the fastening connection of the pre-processing part 1 and the tool clamp, and the inner surface of the pre-processing part 1 applies pressure to the flexible sensor 3; the sensing unit 31 is deformed after being pressurized, so that an electric signal is output to an upper computer;
5) the upper computer judges whether the shape difference exists between the surface of the preprocessed part 1 and the inner surface of the tool clamp 2 or not on the basis of the received electric signals, if not, the part processing is finished, and if so, the step 6 is carried out);
the shape difference can be expressed as that the shape difference is inconsistent with the curvature of the standard curved surface of the tool clamp, so that the deformation of the flexible sensor is inconsistent;
the method for judging whether the shape difference exists between the surface of the preprocessed part 1 and the inner surface of the tool clamp 2 comprises the following steps: judging whether the electric signals output by each sensing unit 31 are equal, if so, judging that the shape difference does not exist between the inner surfaces of the preprocessed part 1 and the tool clamp 2, otherwise, judging that the shape difference exists;
when the shape difference exists between the machined part and the inner surface of the tool clamp 2, the number of repeated electric signal values is recorded, and the electric signal with the largest number of repeated electric signals is taken as a reference electric signal; the sensing unit 31 which records that the electric signal is not equal to the reference electric signal is the sensing unit 31 to be processed.
6) Determining a sub-area of the preprocessed part 1 with the shape difference, and recording as a sub-area to be processed;
determining the difference degree between the sub-area to be processed and the inner surface of the tool clamp 2; the degree of difference includes a difference shape and a difference thickness;
the sub-area of the pre-processed part 1 with the shape difference is the area corresponding to the sensing unit 31 to be processed.
7) The upper computer controls the processing cutter 4 to process the subarea to be processed according to the difference degree; after the processing is finished, returning to the step 5); during and after the machining process, the sensing unit 31 continuously generates an electric signal under the pressure of the pre-machined part 1 and sends the electric signal to an upper computer.
The flexible sensor 3 also monitors the real-time pressure of the tool bit action position of the machining tool 4, and feeds the real-time pressure back to the upper computer, so that the upper computer adjusts and compensates the force of the tool bit on the pre-machined part 1 during machining.
The sensor structure adopted by the embodiment comprises a floating electrode, an insulating layer, an organic elastomer, a pre-structured conductive elastomer, a driving electrode, an induction electrode, a flexible PCB and a substrate.
A layer of hemispherical convex layer covers the M multiplied by N floating electrode array.
A plurality of floating electrodes are adhered to the upper surface of the first insulating layer.
The second insulating layer covers the flexible PCB.
The pre-structured conductive elastomer is located between two insulating layers.
The pre-structured conductive elastomer includes an organic elastomer and a plurality of magnetic particles.
The organic elastomer is a hollow cavity.
A plurality of magnetic particles are distributed inside the organic elastomer.
And establishing a three-dimensional Cartesian coordinate system by taking the gravity center point of the pre-structured conductive elastomer as the origin of coordinates. The part of the pre-structured conductive elastic body, which is positioned in a three-dimensional Cartesian coordinate system, of the first diagram limit and the fifth diagram limit is marked as a first subregion, the part of the pre-structured conductive elastic body, which is positioned in a three-dimensional Cartesian coordinate system, of the first diagram limit and the fifth diagram limit is marked as a second subregion, the part of the pre-structured conductive elastic body, which is positioned in a three-dimensional Cartesian coordinate system, of the pre-structured conductive elastic body, and of the pre-structured conductive elastic body, wherein the part of the first diagram limit and the fifth diagram limit are positioned in a three-dimensional Cartesian coordinate system. The parts of the x + axis, the y + axis and the z + axis are first diagram limits, the parts of the x-axis, the y + axis and the z + axis are second diagram limits, the parts of the x-axis, the y-axis and the z + axis are third diagram limits, the parts of the x + axis, the y-axis and the z + axis are fourth diagram limits, the parts of the x + axis, the y + axis and the z-axis are fifth diagram limits, the parts of the x-axis, the y + axis and the z-axis are sixth diagram limits, the parts of the x-axis, the y-axis and the z-axis are seventh diagram limits, and the parts of the x + axis, the y-axis and the z-axis are eighth diagram limits.
When the three-dimensional flexible touch sensor is in an initial state, the magnetic particles in the first sub-area are inclined towards the direction of the x + axis, and the inclination angle is recorded as thetax+. The magnetic particles in the second sub-region are tilted in the y + direction by an angle thetay+. The magnetic particles in the third sub-region are tilted in the x-axis direction by an angle thetax-. The magnetic particles in the fourth sub-region are tilted to the y-axis direction by the tilt angleIs marked as thetay-. The angle of inclination is denoted as θy-。θx+And thetay+May be equal, θx-And thetay-May be equal.
In one floating electrode array, the floating electrode with the projection in the first sub-area is marked as an x + electrode unit, the floating electrode with the projection in the second sub-area is marked as a y + electrode unit, the floating electrode with the projection in the third sub-area is marked as an x-electrode unit, and the floating electrode with the projection in the fourth sub-area is marked as a y-electrode unit. The x + electrode units and the y + electrode units are positioned in different rows and different columns, and the x-electrode units and the y-electrode units are positioned in different rows and different columns.
When the three-dimensional flexible touch sensor is subjected to gliding force in the direction of the x + axis, the inclination angle thetax-The overlapping area of the projection of the floating electrode in the x-electrode unit and the corresponding driving electrode and the induction electrode is increased, and the inclination angle theta is reducedx+And the overlapping area of the projection of the floating electrode in the x + electrode unit and the corresponding driving electrode and the induction electrode is reduced.
When the three-dimensional flexible touch sensor is subjected to gliding force in the x-axis direction, the inclination angle theta is inclinedx-The overlapping area of the projection of the floating electrode in the x-electrode unit and the corresponding driving electrode and sensing electrode is reduced, and the inclination angle theta is increasedx+And the overlapping area of the projection of the floating electrode in the x + electrode unit and the corresponding driving electrode and sensing electrode is increased.
When the three-dimensional flexible touch sensor is subjected to gliding force in the y + axis direction, the inclination angle thetay-The overlapping area of the projection of the floating electrode in the y-electrode unit and the corresponding driving electrode and the induction electrode is increased, and the inclination angle theta is reducedy+And increasing the area of the projection of the floating electrode in the y + electrode unit, and the overlapping area of the corresponding driving electrode and the corresponding sensing electrode.
When the three-dimensional flexible touch sensor is subjected to gliding force in the y-axis direction, the inclination angle theta is inclinedy-The overlapping area of the projection of the floating electrode in the y-electrode unit and the corresponding driving electrode and sensing electrode is reduced, and the inclination angle theta is increasedy+Reducing the projection of the floating electrode in the y + electrode unit and the corresponding drive electrode, senseThe overlapping area of the electrodes should be increased.
The driving electrode and the induction electrode are attached to the bottom surface of the organic elastomer;
one driving electrode and one sensing electrode correspond to one floating electrode. Wherein the projection of the driving electrode and the floating electrode are overlapped. The sensing electrode overlaps the projection of the array of floating electrodes.
The flexible PCB is positioned on the upper surface of the base.
The three-dimensional flexible touch sensor also comprises a hemispherical convex layer covering the floating electrode array arranged in an M multiplied by N mode.
The three-dimensional flexible touch sensing unit comprises a hemispherical convex layer, a floating electrode array arranged in an M multiplied by N mode, a pre-structured conductive elastomer, a driving electrode and an induction electrode.
In a three-dimensional flexible touch sensing unit, the projection overlapping areas of the driving electrode, the sensing electrode and the floating electrode are different.
When the three-dimensional flexible touch sensor is subjected to normal force, the pre-structured conductive elastomer deforms upwards in the normal direction, and the magnetic particles generate a rearrangement effect.
The three-dimensional flexible touch sensing unit measures the magnitude and direction of external contact force through the magnitude of charges generated at two ends of each floating electrode.
The three-dimensional flexible tactile sensing unit is subjected to gliding forces in the x-direction and the y-direction simultaneously.
Example 2:
referring to fig. 1, the method for processing a curved surface part based on a flexible sensor 3 comprises the following steps:
1) determining a preprocessed part 1; the pre-machined part 1 has special-shaped curved surface characteristics.
2) The surface of the tool clamp 2 is coated with a flexible sensor 3; the flexible sensor 3 has several sensing units 31; one sensing unit 31 corresponds to one sub-area of the prefabricated part 1;
the flexible sensor 3 comprises a piezoresistive flexible sensor 3 and a piezoresistive flexible sensor 3.
The flexible sensor 3 is of an elastic material and has a thickness denoted h.
The inner surface of the tool clamp 2 is completely matched with a standard workpiece.
The flexible linear array pressure sensor comprises a flexible substrate and a plurality of pressure sensor linear array units.
The flexible substrate is constructed with a plurality of micro-nano structures. The pattern of the micro-nano structure comprises a pyramid, a column and a hemisphere.
The material of the flexible substrate comprises silicon rubber, polyurethane elastomer and Eco-Flex.
And a plurality of pressure sensor linear array units are integrated on the surface of the flexible substrate.
And stress conducting contacts are arranged on the surface of each linear array unit of the pressure sensor.
The area of the stress conduction contact is smaller than that of the linear array unit of the pressure sensor.
The stress-conducting contacts are made of an elastic material.
The pressure sensor linear array unit comprises interdigital electrodes and a semi-conformal micro-nano force-sensitive film, wherein the interdigital electrodes and the semi-conformal micro-nano force-sensitive film are integrated on the surface of a flexible substrate.
The semi-conformal micro-nano force-sensitive film comprises a micro-nano conformal conducting layer and a semi-conformal piezoelectric tunneling layer.
The micro-nano conformal conducting layer covers the surface of the micro-nano structure.
The semi-conformal piezoelectric tunneling layer partially covers the surface of the micro-nano conformal conductive layer.
The material of the micro-nano conformal conducting layer comprises graphene, a graphene nano wall, a carbon nano tube, carbon black, a conducting polymer and metal.
The material of the semi-conformal piezoelectric tunneling layer comprises PVDF, TrFE and PVDF-HFP.
The semi-conformal piezoelectric tunneling layer is subjected to high-voltage polarization treatment, and the piezoelectric property is improved.
The semi-conformal piezoelectric tunneling layer does not wrap the top of the micro-nano conformal conductive layer.
3) Placing the preprocessed part 1 on a tool clamp 2, and enabling the inner surface of the preprocessed part 1 to be attached to a flexible sensor 3; a pre-processing error gap exists between the inner surface of the pre-processing part 1 and the flexible sensor 3;
4) fastening and connecting the preprocessed part 1 and the tool clamp 2, and applying pressure to the flexible sensor 3 by the inner surface of the preprocessed part 1; the sensing unit 31 is deformed after being pressurized, so that an electric signal is output to an upper computer;
5) the upper computer judges whether the shape difference exists between the surface of the preprocessed part 1 and the inner surface of the tool clamp 2 or not on the basis of the received electric signals, if not, the part processing is finished, and if so, the step 6 is carried out);
the method for judging whether the shape difference exists between the surface of the preprocessed part 1 and the inner surface of the tool clamp 2 comprises the following steps: judging whether the difference between the electrical signals output by any two sensing units 31 is larger than a preset threshold value deltamaxIf so, judging that the shape difference exists between the inner surfaces of the preprocessed part 1 and the tool clamp 2, otherwise, judging that the shape difference does not exist;
when the shape difference exists between the machined part and the inner surface of the tool clamp 2, the difference value between the electric signal output by the ith sensing unit 31 and the electric signals output by the other sensing units 31 is written into the difference value set deltaiPerforming the following steps; 1,2, …, n; n is the total number of sensing units 31; judging whether each difference value set is smaller than a preset threshold value deltamaxAnd selects the difference set with the largest number of elements, and takes the electrical signal output by the sensing unit 31 corresponding to the difference set as the reference electrical signal; the difference between the recording electric signal and the reference electric signal is greater than a preset threshold value deltamaxThe sensing unit 31 of (1) is a to-be-processed sensing unit 31.
6) Determining a sub-area of the preprocessed part 1 with the shape difference, and recording as a sub-area to be processed;
determining the difference degree between the sub-area to be processed and the inner surface of the tool clamp 2; the degree of difference includes a difference shape and a difference thickness;
the sub-area of the pre-processed part 1 with the shape difference is the area corresponding to the sensing unit 31 to be processed.
7) The upper computer controls the processing cutter 4 to process the subarea to be processed according to the difference degree; after the processing is finished, returning to the step 5); during and after the machining process, the sensing unit 31 continuously generates an electric signal under the pressure of the pre-machined part 1 and sends the electric signal to an upper computer.
The flexible sensor 3 also monitors the real-time pressure of the action position of the cutter head and feeds the real-time pressure back to the upper computer, so that the upper computer adjusts and compensates the force of the cutter head on the part 1 to be machined during machining.
Example 3:
referring to fig. 1, the method for processing a curved surface part based on a flexible sensor 3 comprises the following steps:
1) the preprocessed part 1 with the special-shaped curved surface characteristics is obtained after stamping, die forming or any conventional mechanical preprocessing, the preprocessed part 1 has local and even global thickness difference and shape difference, and can not meet the precision required by specific application occasions, namely the inner surface and the outer surface of the preprocessed part need secondary fine processing.
2) A layer of flexible sensor 3 is attached to the surface of a tool clamp 2 with a standard inner surface, and the sensor is actually an array of a plurality of flexible pressure/strain sensing units 31 with certain area resolution. Due to the elastic mechanical property of the flexible sensor 3, the flexible sensor can flexibly cover the tool clamp 2 with different special-shaped curved surfaces. The flexible sensor 3 may be any type of known technology or product, and the principles include, but are not limited to, piezoresistive type, and the like.
In order to achieve higher detection resolution for the curved surface of the prefabricated part 1, the flexible sensors 3 have higher distribution density of the sensing units 31. The higher the distribution density of the sensing units 31, the smaller the range of shape and thickness differences can be detected. The distribution density of the sensing units 31 is determined by practical requirements, and the size of the single sensing unit 31 is preferably 1.0 × 1.0mm2 to 10.0 × 10.0mm 2.
3) Placing the pre-processing part 1 obtained in the step 1) on a tool clamp 2 (without fastening), wherein the inner surface of the pre-processing part 1 is basically attached to a flexible sensor 3 on a standard special-shaped curved surface of the tool clamp 2, but because the pre-processing part 1 has certain errors, a certain pre-processing error gap exists between the flexible sensor 3 and the inner surface of the pre-processing part 1.
4) The pre-processing part 1 and the tool clamp 2 are fastened and connected, even if a certain pressure is applied to the flexible sensor 3 by the inner surface of the pre-processing part 1, the flexible sensor 3 is pressed by the inner surface of the pre-processing part 1 and is compressed and deformed, and therefore the global pressure/strain distribution detection of the whole curved surface is achieved. Because the electrical output parameter value of the flexible pressure/strain sensing unit 31 and the compression deformation amount form a certain correlation, if the inner surface of the preprocessed part 1 is consistent with the standard curved surface of the tool clamp 2, the electrical output value of each pressure sensing unit 31 is consistent (or within an allowable threshold range); if there is a difference in shape between some areas of the inner surface of the prefabricated part 1 and the standard curved surface of the tooling fixture 2, the electrical output values of the pressure/strain sensing unit 31 are not consistent. And then, by combining the relationship between the strain and the pressure of the flexible pressure/strain sensing unit 31, the shape difference and the thickness difference of the area with inconsistent electrical output values (or not in the allowable threshold range) on the inner surface of the preprocessed part 1 relative to the standard curved surface of the tool clamp 2 can be further known, and the curved surface position of the area is known by the coordinate value of the array where the flexible sensing unit 31 is located, and after the coordinate value is recorded by the signal processing circuit of the flexible sensor 3, the area can be cut by the subsequent processing step, so that the shape difference and the thickness difference of the relevant area of the outer surface are eliminated, and the conformal coincidence with the standard curved surface of the tool clamp 2 is realized.
In step 4), in order to allow the tooling fixture 2 to accommodate a certain tolerance of the pre-machined part 1, the flexible sensor 3 should have a certain elastic thickness. The larger the elastic thickness is, the larger the allowable strain range (strain range) of the flexible sensor 3 is, and the larger shape and thickness error of the prefabricated part 1 can be accommodated. The elastic thickness is determined by practical requirements, and preferably can be 0.1-5.0 mm.
5) Through the flexible sensor 3 on the standard curved surface of the tool clamp 2, the shape difference and the thickness difference of the area with inconsistent electrical output values (or not in the allowable threshold range) on the inner surface of the preprocessed part 1 relative to the standard curved surface of the tool clamp 2 are obtained, and the curved surface position of the area is obtained through the coordinate value of the array where the flexible sensing unit 31 is located, so that after the recording is carried out by a signal processing circuit of the flexible sensor 3, the subsequent processing step can carry out cutting on the area, the shape difference and the thickness difference of the relevant area of the outer surface are eliminated, and the conformal coincidence with the standard curved surface of the tool clamp 2 is realized.
Since the shape difference and the thickness difference, which are inconsistent with the tool holder 2, on the inner surface and the coordinate position thereof are known in the step 4), the corresponding difference area of the inner surface can be cut by the machining tool 4 according to the measured thickness difference, and the inner surface consistent with the curved surface of the tool holder 2 can be obtained, namely, the result shown in the step 6) is obtained.
6) Since the thickness difference and the coordinate position thereof on the outer surface inconsistent with the tool holder 2 are known in the step 5), the corresponding coordinate area of the outer surface can be cut by the machining tool 4 according to the measured thickness difference, and the inner surface consistent with the curved surface of the tool holder 2 can be obtained, and the final result is finally obtained.
Repeating the steps 3) -6) for a plurality of times, and continuously improving the consistency of the shape and the thickness of the special-shaped curved surface part until the expected index is reached.
Because the flexible sensor 3 provides real-time pressure detection of the whole curved surface in the tool bit machining process in the steps 5) and 6) of the invention and also comprises real-time pressure detection of the action position of the tool bit, the stress condition can be fed back to an operator or a numerical control machine tool in real time so as to adjust and compensate the force generated by the tool bit on the part during machining and further ensure the machining precision.
Claims (10)
1. The curved surface part processing method based on the flexible sensor is characterized by comprising the following steps:
1) -determining said pre-machined part (1).
2) A flexible sensor (3) is attached to the surface of the tool clamp (2); the flexible sensor (3) is provided with a plurality of sensing units (31); a sensing unit (31) corresponds to a sub-region of the pre-machined part (1);
3) placing the preprocessed part (1) on a tool clamp (2), and enabling the inner surface of the preprocessed part (1) to be attached to the flexible sensor (3); a pre-processing error gap exists between the inner surface of the pre-processing part (1) and the flexible sensor (3);
4) the pre-processing part (1) and the tool clamp (2) are tightly connected, and the inner surface of the pre-processing part (1) applies pressure to the flexible sensor (3); the sensing unit (31) generates deformation after being subjected to pressure, so that an electric signal is output to an upper computer;
5) the upper computer judges whether the surface of the preprocessed part (1) is different from the inner surface of the tool clamp (2) in shape or not on the basis of the received electric signals, if not, the part processing is finished, and if so, the step 6 is carried out;
6) determining the sub-area of the preprocessed part (1) with the shape difference, and recording the sub-area as a sub-area to be processed;
determining the difference degree between the sub-area to be processed and the inner surface of the tool clamp (2); the degree of difference includes a difference shape and a difference thickness;
7) the upper computer controls the processing cutter (4) to process the subarea to be processed according to the difference degree; after the processing is finished, returning to the step 5); during the machining process and after the machining is finished, the sensing unit (31) continuously generates an electric signal under the pressure action of the pre-machined part (1) and sends the electric signal to an upper computer.
2. The method for machining curved parts based on flexible sensors (3) according to claim 1, characterized in that: the pre-processing part (1) has the characteristic of a special-shaped curved surface.
3. The method for machining curved parts based on flexible sensors (3) according to claim 1, characterized in that: the inner surface of the tool clamp (2) is completely fit with a standard workpiece.
4. The method for machining curved parts based on flexible sensors (3) according to claim 1, characterized in that: the flexible sensor (3) comprises a piezoresistive flexible sensor (3) and a piezoresistive flexible sensor (3).
5. The method for machining curved parts based on flexible sensors (3) according to claim 1, characterized in that: the flexible sensor (3) is made of elastic material and has a thickness h.
6. The method for machining curved parts based on flexible sensors (3) according to claim 1, characterized in that: the flexible sensor (3) also monitors the real-time pressure of the tool bit action position of the machining tool (4) and feeds the real-time pressure back to the upper computer, so that the upper computer adjusts and compensates the force of the tool bit on the pre-machined part (1) during machining.
7. The method for machining curved parts based on flexible sensors (3) according to claim 1, characterized in that: the shape difference is represented as the fact that the surface of the preprocessed part (1) is inconsistent with the curvature of the standard curved surface of the tool clamp (2).
8. The curved surface part machining method based on the flexible sensor (3) as claimed in claim 7, wherein the method for judging whether the shape difference exists between the surface of the preprocessed part (1) and the inner surface of the tool clamp (2) comprises the following steps: judging whether the electric signals output by each sensing unit (31) are equal, if so, judging that the shape difference does not exist between the inner surfaces of the preprocessed part (1) and the tool clamp (2), and otherwise, judging that the shape difference exists;
when the shape difference exists between the machined part and the inner surface of the tool clamp (2), the number of repeated electric signal values is recorded, and the electric signal with the largest number of repeated electric signals is taken as a reference electric signal; the sensing unit (31) which records the electric signal not equal to the reference electric signal is the sensing unit (31) to be processed.
9. The curved surface part machining method based on the flexible sensor (3) as claimed in claim 7, wherein the method for judging whether the shape difference exists between the surface of the preprocessed part (1) and the inner surface of the tool clamp (2) comprises the following steps: judging whether the difference between the electric signals output by any two sensing units (31) is larger than a preset threshold value deltamaxIf yes, judging that the shape difference exists between the inner surfaces of the preprocessed part (1) and the tool clamp (2), otherwise, judging that the shape difference does not exist;
when the shape difference exists between the processed part and the inner surface of the tool clamp (2), the first step is toThe difference between the electric signals output by the i sensing units (31) and the electric signals output by the other sensing units (31) is written into a difference set deltaiPerforming the following steps; 1,2, …, n; n is the total number of sensing units (31); judging whether each difference value set is smaller than a preset threshold value deltamaxAnd selecting a difference set with the largest number of elements, and taking the electric signal output by the sensing unit (31) corresponding to the difference set as a reference electric signal; the difference between the recording electric signal and the reference electric signal is greater than a preset threshold value deltamaxThe sensing unit (31) of (1) is a sensing unit (31) to be processed.
10. The method for machining curved parts based on flexible sensors (3) according to claim 8 or 9, characterized in that the pre-machined part (1) sub-area with shape difference is the area corresponding to the sensing unit (31) to be processed.
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