CN115016394A - Flaw cutter point identification method based on flaw type - Google Patents
Flaw cutter point identification method based on flaw type Download PDFInfo
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Abstract
A flaw knife point identification method based on flaw types comprises the steps of firstly extracting knife point information, then constructing a flaw knife point screening method, wherein flaw knife points comprise dense flaw points, abnormal feeding protrusion flaw points, repeated processing flaw points and flaw points with inconsistent adjacent tracks, and constructing corresponding screening methods for different types of flaw knife points; aiming at a complex curve formed by tiny line segments, carrying out dense flaw point screening on the reciprocal of the length of the line segment by using an MAD method, and further locking an abnormal value by NURBS fitting; judging the abnormal feeding direction of the abnormal feeding protrusion flaw point by using an MAD method, and judging whether the abnormal feeding protrusion flaw point is a small-range protrusion locking abnormal value; aiming at the defects of repeated processing, comparing the feeding difference of each direction of adjacent tracks, and locking a repeated processing curve; locking the inconsistent range of the adjacent tracks by using the length difference of the adjacent line segments aiming at the inconsistent points of the adjacent tracks; the method specifically screens the tool bit positions according to the defect types, and screening and judging the defect tool bit positions before machining are realized.
Description
Technical Field
The invention belongs to the technical field of numerical control machine tools, and particularly relates to a flaw cutter location point identification method based on flaw types.
Background
The discrete continuous small straight line segment is a tool path form commonly used in engineering, due to the error of CAD curve modeling, the precision of a CAM algorithm and other reasons, flaws exist in a tool location point, the existence of the flaws can cause fluctuation of interpolation instructions, and machining precision and machining efficiency are affected.
The smooth optimization of the tool path in the numerical control system can eliminate the negative influence of the flaw point on the interpolation instruction to a certain extent, but the smooth algorithms are not specially designed for the flaw point, can only process partial flaw points frequently, and cannot completely overcome the adverse influence of the flaw point on the interpolation instruction.
So far, only a few studies have been reported on the treatment of blemishes. Some people divide the coordinates of the flaw points into three types, namely small line segments with uneven lengths, retrograde motion, sharp points generating protrusions and the like, and identify and correct each flaw point (Wu Chun, research on NURBS fitting and interpolation algorithm of a curved surface numerical control machining programming track [ D ] China university of science and technology, 2012.). Some have preprocessed and modified curves mainly for "Z" -shaped points, cusps, etc. (charjiavin. study of trajectory optimization algorithms based on trajectory features and processing modes [ D ]. harbin university of industry, 2018.). Mutation points and self-intersection points have been eliminated, and tool trajectories have been smoothed (chenlong. study and application of free-form surface processing trajectory planning method and interpreter key technology [ D ]. university of science and technology in china, 2013). Most of the existing screening methods aim at common geometric characteristics of curves, such as line length, corner, arch height and the like, the screening method only depends on the geometric characteristics and characteristic mutation of a single knife location point, can only complete single-point flaw screening, has poor screening effect on multi-point flaws and flaws between adjacent tracks, and is difficult to complete the screening of the flaws.
Disclosure of Invention
In order to overcome the defects of the prior art, the invention aims to provide a defective cutter location identification method based on defect types, and the method is used for completing the screening of defective cutter locations according to the characteristics of different types of defective cutter locations.
In order to achieve the purpose, the invention adopts the technical scheme that:
a flaw cutter point identification method based on flaw types comprises the following steps:
1) extracting the cutter location point information: analyzing the tool position data points, extracting the tool position data points from the G codes, only retaining tool position information, and eliminating other information in the G codes, wherein the other information comprises size characters, preparation function characters, auxiliary function characters, main shaft rotating speed function characters, cutter function characters and the like;
2) constructing a defective knife point screening method, wherein defective knife points comprise dense defect points, abnormal feeding protrusion defect points, repeated processing defect points and adjacent track inconsistent defect points, and constructing corresponding screening methods for different types of defective knife points:
2.1) dense flaw point screening method: aiming at a complex curve formed by tiny line segments, a new parameter C which is 1/L is constructed, the parameter is suitable for a free-form surface formed by discrete small line segments, namely, the length L of most line segments is less than 1mm, and the smaller the length of the line segment is, the larger the reciprocal of the line segment is, namely, the larger the amplification ratio of the length of the line segment is; screening parameter abnormal values by using an MAD absolute median difference method, and determining the parameter abnormal values as undetermined dense flaw points; determining a screening result by NURBS fitting, comparing, analyzing and judging the original cutter point with a fitting result N1 of the original cutter point and a fitting error obtained by a fitting result N2 after the undetermined dense flaw point is deleted, wherein when the difference of the fitting error results of two times is small, the undetermined dense flaw point is deleted without influence on the original cutter point;
2.2) abnormal feeding protrusion defect screening method: the abnormal feeding protrusion defect is divided into two types, wherein one type is mutation of a single cutter position, and the other type is mutation of a plurality of cutter positions; the mutation of a single knife location point is judged by the size of a corner; aiming at the mutation of a plurality of cutter positions, the defect is characterized in that a plurality of small-range salient points exist in the feeding direction, and the judgment conditions are as follows: y represents i+1 -Y i Calculating the Y-direction feeding difference value of two adjacent cutter positions, screening an abnormal value by using an MAD absolute median difference method, determining the abnormal value as a protrusion and flaw point to be abnormally fed, judging whether a continuous point is in small-range mutation or not by using the lengths of the front and rear dotted line segments of the protrusion, and further verifying whether the to-be-detected point is a flaw point or not;
2.3) a method for screening fault points of repeated processing: through curve segmentation processing, comparing two adjacent curves, judging the error sizes of the two curves in three directions, and if the errors of the two curves in the three feeding directions are smaller than a set threshold value, determining the two curves as repeated processing curves;
2.4) screening method of flaw points with inconsistent adjacent tracks: and performing segmentation processing through the curves, comparing the length difference of the line segments of the nearest points of the two adjacent curves, setting a threshold value of the length difference of the line segments, and if the length difference of the line segments of the two curves is greater than the threshold value, determining that the line segments of the region are inconsistent, namely the points are unevenly distributed.
The invention has the following beneficial effects: the invention sets corresponding screening methods for different types of flaw points, and provides a new screening parameter and verification method for improving the dense flaw screening method aiming at unsatisfactory dense flaw screening results; designing a brand new judgment method and a screening process aiming at the abnormal feeding protrusion flaws, the repeated processing flaws and the adjacent track inconsistent flaws; the method specifically screens the tool bit positions according to the defect types, and can well complete the screening of common defect points.
Drawings
FIG. 1 is a flow chart of the present invention.
FIG. 2 shows the file format in the code of the embodiment G.
FIG. 3 is a schematic diagram illustrating segment lengths according to an embodiment.
Fig. 4 is a schematic diagram of probability distributions of two test pieces and a segment length according to the embodiment.
Figure 5 is a flow chart of the embodiment of dense defect screening.
Fig. 6 shows the results of the NURBS fitting of the example.
FIG. 7 shows the absolute fitting error of the curve and the final dense point positions of the example.
FIG. 8 is a flow chart of screening of the abnormal feeding protrusion defect points according to the embodiment.
Figure 9 is an example abnormal feed bump defect screening station.
Figure 10 is a flow chart of the example rework flaw screening process.
Fig. 11 shows the directional feed error of the two curves Y, Z of the example.
Figure 12 is an example rework blemish screening site.
Figure 13 is a flow chart of example adjacent trace inconsistent defect screening.
Figure 14 shows example adjacent trace inconsistent defect screening locations.
Detailed Description
The present invention will be described in detail below with reference to the accompanying drawings and examples.
Referring to fig. 1, a method for identifying a defective blade point based on a type of a defect includes the steps of: 1) extracting the cutter location point information: the numerical control machine tool generally uses G codes to describe processing information of the machine tool, such as a feed path, a coordinate system selection, opening of a cooling liquid and the like, and as shown in fig. 2, a part processes the G codes, and a general program segment is composed of the following functional words:
N_G_X_Y_Z_F_S_T_M_
the program segment generally includes a program number N, a preparation function G for specifying a plurality of machining operations such as a relative movement trajectory of the tool and the workpiece, a machine coordinate system, a coordinate plane, tool compensation, and coordinate offset, a coordinate function word X, Y, Z for setting a displacement amount of each coordinate of the machine tool, a coordinate value (X, Y, Z), a feed speed, a spindle speed, a tool, an auxiliary function, and the like; the feeding function word F is used for specifying the speed of the tool moving relative to the workpiece; the spindle function word S is used to specify spindle speed; the tool function word T is used for selecting a replaced tool, and the auxiliary function word M code is mainly used for controlling the switching value of the numerical control machine;
analyzing the tool position data points, extracting the tool position data points from the G codes, only retaining tool position information, and eliminating other information in the G codes, wherein the other information comprises size characters, preparation function characters, auxiliary function characters, main shaft rotating speed function characters, cutter function characters and the like; in the G code file output by the CAM after post-processing, the triaxial G code is: G01X _ Y _ Z _ F, the code contains the actual position information of each driving shaft of the machine tool, namely the cutter position information;
2) constructing a defective cutter point screening method, wherein according to analysis, defective cutter points comprise dense defective points, abnormal feeding protrusion defective points, repeatedly processed defective points and adjacent track inconsistent defective points, and constructing corresponding screening methods for different types of defective cutter points:
2.1) a dense flaw point screening method: aiming at a complex curve formed by tiny line segments, defining a point with a smaller segment length as a dense flaw point, wherein the traditional flaw screening method is to set a segment length threshold value, and the setting of the threshold value depends on engineering experience and the segment length of a free-form surface; this determination requires setting a segment length threshold for each curve in the region. The calculation method of the length of the knife point line shown in fig. 3 is as follows: setting the nth knife location: p is a radical of n (x n ,y n ,z n ) N +1 th knife site: p is a radical of n+1 (x n+1 ,y n+1 ,z n+1 ) If the length of the nth segment is: l is n ＝|P n P n+1 L, |; two test pieces consisting of discrete small segments as shown in fig. 4 have most segment lengths distributed below 1mm, the average values of the segment lengths are 0.86mm and 0.15mm, respectively, and the sizes of the abnormal segment lengths are 0.02mm and 0.01mm, respectively. Therefore, different line segment length thresholds are needed to be set for judging whether the two parts have dense defect points;
the dense flaw screening process is shown in fig. 5, because the length of the whole line segment of the free-form surface is small, the difference between the length of the dense flaw point line segment and the length of the normal line segment is small, a new parameter C is constructed to be 1/L, and the parameter is suitable for the free-form surface consisting of discrete small line segments, namely the length L of most line segments is less than 1 mm. The smaller the length of the line segment, the larger the reciprocal of the line segment, namely the larger the amplification ratio of the length of the line segment;
parameter outliers were screened using mad (media Absolute development) Absolute median difference. The method for judging an abnormal value by using the potential difference between absolute values is shown in the following formula (1) and formula (2);
MAD＝k*median(|x i -x m | (1)
wherein x is i Is a data point, x m Is the median of the data points, k is the coefficient, based onExperience, usually takes the values: k is 1.4826;
before judging the abnormal value, defining a standard; similar to the judgment standard of the mean value and the standard deviation, values of 3 (very conservative), 2.5 (moderately conservative) and even 2 (poor conservative degree) are provided according to the strict degree of the research standard, and the conservative degree is in positive correlation with the range of normal values; using a very conservative judgment method, C ═ 3; the upper and lower ranges of the abnormal value screening are shown in the following equation (3).
x m -3*MAD<x i <x m +3*MAD (3)
Setting the result of MAD judgment as the fault point to be determined, using NURBS fitting to determine the final screening result, respectively comparing and judging the fitting result N1 of the original cutter position and the fitting result N2 after the fault point to be determined is deleted, and when the difference of the fitting error results of two times is small, considering that the position of the deleted compact cutter has no influence on the original cutter position;
the complex curve is composed of discrete small line segments, and the line segment lengths processed by different curves have larger difference, for example, the length of a plane processing line segment is larger, the length of a curved surface processing line segment is smaller, so that the complexity of the fitting operation at different curved surface parts is different, and the fitting accuracy is also different; global NURBS fitting is difficult, and fitting errors are large; in order to improve the fitting precision, local segmentation fitting is adopted, and a segmented NURBS fitting curve is used for replacing a trend line of an initial tool location data point to fit a discrete tool location point; the NURBS fitting diagram shown in fig. 6 includes model points, control points and fitting curves, the error between the original tool position and the fitting curves of two times is calculated, and defined as an absolute fitting error, if the absolute fitting error is greater than a set threshold, undetermined dense flaw points existing in 6 points before and after the position are retained, and the absolute fitting error of a certain curve and the final screening result are shown in fig. 7;
2.2) abnormal feeding protrusion defect point screening method: the abnormal feeding protrusion defect is divided into two types, wherein one type is mutation of a single cutter position, and the other type is mutation of a plurality of cutter positions; mutation of a single knife site is judged by the size of the corner, and the research of the protrusion flaw is carried outCompleting; aiming at the mutation of a plurality of cutter positions, the defect is characterized in that a plurality of small-range salient points exist in the feeding direction, and the judgment conditions are as follows: calculating the difference of Y-direction feeding of two adjacent cutter location points, wherein Y is equal to Y i+1 -Y i Screening an abnormal value by using an MAD absolute median difference method, determining the abnormal value as an undetermined abnormal feeding protrusion defect point, judging whether a continuous point is in small-range mutation or not by using the lengths of front and rear dotted line segments of protrusion, and further verifying whether the undetermined point is a defect point or not;
the abnormal feeding protrusion defect is caused by abnormal change in a certain feeding direction, the characteristics of the defect are observed, the defect mainly has abnormal feeding different from other points, whether the feeding is the feeding planned by a curve is judged, and the condition limitation needs to be added on the protrusion defect of the screened abnormal feeding.
The abnormal feed protrusion defect screening process is shown in fig. 8, and lists the characteristics of such defects: the defective cutter positions have abnormal feeding in the Y direction, and the overall occurrence range is small; calculating the difference between Y-direction feeding of two adjacent cutter positions, i.e. Y is equal to Y i+1 -Y i The abnormal value is determined by the above-described MAD, and the determination result is as shown in fig. 9, where a small Y-direction protrusion is present at a part of the curve; feeding mutations also exist at the positions and the boundaries of the curve features, the feeding is widely and reasonably existed, and meanwhile, aiming at two reasons that the defects cannot be identified by the existing method, namely non-single-point protrusion and unobvious geometric features, the undetermined abnormal feeding protrusion defect point is further judged; separating continuous points in the fault to be determined to obtain the length dL of the line segment formed by the two points before and after the continuous points<Points in the L _ limit are flaw points, and the rest points are normal points; the type of protrusion defect finally screened out by the curve is shown in fig. 9, and there are some points in this area where there are abnormal protrusions in the Y direction;
2.3) a method for screening fault points of repeated processing: the repeated machining flaws are formed by machining the same curve for multiple times in the machining process, and the discrete positions of the cutter points machined twice cannot be consistent, so that an error exists in the machining process of a machine tool at the position; designing a screening method according to the characteristics, taking multiple points of a curve as a reference, interpolating the other curve to the same points according to a piecewise linear interpolation method, and comparing the error magnitude of the points at the same position; the error magnitudes of the two terms are compared Y, Z with the X direction as a reference, the error result is shown in fig. 11, the error in the Y direction of the two curves is zero, the difference between the error in the Z direction is less than 4 μm at some positions, and the error in other positions is zero.
The repeated processing flaw screening process is shown in fig. 10, and the parts are processed in a segmented manner, and the size of the three-axis motion feeding in the two adjacent tool path sets is compared; interpolating one point set in adjacent tracks into another point set by adopting a piecewise linear interpolation method, and interpolating other directions by taking one coordinate direction of a cutter position point as a reference, wherein in the embodiment, two adjacent track sets are respectively set as { Pi } and { Pj } by taking an X axis as a reference; cutting the two tracks to the same starting point and end point according to the X direction, interpolating the fewer coordinate points to the same coordinate quantity by adopting a piecewise linear interpolation method, and obtaining coordinate error values of other two directions; setting the judgment condition as Y-direction feeding difference | Delta Y & lt As & gt according to the obtained characteristics of repeated processing<Y lim, while using the Z-direction relative error, i.e., the ratio of the Z-direction feed difference to the Z-coordinate position,
performing auxiliary judgment, defining two curves meeting the two conditions as repeated processing curves, and obtaining a figure 12 of the screened repeated processing flaw points;
2.4) screening method of flaw points with inconsistent adjacent tracks: the inconsistency of adjacent tracks is a defect point with inconsistent distribution of adjacent track points when processing is carried out in the same area and the same characteristic position; the screening process is shown in fig. 13, and the inconsistent features of adjacent tracks are: 1) the length difference of the line segments is large; 2) edge points of non-contour feeding of the screened cutter location points; according to the two characteristics, a screening method of inconsistent points of adjacent tracks is established, the length difference of the line segments of the two curves is greater than a set threshold value, and meanwhile, the screening method of the part boundary is as follows: min _ x < x < max _ x. The distribution of points with inconsistent processing of the adjacent tracks of the two curves is shown in fig. 14, and the method can well complete the screening of the points with inconsistent line lengths of the adjacent curves.
In the present embodiment, a plurality of types of defect points included in a part are found, fig. 7 shows a dense defect screening result, fig. 9 shows an abnormal feed direction protrusion screening result, fig. 12 shows a repeated machining defect screening result, and fig. 14 shows a defect screening result in which adjacent trajectories do not coincide.
Claims (5)
1. A flaw cutter point identification method based on flaw types is characterized by comprising the following steps:
1) extracting the cutter location point information: analyzing the tool position data points, extracting the tool position data points from the G codes, only retaining tool position information, and eliminating other information in the G codes, wherein the other information comprises size words, preparation function words, auxiliary function words, main shaft rotating speed function words and tool function words;
2) and constructing a defective cutter point screening method, wherein the defective cutter points comprise dense defective points, abnormal feeding protrusion defective points, repeatedly processed defective points and defective points with inconsistent adjacent tracks, and constructing corresponding screening methods for different types of defective cutter points.
2. The method of claim 1, wherein step 2) comprises a dense defect point screening method: aiming at a complex curve formed by tiny line segments, a new parameter C is constructed, wherein the parameter C is 1/L, the parameter is suitable for a free-form surface formed by discrete small line segments, namely the length L of a majority of line segments is less than 1mm, and the smaller the length of the line segments is, the larger the reciprocal of the line segments is, namely the larger the amplification ratio of the length of the line segments is; screening parameter abnormal values by using an MAD absolute median difference method, and determining the parameter abnormal values as undetermined dense flaw points; and determining a screening result by using NURBS fitting, comparing, analyzing and judging the original cutter point with a fitting result N1 of the original cutter point and a fitting error obtained by a fitting result N2 after the undetermined dense flaw point is deleted, wherein when the difference of the fitting error results of two times is small, the undetermined dense flaw point is deleted without influence on the original cutter point.
3. A method according to claim 1, characterized in that said step 2) comprises an abnormal feed bump defect screening method: the abnormal feeding protrusion defect is divided into two types, wherein one type is mutation of a single cutter position, and the other type is mutation of a plurality of cutter positions; the mutation of a single knife location point is judged by the size of a corner; aiming at the mutation of a plurality of cutter positions, the defect is characterized in that a plurality of small-range salient points exist in the feeding direction, and the judgment conditions are as follows: y represents i+1 -Y i And calculating the Y-direction feeding difference value of two adjacent cutter positions, screening an abnormal value by using an MAD absolute median difference method, determining the abnormal value as the protrusion and flaw point of the to-be-determined abnormal feeding, judging whether the continuous point is in small-range mutation or not by using the lengths of the front and rear dotted lines of the protrusion, and further verifying whether the to-be-determined point is the flaw point or not.
4. A method according to claim 1, wherein said step 2) comprises repeating the process defect screening method: and comparing two adjacent curves through curve segmentation processing, judging the error sizes of the two curves in three directions, and if the errors of the two curves in the three feeding directions are smaller than a set threshold value, determining that the two curves are repeated processing curves.
5. A method according to claim 1, wherein said step 2) comprises a neighboring track inconsistency defect screening method: and performing segmentation processing through the curves, comparing the length difference of the line segments of the nearest points of the two adjacent curves, setting a threshold value of the length difference of the line segments, and if the length difference of the line segments of the two curves is greater than the threshold value, determining that the line segments of the region are inconsistent, namely the points are unevenly distributed.
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Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN115906528A (en) * | 2022-12-30 | 2023-04-04 | 山东理工大学 | Automatic preprocessing method, system, equipment and storage medium for welding structure model |
| CN116974239A (en) * | 2023-09-22 | 2023-10-31 | 深圳市艾姆克斯科技有限公司 | Processing track control method and system based on cnc engraving and milling machine |
| CN117140204A (en) * | 2023-10-31 | 2023-12-01 | 南通弘铭机械科技有限公司 | Target fixing method for machining |
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Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN115906528A (en) * | 2022-12-30 | 2023-04-04 | 山东理工大学 | Automatic preprocessing method, system, equipment and storage medium for welding structure model |
| CN116974239A (en) * | 2023-09-22 | 2023-10-31 | 深圳市艾姆克斯科技有限公司 | Processing track control method and system based on cnc engraving and milling machine |
| CN116974239B (en) * | 2023-09-22 | 2023-12-01 | 深圳市艾姆克斯科技有限公司 | Processing track control method and system based on cnc engraving and milling machine |
| CN117140204A (en) * | 2023-10-31 | 2023-12-01 | 南通弘铭机械科技有限公司 | Target fixing method for machining |
| CN117140204B (en) * | 2023-10-31 | 2023-12-26 | 南通弘铭机械科技有限公司 | Target fixing method for machining |
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