CN115828566A - Process design and verification method for milling surface precision distribution consistency of end mill - Google Patents
Process design and verification method for milling surface precision distribution consistency of end mill Download PDFInfo
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Abstract
The invention relates to the technical field of milling, in particular to a process design and verification method for the consistency of the milling surface precision distribution of an end mill, which comprises the following steps of S1, designing the consistency of the milling side vertical face processing error of the end mill; s2, identifying and analyzing design variables of machining error consistency of the milling side vertical face of the end mill; s3, milling a design model with consistent machining errors of the side vertical face by using the end mill; and S4, verifying the design flow of the consistency of the milling side vertical face machining errors of the end mill. The invention provides a design target of the consistency of the milling side vertical face machining error of the end mill, a given design variable of the consistency of the milling side vertical face machining error of the end mill, a proposed design model of the consistency of the milling side vertical face machining error of the end mill and a proposed verification method of the design process of the consistency of the milling side vertical face machining error of the end mill, which can improve the consistency level of the machining precision and verify the feasibility and consistency level of the process scheme.
Description
The application is divisional application with application number 202210162380.3, application date 2022, 02/22 and invention name "process design and verification method for milling surface precision distribution consistency".
Technical Field
The invention relates to the technical field of milling, in particular to a process design and verification method for milling surface precision distribution consistency of an end mill.
Background
How to realize efficient and accurate cutting by milling is an important development direction nowadays, and the milling tool becomes an important realization way for high-quality processing of key parts in the high-end manufacturing fields of modern aerospace, medical instruments and the like by virtue of the process characteristics of high efficiency and high precision. When high-efficient milling, receive the influence of milling vibration, sword tooth error, the processing surface formation process constantly changes, leads to the processing surface error to present manifold change characteristic along feed speed direction and depth of cut direction, and then produces the influence to the processing surface performance. The existing measurement method judges the whole or local level of the quality of the processed surface, and the study on the specific change characteristics of the processing error on the processed surface still has ambiguity and uncertainty.
The existing error measurement method only judges the whole or local level of the processed surface, and does not deeply research the consistency of the processing precision, thereby influencing the control effect of the whole process on the processed surface and reducing the milling quality of the processed surface.
Therefore, a process design and verification method for milling surface precision distribution consistency is provided.
Disclosure of Invention
The invention aims to provide a process design and verification method for milling surface precision distribution consistency of an end mill, so as to solve the problems in the background technology.
In order to achieve the purpose, the invention provides the following technical scheme: a process design and verification method for milling surface precision distribution consistency specifically comprises the following steps:
s1, designing the consistency of machining errors of the milling side vertical face of the end mill:
the design target of the consistency of the milling side elevation machining errors of the end mill is provided, and the consistency of the machining surface precision is judged by utilizing the design target, so that the machining surface precision consistency can be improved;
s2, identifying and analyzing design variables of machining error consistency of milling side vertical surfaces of the end mill:
redesigning and planning the design variables of the machining surface precision, providing a design variable identification and analysis method for the consistency of the machining errors of the milling side vertical surface of the end mill, and analyzing the influence degree of the influencing factors and the interaction thereof so as to control the design variables;
s3, designing a model for machining error consistency of the milling side vertical face of the end mill:
optimizing the existing process design method through a design target and a design variable, and providing a new design model of the consistency of the milling side vertical face machining errors of the end mill;
s4, a verification method of the design process of the consistency of the milling side vertical face machining errors of the end milling cutter comprises the following steps:
and providing a verification method of the design flow of the consistency of the milling error of the side vertical face of the end mill, thereby verifying the machining precision and consistency level of the design model.
In the step S1, when the machined surface is formed, the degrees of influence of the machined surface errors by the respective factors are different, the machined surface accuracy consistency is a variation characteristic exhibited by the distribution of the machined surface accuracy in the feed speed direction and the cutting depth direction, and in order to evaluate the machined surface accuracy consistency, a design target of the end mill milling side elevation machining error consistency is proposed, and the method firstly separates the design target from the plurality of influencing factors as shown in fig. 1.
The various influencing factors are obtained from fig. 1, and finally, the variable sets shown in the following formula are obtained in a summary mode.
Q＝{n，f z ，a p ，a e ，M，a，d,l,β，θ，Δy} (1)
In the formula, n is the rotating speed of the main shaft; f. of z The feed amount per tooth is taken; a is p Milling depth; a is e Milling width; m is milling vibration; a is the error distribution of cutter teeth; d is the diameter of the milling cutter; l is the length of the blade; beta is a helix angle; theta is an angle error; Δ y is the position error.
The design targets are extracted from the variable set as an angle error and a position error, and then the error values of the machined surface are respectively calculated by extracting feature points, as shown in fig. 2 to 5.
As shown in fig. 2 to 5, distances of 0mm, 5mm, 10mm in the feed speed direction and the cutting depth direction from the start cutting position to the cutting end position in the feed speed direction and the cutting depth direction according to the radius of the milling cutter of 1/2 in the feed speed direction and the cutting depth direction on the actual machined surface and the design reference surface, respectively, are taken as n xi And n γi Calculating the distribution curves of the errors of the machined surface corresponding to the points in the feeding speed direction and the cutting depth direction by an error calculation method, dividing the errors of the machined surface into position errors and angle errors, and analyzing the average value of the errors of the characteristic point positions of the machined surface
. Mean value of errors in the position of the feature points of the machined surface
Indicating the average level of the machined surface and the maximum value M of the errors of the positions of the characteristic points of the machined surface amax It is indicated that the maximum level allowed by the errors in the positions of the feature points is as close as possible to the average of the errors in the positions of the feature points of the machined surface. Minimum value M of machining surface characteristic point position error amin The minimum level allowed by the position error of the characteristic point is indicated, the position error of the characteristic point is better as being closer to the average value of the position error of the characteristic point of the machined surface, the angle error of the characteristic point is an included angle formed by plane normal vectors of selected characteristic points of a design reference surface and an actual machined surface, wherein the normal vector of the design reference surface is represented by l, the normal vector of the actual machined surface is represented by Nm, and the angle is not included because the design reference surface has an angle, so that the angle is not includedThe error is itself, and the closer the angle error is to 0, the better the consistency degree is, and the machining surface precision consistency level is analyzed by the correlation degree using the error correlation degree calculation method. The error calculation formula is shown below.
Δy＝y g -y g(0) (2)
In the formula, theta 1 For the angle error theta at x g o g y g Projection on a surface; theta 2 For the angle error theta at y g o g z g Projection on a surface.
For calculating the error correlation degree, the extracted characteristic points of the error distribution curve are respectively used as reference sequences Y q ap And comparison of sequence Y q ap *。
Calculating reference sequence Y of surface errors in the direction of feed speed by using improved grey relative correlation analysis method q ap Sequence of comparisons Y with surface errors in the depth of cut direction q ap * The degree of association between them. Wherein q =1 is a machined surface position error sequence and q =2 is an angle error sequence.
γ Ma The closer to 1, the higher the machining accuracy consistency level, the more the conventional correlation degree is between 0.5 and 0.8, and the patent takes the correlation degree of 0.8 as a judgment index, extracts characteristic points at the positions with the cutting depths of 0mm, 5mm and 10mm respectively, analyzes the characteristic points by using a spread software, and if the distribution of the characteristic points is normal distribution, the better the machining quality is.
The evaluation index given by combining the above methods is shown in the following formula.
In the formula, M amax Is the maximum value of the error of the actual processing surface; [ M ] A amax ]Is the maximum value of the error of the design reference surface
The error average value of the actual processing surface is obtained;
is the mean value of the error of the design reference surface; m amin Is the minimum value of the error of the actual processing surface; [ M ] A amin ]Is the design reference surface error minimum.
And finally, obtaining the design target of the machining error consistency of the milling side vertical face, as shown in figure 6.
The step S2 specifically includes the following steps:
s201, a main design variable identification method:
in the milling process, the influence of various design variables and even the interaction are existed, the influence of various design variables on the consistency of the processing error is considered, and various variables are identified and analyzed.
In the machining process, the machining surface has direct influence on the machining surface, namely design variables such as vibration, cutter tooth error and feed quantity of each tooth, in order to more comprehensively identify the design variables with direct influence, the root distance graph 1 selects the main design variables of the machining surface error as the rotation speed of a milling cutter spindle, the feed quantity of each tooth, the cutting depth, the cutting width, the cutter tooth error distribution, the milling vibration, the diameter of the milling cutter, the length of a cutting edge and the spiral angle, and a variable set formula is given according to a cutter relation graph and is shown as the following formula.
Q＝{n，f z ，a p ，a e ，M，a，d,l,β} (7)
In order to identify design variables which directly affect the machined surface, performing one-factor variance analysis on the design variables, wherein an F value obtained in a one-factor variance experiment is the ratio of the mean squares of the two design variables, fcrit is a critical value of the F value under the corresponding significance level, and if the F value is greater than the Fcrit, the effect is significant; p-value is the confidence probability for the corresponding F value, typically less than 0.05 for both significant effects, and less than 0.001 for highly significant effects. According to variance value analysis, the influence degrees on various design variables are ranked from large to small, milling vibration, cutter tooth error, feed per tooth, cutting width, cutting depth, milling cutter spindle rotation speed, milling cutter diameter and cutting edge length are ranked, wherein the influence degrees of influence factors of the milling cutter diameter, the cutting edge length and the cutting edge angle on the consistency of the machining surface precision are small, and therefore the design variables are determined to be the spindle rotation speed, the feed per tooth, the milling depth, the milling width, the milling vibration and the cutter tooth error distribution.
S202, designing a variable influence degree identification method:
the influence degrees of the various influencing factors on the machined surface are different, and in order to improve the consistency of the precision of the machined surface, the influence degrees of the various factors are analyzed, so that an influencing factor analysis method for the consistency of the machining errors of the milling side elevation is provided and shown in fig. 7.
As shown in FIG. 7, first, design variables n and f are set z 、a p 、a e Respectively carrying out surface morphology simulation on M and a, and then calculating by an error calculation method to obtain an error average value of the position error
(ii) a Maximum value of error M amax (ii) a Minimum value of error M amin (ii) a And then judging the consistency degree of each design variable by the judging method proposed by the above complaint.
S203, designing a variable coupling identification method:
the method comprises the steps of firstly analyzing response surfaces when various design variables have coupling effects, then analyzing the significance of the response surfaces of a response surface model to obtain interaction effects among influence factors, finally analyzing multi-factor variance to obtain the coupling effects among the influence factors, then analyzing the response surfaces to obtain a central experimental design scheme, and then constructing the response surface model according to the central experimental design scheme and simulation results of the previous design variables, so that a second-order expression is constructed to analyze the response characteristics of machining surface errors to milling process design variables, wherein the second-order expression is shown as a formula (8).
In the formula, y 0 To be initially undetermined, p i Is x i Influence coefficient of (1), p ij Is x i And x j The interaction coefficient, Q, is the fitting error and noise contribution, which is obeyed by the normal distribution in this model.
Finally, the method for obtaining the coupling effect of the influencing factors of the milling side elevation machining error consistency is shown in fig. 8.
In the step S3, the design model comprehensively utilizes the optimization design and the collaborative design, considers the influence of the machining error and the milling vibration on the machining, and improves the machining precision consistency level, and establishes a new design model of the machining error consistency of the milling side elevation by taking the machining error overall level and the consistency of the distribution thereof as the design target, the machining precision consistency as the constraint condition, and the influence degree of each design variable as shown in fig. 9.
As shown in fig. 9, the design model of milling side elevation machining error consistency starts from improving machining precision consistency, starts from researching the characteristic parameters of the milling cutter, researches the characteristic parameters of the milling cutter through a milling process method and a machine tool to obtain each influence factor, then performs surface morphology simulation on each influence factor to obtain a machining surface error and an angle error, performs machining surface error calculation on the machining surface error from the feeding speed direction and the cutting depth direction respectively, judges the machining surface precision integral level and consistency degree of a calculation result through a design target of milling side elevation machining error consistency, and if the judgment is unqualified, adjusts and plans each design variable through identification of the machining surface precision integral level influence factor, provides a new machining precision consistency process scheme, and re-calculates the machining precision consistency process scheme. If the judgment is qualified, milling experiment verification is carried out, if the experiment verifies that the consistency level of the machining precision is improved, the consistency and the feasibility of the process design scheme are demonstrated, and if the experiment verification fails, the experiment scheme is redesigned for judgment.
In the step S4, in order to check the accuracy of the design model of the machining error consistency, a verification method of the design flow of the machining error consistency of the milling side elevation is specifically provided and shown in fig. 10.
The verification method mainly verifies the machining precision consistency of the design model of the milling side elevation machining error consistency by respectively comparing the new process scheme with the old process scheme and the experimental scheme. Firstly, respectively taking n from the actual processing surface and the design reference surface in the new process scheme, the old process scheme and the experimental scheme according to the design target of the consistency of the processing error of the milling side vertical surface along the feeding speed direction and the cutting depth direction according to the distance of 1/2 of the radius of the milling cutter xi And n γi Calculating the error distribution curves of the machined surface corresponding to the points in the feeding speed direction and the cutting depth direction by adopting an error calculation method, and analyzing the average value of the position error and the angle error of the characteristic point of the machined surface according to a judgment method
Maximum value M amax And minimum value M amin And then, performing grey correlation degree analysis and calculation on the new process scheme and the old process scheme, judging whether the consistency is good or bad according to a judgment standard, comparing the new process scheme with the old process scheme according to the judgment standard, if the correlation degrees of the new process scheme are higher than the correlation degrees of the old process scheme, indicating that the consistency degree of the new process scheme is high, comparing the maximum value and the minimum value of errors with the average value by the new process scheme and the experimental scheme, and if the error degrees of the new process scheme are closer to the average value of the errors than the maximum value and the minimum value of the errors of the experimental scheme, indicating that the precision of the new process scheme is high and the errors are small, thereby verifying the processing precision consistency of the design model.
Compared with the prior art, the invention has the beneficial effects that:
1. the design target of the consistency of the milling side elevation processing errors of the end mill, provided by the invention, is used for analyzing the distribution characteristics of the processing surface errors, obtaining the angle errors and the position errors by using a characteristic point extraction method, calculating by using an error calculation method, and finally judging the consistency of the processing errors by using a correlation analysis method, so that the consistency level of the processing precision is improved;
2. the design variables of the consistency of the milling side elevation processing errors of the end mill are designed, the variables are re-integrated and planned, relevant influence factors are separated out, the influence degree of the influence factors is obtained by using a single-factor variance analysis method, and the interaction influence degree among the influence factors is obtained by using a multi-factor variance analysis method, so that the influence factors are better controlled, and the processing precision consistency is improved;
3. according to the design model for the consistency of the milling error of the side vertical face of the end mill, the technical scheme that the consistency level of the processing precision is high and the whole level of the processing precision meets the processing technical requirements, and the precision level and the consistency level of the processing precision are obtained;
4. the verification method for the design process of the milling side elevation machining error consistency of the end mill provided by the invention utilizes a judgment method to verify the feasibility and consistency level of the process scheme through experimental comparison.
Drawings
FIG. 1 is a schematic diagram of the influencing factors of the milling process of the present invention;
FIG. 2 is a schematic diagram of a feature point extraction method according to the present invention;
FIG. 3 is a graph of the feed speed direction machined surface error profile of the present invention;
FIG. 4 is a profile of the error of the machined surface in the cutting depth direction according to the present invention;
FIG. 5 is a schematic view of an angle error model of the present invention;
FIG. 6 is a flow chart of the design objective of milling side elevation machining error consistency of the present invention;
FIG. 7 is a flowchart of an impact factor analysis method for milling side elevation machining error consistency according to the present invention;
FIG. 8 is a flowchart of the impact factor coupling analysis method for milling side elevation machining error consistency according to the present invention;
FIG. 9 is a flow chart of a design model for milling side elevation machining error consistency according to the present invention;
FIG. 10 is a flowchart of a method for verifying the consistency of milling side elevation machining errors according to the present invention;
FIG. 11 is a distribution trend chart of the cutting depth z =0 according to the present invention;
FIG. 12 is a distribution trend chart of the cutting depth z =5 according to the present invention;
fig. 13 is a distribution trend graph of the cutting depth z =10 according to the present invention;
FIG. 14 is a histogram of a significant analysis of the process surface position error variation characteristic influencing factors of the present invention;
FIG. 15 is a histogram of significant analysis of factors affecting the angular error variation characteristics of the tangent plane and the xoz plane of the present invention;
FIG. 16 is a histogram showing the significant analysis of the factors affecting the angular error variation characteristics of the tangent plane and the yoz plane according to the present invention;
FIG. 17 is a simulated view of the experimental machined surface of the new process embodiment of the present invention;
FIG. 18 is a line drawing of a new process recipe position error reference point of the present invention;
FIG. 19 is a line graph of the angular error between the tangent plane at the location point of the new process embodiment of the present invention and xoz;
FIG. 20 is a line graph of the angular error between the tangent plane at the location point of the new process embodiment of the present invention and yoz;
FIG. 21 is a diagram showing the result of simulation of the machined surface according to the novel process of the present invention;
FIG. 22 is a plot of a simulated position error reference point line for the new process embodiment of the present invention;
FIG. 23 is a line graph of the angular error between the tangent plane of the new process embodiment simulated location point and xoz;
FIG. 24 is a line drawing of the angular error between the tangent plane to the new process recipe simulation location point and yoz;
FIG. 25 is a simulated view of a machined surface of the present invention with tooth error alone;
FIG. 26 is a simulated view of the machined surface under the action of only milling vibrations in accordance with the present invention;
FIG. 27 is a graph showing the distribution curves of the position error curves under the vibration action of the present invention;
FIG. 28 is a line graph showing the angle error between the tangent plane and the yoz plane at a location point under the vibration of the present invention;
FIG. 29 is a line graph showing the angular error between the tangent plane and the xoz plane at a location point under the vibration action of the present invention;
FIG. 30 is a histogram of the error correlation of the new and old experimental surfaces.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be obtained by a person skilled in the art without making any creative effort based on the embodiments in the present invention, belong to the protection scope of the present invention.
The invention provides a technical scheme that: a process design and verification method for milling surface precision distribution consistency specifically comprises the following steps:
s1, designing the consistency of machining errors of the milling side vertical face of the end mill:
and selecting the characteristic points under different cutting depth conditions by using a judging method, and analyzing the characteristic points by using statistical analysis software SPSS.
The p-p graph is used as a common means for analyzing the distribution form of the variables, and mainly reflects the trend relation between the cumulative proportion of the variables of the selected characteristic points and the cumulative proportion of the designated distribution, so that the distribution situation of the characteristic points can be reflected very intuitively. The feature points are selected at three cutting depths of z =0, z =5 and z =10, and whether the feature points obey normal distribution is judged. As shown in fig. 11-13:
it can be seen from fig. 11-13 that the actual cumulative probability and the expected cumulative probability are approximately on the same straight line, and therefore it can be concluded that the characteristic points of the actual machined surface approximately follow the normal distribution under different cutting depths.
The machining surface errors are resolved at the positions with the cutting depth of z =0mm, z =5mm and z =10mm according to a machining surface error resolving method, error sequences corresponding to three cutting depth error curves of two types of errors are constructed, the change trend is analyzed by a gray correlation analysis method, and the consistency analysis result is shown in table 1.
TABLE 1 machining accuracy consistency analysis
As shown in table 1, the maximum value of the error of the machined surface is smaller at three different cutting depths, and meets the technical requirement of the precision of the machined surface; and the processing error correlation degree of a plurality of positions is higher than 0.8, which shows that the precision consistency is better. In order to comprehensively judge the machining surface precision in the cutting depth direction, the average value of the machining error correlation degrees of all the cutting depths is used as a judgment index, and the average value of the error correlation degrees is higher than 0.8, which shows that the machining precision consistency level is good.
S2, identifying and analyzing design variables of machining error consistency of milling side vertical surfaces of the end mill:
in the design variables of the machining surface errors screened by the design variables of the machining error consistency of the milling side vertical surface, the rotating speed of a main shaft and the feeding amount of each tooth not only directly influence vibration, but also influence the vibration period and the cutter tooth errors, so that the rotating speed of the main shaft, the feeding amount of each tooth, the cutter tooth errors and the milling vibration are used as the influence factors of the machining surface errors, the machining surface errors are resolved through single factor analysis, and preliminary design variable variance analysis is performed on the machining surface errors.
The experimental milling cutter adopts an integral hard alloy end milling cutter (MC 122-20.0A5B-WJ30 TF) manufactured by Walter company, five teeth are equal in pitch, the diameter is 20mm, the cutter length is 104mm, and the helix angle is 50 degrees; the machine tool adopts a three-axis milling center, and the length of the workbench is 1050mm, and the width of the workbench is 560mm. The milling mode is forward milling and dry milling, and the milling titanium alloy is TC4.
The single-factor experiment is carried out by taking the rotation speed of a milling cutter spindle of 1144rpm, the feed per tooth of 0.145mm/z, the cutting depth of 0.5mm and the cutting width of 15mm as basic values, and the results of the single-factor experiment scheme and the results of measuring vibration acceleration signals are shown in Table 2.
TABLE 2 table of variable parameters of single-factor experimental scheme
According to the vibration test result of the single-factor experimental scheme shown in the table 2, the maximum value of the vibration acceleration in three directions is used as the vibration characteristic, and the influence degree of the rotation speed of the main shaft of the milling cutter, the feed amount of each tooth, the cutting depth and the cutting width on the milling vibration is calculated by variance analysis.
Combining the practical conditions of milling vibration in milling experiments, and using signal data of the maximum value of vibration acceleration in three directions of 5 milling experiments, wherein the signal data are a 1 ＝(0.95，2.18，1.77)；a 2 ＝(1.05，5.41，1.24)；a 3 ＝(1.13，2.22，1.84)；a 4 ＝(1.52,5.91，3.21)；a 5 = (1.68, 5.75, 2.55) (unit: m/s) 2 )。
Wherein n =1718rpm, f z ＝0.05mm、M 1 (axial errors 0.045,0.008,0.016,0.037,0.029; radial errors 0.027,0.055,0.017,0.027, 0.018) as basic parameters, to thereby perform an analysis of variance of the design variables of the error distribution characteristics of the machined surface, the analysis results being shown in Table 3.
TABLE 3 results of analysis of variance of processing errors
As shown in table 3, the rotational speed of the milling cutter spindle, the tooth error, the feed per tooth and the F value of the milling vibration are greater than Fcrit, and P-value is less than 0.05, which indicates that various influencing factors have a significant influence on the distribution characteristics of the machining errors. Analyzing the variance value, the influence degree of the influence factors of the position error of the processing surface is as follows: the cutter tooth error is larger than the feed per tooth, the milling vibration is larger than the rotation speed of a milling cutter spindle; influence degree of influence factors of the angle error between the tangent plane and the xoz plane: the cutter tooth error, the milling cutter spindle rotating speed, the milling vibration and the feeding amount of each tooth are calculated; influence degree of the influence factors of the angle error between the tangent plane and the yoz plane: milling vibration > feed per tooth > cutter tooth error > milling cutter spindle speed.
In order to obtain the influence degree of each influence factor on the machining surface error, the machining error distribution response surface model is subjected to significance analysis, so that the influence significance level of the milling cutter spindle rotation speed, the cutter tooth error, the feed amount of each tooth and the milling vibration is obtained. If the variation of the error of the machined surface caused by the self variation is larger than the variation caused by the random error thereof, the influence factor is considered to have a significant influence on the error of the machined surface, and the level (P) of the significant term of the variation of the positional error of the machined surface is shown in fig. 14.
As shown in fig. 14, the significance of the influence of the machining surface position error is arranged from large to small as observed in the P value:
n＞a＞M＞n×a＞f z ×a＞n×f z ＞f z (9)
in the formula, nxa is the interaction of the rotating speed of the main shaft and the milling vibration; f. of z X a is the interaction of feed per tooth and milling vibration; n x f z Is the interaction of the feed per tooth and the spindle speed.
In the design variable of the position error change characteristic of the machined surface, the influence probability level of the rotation speed of the milling cutter main shaft, the cutter tooth error and the milling vibration is less than 0.01, and the influence is high; the degree of influence of the feed amount per tooth is relatively weak, but the influence on the position error of the machined surface is still less than 0.05, and the influence is remarkable. In the interaction of all variables, the interaction influence of the spindle rotation speed and the milling vibration is the most obvious, the spindle rotation speed and the feed amount of each tooth have weaker influence but still have obvious influence when the feed amount of each tooth is twice as large as the milling vibration, and the probability level of other interaction significant items is greater than 0.05, which shows that the interaction is weaker or does not exist, and the influence on the position error change characteristic of the processed surface is not obvious.
The probability level values of significant factors affecting the change characteristics of the angle error between the tangent plane and the xoz plane in the shape error of the machined surface are shown in fig. 15.
As can be seen from fig. 15, in the design variables of the distribution characteristics of the angle errors between the tangent plane and the xoz plane in the shape error of the machined surface, the significant degrees of the influences are ranked from large to small:
f z ＞f z ×a＞n×a＞n＞M＞M×a＞a＞f z ×M＞n×M (10)
in the formula, mxa is the interaction of the cutter tooth error and milling vibration; f. of z The xM is the interaction between the feed amount of each tooth and the error of the cutter tooth; and nxm is the interaction of the spindle rotation speed and the cutter tooth error.
In the influence factors of the angular error distribution characteristics of the tangent plane and the xoz plane, the probability level of the interaction influence significant items of milling vibration, the feed amount of each tooth, the rotating speed of the main shaft and the feed amount of each tooth is less than 0.01, and the influence is significant; among other significant influencing factors, the influence degree of the milling cutter tooth error and the spindle rotation speed is high, and the significant influence degree of the milling vibration is relatively low. The interaction of the cutter tooth error and other three influencing factors is more obvious in the interaction of the influencing factors, which shows that the distribution characteristics of the angular errors of the tangent plane and the xoz plane are mainly influenced by the interaction of milling vibration and the cutter tooth error and other variables. Interactions between other influencing factors have a weaker influence or no interaction.
The probability level values of significant terms of the tangential plane to yoz plane angle error in the machined surface shape error are shown in fig. 16.
As can be seen from fig. 16, among the influencing factors of the angle error between the tangent plane and the yoz plane in the error of the shape of the machined surface, the degree of significance of the influencing factors is arranged from large to small:
M＞f z ＞n×a＞n＞a＞f z ×M (11)
the probability level of the influence of the feed amount of each tooth and the error of the cutter tooth on the angle error of the tangent plane and the yoz plane is less than 0.01, and the influence degree is obvious; among other significant influencing factors, the interaction influence of the rotation speed of the milling cutter spindle and the cutter tooth error of the milling cutter spindle is significant, and the interaction between the feed per tooth and the cutter tooth error is also significant. Other influencing factors and the degree of interaction influence are not significant or no interaction exists.
S3, designing a model for machining error consistency of the milling side vertical face of the end mill:
compared with the existing scheme, the new process scheme has the advantage that the error distribution characteristic of the machined surface is obviously improved, so that the milling simulation experiment is carried out by using the milling parameters in the experimental scheme, and the result of extracting the characteristic points of the machined surface and fitting the machined curved surface is shown in figure 17.
Calculating a simulation result by a design target of milling side elevation machining error consistency and a milling machining error position point error calculation method, dividing an experimental scheme into 5 cutting time periods according to vibration signal characteristics and the same method, respectively constructing machining surface equations of corresponding surfaces, finally calculating machining surface errors after verifying that the fitting degree of the machining surface equations accords with an expected result, wherein an experimental machining surface error distribution curve is shown in fig. 18-20.
As shown in fig. 18-20, the errors of the new process recipe machined surface are similar to the simulation error curve to some extent, which preliminarily indicates the accuracy and reliability of the simulation results. There is still a need to verify the error results of the new process scheme versus the old experimental scheme.
The experimental results of the new process scheme and the simulation model are verified, the machining surface error evaluation index pair ratio is obtained as shown in table 4, and the relative error of the evaluation index is shown in table 5.
TABLE 4 accuracy evaluation index comparison of the calculation model
TABLE 5 relative error of accuracy evaluation index of calculation model
As shown in tables 4 and 5, in the machining surface error evaluation index data of the experimental scheme, the maximum relative error is 19.85% and the minimum relative error is 1.28%, which are both lower than 20%, it is fully explained that the relative error between the simulation model and the machining surface error average value of the experimental value is small, and the simulation error value and the experimental error value are very close in numerical value, which indicates that the reliability and the accuracy of the simulation method are verified numerically.
TABLE 6 correlation degree of simulation and experimental processing error of new scheme
Milling error feature sequences of the experimental scheme are constructed by a processing surface error feature point extraction method, and the correlation degree between the new process scheme simulation and the experimental error is calculated by a grey correlation analysis method and is shown in table 6. The machining error correlation degrees are all larger than 0.8, which indicates that the error change of the simulated surface and the experimental surface of the new process scheme is similar. And the verification of the error values is combined with the table 4 and the table 5, which shows that the simulation result can accurately represent the experimental surface.
S4, a verification method of the design process of the consistency of the milling side vertical face machining errors of the end milling cutter comprises the following steps:
in order to verify the processing error distribution condition of the new process scheme, the experimental milling cutter adopts an integral hard alloy end milling cutter (MC 122-20.0A5B-WJ30 TF) manufactured by Walter company, five teeth are at equal pitch, the diameter is 20mm, the cutter length is 104mm, and the helix angle is 50 degrees; a machine tool adopts a three-axis milling center, and the length of a workbench is 1050mm, and the width of the workbench is 560mm. The milling mode is forward milling and dry milling, and the milling titanium alloy is TC4.
In milling, the reasonable selection of cutting parameters can improve the processing efficiency and reduce the production loss, and after the milling cutter, the processing machine tool and the milling workpiece are selected, the selection of the cutting parameters has a certain range. The cutting efficiency is an important index for measuring the quality of processing production, so that the milling efficiency range is ensured to be 300cm 3 /min-380cm 3 On the premise of min, the rotation speed n of the milling cutter is 1719r/min, and the feeding speed v f 573mm/min, depth of cut a p Is 10mm, cutting width a e Is 0.5mm.
And constructing a machining error calculation model for the new process scheme, and then calculating the constructed machining surface by using a machining error calculation method, wherein the result of the simulated surface is shown in figure 21, and the result of the calculation of the simulated surface error is shown in figures 22-24.
As shown in fig. 22 to 24, the error variation degree at each depth cut is closer to the old experimental scheme in the parameters of the error of the 3 processed surfaces of the new process scheme, so that the consistency of the processed surfaces of the new process scheme can be considered to be improved, but further verification is still needed.
In order to obtain the influence degree of milling vibration and cutter tooth error on the machining error, simulation and machining error characterization are carried out on two situations of only vibration action and cutter tooth error action under the milling condition of the new experimental scheme through the constructed calculation model and the machining surface error calculation result, and the results are shown in fig. 25-26.
The milling error forming process is used for calculation, the cutting depth errors of all places under the action of the cutter tooth errors are the same, the position error of the machined surface is 0.010, the errors of two angles are 0, namely theta 1 、θ 2 Is 0, Δ y is 0.008. Since the milling vibration has a certain influence on the contact relation of the tool bit and the influence on the machining error needs error calculation to be revealed, the error point calculation of the machined surface under the vibration action is shown in fig. 27-29.
As shown in fig. 27-29, the machining surface error under the combined action is significantly different from the machining surface error under the action of vibration, which indicates that factors such as the cutter tooth error and the feed amount per tooth have a certain influence on the milling vibration, and compared with the error under the combined action, the error distribution curves of the cutting depths at three places have a consistent degree of change.
In order to reveal the influence degree characteristics of the cutter tooth error and the milling vibration on the forming process of the machined surface under the new process scheme, a grey correlation analysis method is used for resolving the correlation degree of the error distribution and the simulated machined surface error distribution under the action of the two single factors, and the analysis result is shown in a table 7.
TABLE 7 correlation of machined surface errors
As shown in table 7, the correlation between the machining error and the experimental error is about 0.6 and the correlation between the milling vibration and the cutting tooth error is about 0.75-0.81, which indicates that the milling vibration plays a major role in the formation of the milling machining error.
According to the calculation result of the machining error forming process, the integral level conditions of the machining surface errors of 3 places for cutting are compared, and the difference value of the simulation results of the new process scheme and the old process scheme is calculated, as shown in table 8.
TABLE 8 Overall level difference of surface errors in new and old process schemes
As shown in table 8, the overall error levels of the old and new schemes have small differences, and the overall variation level of each error is calculated as: the position error of the new process scheme is reduced by 0.13 percent compared with the position error of the old process scheme, the included angle error of the tangent plane and the xoz plane is improved by 0.09 percent, the included angle error of the tangent plane and the yoz plane is improved by 0.05 percent, and the integral horizontal change of the error of the two process schemes is small.
The machining precision consistency of the simulated machined surface is resolved and analyzed through a design target of the machining error consistency of the milled side vertical surface and the analysis of the single-factor influence effect of the constructed machining error, and the analysis result is shown in table 9.
TABLE 9 milling accuracy consistency analysis
Comparing the results of the surface accuracy consistency analysis of the original scheme and the new scheme, the mean value of the correlation degree of each machining error is used as the comprehensive judgment result of the machining accuracy consistency, as shown in fig. 30.
As shown in fig. 30, the new version produced a significantly improved surface consistency result compared to the old version. Since the degree of association is less than 0.5, the degree of association is not considered when the degree of association is increased. Through calculation, the distribution consistency of errors of the positions of the machined surfaces is improved by 11.96%, the distribution consistency of errors of included angles of the tangent plane and the xoz plane is improved by 11.5%, and the distribution consistency of errors of included angles of the tangent plane and the yoz plane is improved by 17.48%.
Compared with the original process scheme, the new process scheme has the advantages that the machining surface precision consistency level is effectively improved while the integral machining surface error condition is kept at the original level, and in conclusion, the new design model for the machining surface precision consistency of the milling side elevation can ensure that the machining surface precision can be kept at the original level in the integral degree and the consistency and the reliability of the machining surface precision can be improved.
Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes, modifications, substitutions and alterations can be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.
Claims (1)
1. The process design and verification method for the milling processing surface precision distribution consistency of the end mill is characterized by comprising the following steps: the method specifically comprises the following steps:
s1, designing the consistency of machining errors of the milling side vertical face of the end mill:
a design target of the consistency of the milling side vertical face machining errors of the end mill is provided, and the consistency of the machining surface precision is judged by utilizing the design target;
when the machined surface is formed, the influence degrees of the errors of the machined surface are different due to various factors, the consistency of the precision of the machined surface is the change characteristic presented by the distribution of the precision of the machined surface along the direction of the feeding speed and the direction of the cutting depth, in order to judge the consistency of the precision of the machined surface, the design target of the consistency of the machining errors of the milling side vertical surface of the end mill is provided, and a variable set is obtained by summarizing a plurality of influence factors and is Q = { n, f z ，a p ，a e M, a, d, l, beta, theta, delta y, wherein n is the rotation speed of the main shaft; f. of z The feed amount per tooth is taken; a is p Milling depth; a is e Milling width; m is milling vibration; a is the error distribution of cutter teeth; d is the diameter of the milling cutter; l is the length of the blade; beta is a helix angle; theta is an angle error; Δ y is the position error;
the position error calculation formula is as follows: Δ y = y g -y g(0) ；
S2, identifying and analyzing design variables of machining error consistency of milling side vertical surfaces of the end mill:
redesigning and planning the design variables of the machining surface precision, providing a design variable identification analysis method for the consistency of the machining errors of the milling side vertical surface of the end mill, and analyzing the influence degree of the influence factors and the interaction thereof so as to control the design variables;
the method specifically comprises the following steps:
s201, identifying a main design variable;
the method comprises the following steps that the condition that various design variables influence even interact in the milling process is considered, the influence of each design variable on the consistency of machining errors is considered, each variable is identified and analyzed, the main design variables of the machining surface errors are selected as the rotation speed of a milling cutter spindle, the feed quantity of each tooth, the cutting depth and the cutting width, the error distribution of cutter teeth, the milling vibration, the diameter of the milling cutter, the length of a cutting edge and the spiral angle, in order to identify the design variables directly influencing the machining surface, the above design variables are subjected to single-factor variance analysis, the F value obtained in the single-factor variance experiment is the mean square ratio of the two design variables, the Fcrit is a critical value under the corresponding significant level of the F value, and the influence is significant if the F value is greater than the Fcrit; p-value is the confidence probability for the corresponding F value, typically less than 0.05 for both significant effects, less than 0.001 for highly significant effects; according to variance value analysis, the influence degrees of all design variables are ranked from large to small, milling vibration, cutter tooth error, feed per tooth, cutting width, cutting depth, milling cutter spindle rotation speed, milling cutter diameter and cutting edge length are ranked, wherein the influence degrees of influence factors of the milling cutter diameter, the cutting edge length and the cutting edge angle on the consistency of the machining surface precision are small, and therefore the design variables are determined to be the spindle rotation speed, the feed per tooth, the milling depth, the milling width, the milling vibration and the cutter tooth error distribution;
s202, designing a variable influence degree identification method;
firstly, design variables n and f are matched z 、a p 、a e Respectively carrying out surface morphology simulation on M and a, and then calculating by an error calculation method to obtain an error average value of the position error
Maximum value of error M amax (ii) a Minimum value of error M amin (ii) a Then, judging the consistency degree of each design variable through a judging method proposed by the complaint;
s203, designing a variable coupling identification method;
the method comprises the steps of firstly analyzing response surfaces when various design variables have coupling effects, then analyzing the significance of the response surfaces of response surface models to obtain interaction effects among influence factors, finally analyzing multi-factor variance to obtain the coupling effects among the influence factors, then analyzing the response surfaces to obtain a central experimental design scheme, and then constructing the response surface models according to the central experimental design scheme and simulation results of the previous design variables, so that the surface errors of the machined surfaces can be analyzedConstructing a second-order expression for the response characteristics of the milling process design variables
In the formula, y 0 To an initial undetermined value, p i Is x i Influence coefficient of (1), p ij Is x i And x j Interaction influence coefficient, Q is fitting error and noise influence, and is normally distributed in this model;
s3, designing a model for machining error consistency of the milling side vertical face of the end mill:
optimizing the existing process design method through a design target and a design variable, and providing a new design model of the consistency of the milling side vertical face machining errors of the end mill;
starting from the improvement of the machining precision consistency, the design model for the machining error consistency of the milling side vertical face of the end mill starts from the research of the characteristic parameters of the milling cutter, the characteristic parameters of the milling cutter are researched through a milling process method and a machine tool to obtain each influence factor, then the surface appearance simulation of each influence factor is carried out to obtain the machining surface error and the angle error, the machining surface error is calculated respectively from the feeding speed direction and the cutting depth direction, the machining surface precision integral level and the consistency degree of the calculation result are judged through the design target of the machining error consistency of the milling side vertical face, if the judgment is unqualified, the machining surface precision integral level influence factor is identified, then each design variable is adjusted and planned, a new machining precision consistency process scheme is provided, and the calculation is carried out again; if the judgment is qualified, milling experimental verification is carried out, if the experimental verification proves that the consistency level of the machining precision is improved, the consistency and feasibility of the process design scheme are demonstrated, and if the experimental verification fails, the experimental scheme is redesigned for judgment;
s4, a verification method of the design process of the consistency of the milling side vertical face machining errors of the end milling cutter comprises the following steps:
the verification method of the design flow of the consistency of the milling side vertical face machining errors of the end mill is provided, and the verification method mainly divides a new process scheme intoComparing the design model with the old process scheme and the experimental scheme to verify the machining precision consistency of the design model with the milling side elevation machining error consistency; firstly, according to the design target of the machining error consistency of the milling side vertical surface, respectively taking n from the distances of the actual machining surface and the design reference surface in the new process scheme, the old process scheme and the experimental scheme along the feeding speed direction and the cutting depth direction according to the distance of 1/2 of the radius of the milling cutter and the cutting depth direction of 0mm, 5mm and 10mm xi And n γi Calculating the distribution curves of the errors of the machined surface corresponding to the points in the feeding speed direction and the cutting depth direction by an error calculation method, and analyzing the average value of the errors of the positions and the angles of the characteristic points of the machined surface according to a judgment method
Maximum value M amax And minimum value M amin And then, performing grey correlation degree analysis and calculation on the new process scheme and the old process scheme, judging whether the consistency is good or bad according to a judgment standard, comparing the new process scheme with the old process scheme according to the judgment standard, if the correlation degrees of the new process scheme are higher than the correlation degrees of the old process scheme, indicating that the consistency degree of the new process scheme is high, comparing the maximum value and the minimum value of errors with the average value by the new process scheme and the experimental scheme, and if the error degrees of the new process scheme are closer to the average value of the errors than the maximum value and the minimum value of the errors of the experimental scheme, indicating that the precision of the new process scheme is high and the errors are small, thereby verifying the processing precision and the consistency level of the design model.
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