CN116117460A - Efficient processing method for array holes on outer surface of thin-wall shell - Google Patents
Efficient processing method for array holes on outer surface of thin-wall shell Download PDFInfo
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- CN116117460A CN116117460A CN202310041270.6A CN202310041270A CN116117460A CN 116117460 A CN116117460 A CN 116117460A CN 202310041270 A CN202310041270 A CN 202310041270A CN 116117460 A CN116117460 A CN 116117460A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P17/00—Metal-working operations, not covered by a single other subclass or another group in this subclass
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
- B23Q15/00—Automatic control or regulation of feed movement, cutting velocity or position of tool or work
- B23Q15/007—Automatic control or regulation of feed movement, cutting velocity or position of tool or work while the tool acts upon the workpiece
- B23Q15/14—Control or regulation of the orientation of the tool with respect to the work
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
- B23Q17/00—Arrangements for observing, indicating or measuring on machine tools
- B23Q17/24—Arrangements for observing, indicating or measuring on machine tools using optics or electromagnetic waves
- B23Q17/2428—Arrangements for observing, indicating or measuring on machine tools using optics or electromagnetic waves for measuring existing positions of tools or workpieces
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
- B23Q17/00—Arrangements for observing, indicating or measuring on machine tools
- B23Q17/24—Arrangements for observing, indicating or measuring on machine tools using optics or electromagnetic waves
- B23Q17/2452—Arrangements for observing, indicating or measuring on machine tools using optics or electromagnetic waves for measuring features or for detecting a condition of machine parts, tools or workpieces
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Abstract
The invention discloses a high-efficiency processing method for array holes on the outer surface of a thin-wall shell, and belongs to the technical field of processing. According to the method, the actual pose information of the array mounting seat is obtained based on a line laser measurement method, the final machining positions of adjacent symmetrical mounting seat holes are solved, efficient and automatic machining of the threaded holes with controllable depth is realized, and the problems that the array mounting seat holes are difficult to position, low in efficiency and insufficient in precision are solved. The method is suitable for the condition of automatic position trimming by programming in the self-adaptive machining system of the array holes on the outer surface of the thin-wall shell part, the trimming process is simple, the coupling influence between the array holes and the safe machining requirement are considered, and the result is reliable. The method can meet the demand of self-adaptive machining of the characteristics of the mounting seat hole facing the manufacturing site environment.
Description
Technical Field
The invention belongs to the technical field of processing, and relates to a high-efficiency processing method for array holes on the outer surface of a thin-wall shell.
Background
The mounting holes are common features on key thin-wall structural parts in the aerospace field, and the machining quality of the mounting holes seriously affects the overall performance and the safety service life of the core component. Because of the characteristics of thin wall, low rigidity and the like, the thin-wall shell is extremely easy to generate unpredictable pose deformation under the actions of factors such as initial residual stress, cutting force, clamping conditions and the like in the processing process, so that the array characteristics deviate from the theoretical positions. And (3) hole forming is carried out according to the theoretical machining position, so that the size precision and the service performance of the array hole are seriously affected. In machining, the array holes need to meet the position and size requirements while the holes should be as close as possible to the center of the mount, i.e., the wall thickness requirement, and the relative position requirements of adjacent mount holes. When the hole is made manually, a worker performs radial positioning in a scribing mode, uses the former hole as a positioning reference of the latter hole, and performs axial positioning by using a vernier caliper. This causes an accumulation of errors, which results in an increasingly larger machining error for the holes in the second half of the workpiece. The manual scribing and punching efficiency is very low, the precision is difficult to guarantee, and multiple constraints are difficult to consider. Therefore, pose change data of a hole matrix to be processed in the processing process are obtained in an on-machine measurement mode, position constraint, wall thickness constraint and relative position constraint of adjacent characteristic holes are comprehensively considered, trimming compensation is carried out on the processing position of the hole, the optimal processing position of the hole is solved, self-adaptive controllable processing of the hole is realized, processing precision of a large thin-wall part is improved, and further safety service performance and service life of an aerospace core part are improved.
In 2020, zhu Saimeng et al disclose a self-adaptive compensation processing method for a turbine blade air film cooling hole in patent CN202010656092.4, which improves the processing precision and automation degree of the hole, but the method only utilizes coordinate system offset transformation after point cloud registration to solve the processing position of the hole, has low efficiency, does not consider the relative position requirement between holes, and is not suitable for processing array holes. In 2018, kang Renke et al disclose a laminated member hole making method with adaptively adjusted machining parameters in patent CN201811126903.9, in the method, a sensor is used to monitor the rotation speed and rotation speed change of a cutter driving device after stabilization, and the type of a material to be machined and the machining process are judged, so that the hole making parameters are adaptively changed, the manual intervention during hole making is reduced, and the machining efficiency is improved. However, the method does not consider the self-adaptive correction processing after the position of the substrate of the hole to be processed is changed, and cannot make specific processing position correction on the changed hole characteristics.
The above research has not mentioned a method for efficiently processing array holes on the outer surface of a thin-wall shell.
Disclosure of Invention
Aiming at the problems of difficult manual positioning and processing and low efficiency of the array mounting holes on the outer surface of the thin-wall part, the invention provides a high-efficiency processing method for the array holes on the outer surface of the thin-wall shell. In the method, the actual pose information of the mounting seat is acquired by using a line laser measuring method, and an axial positioning reference and a radial positioning reference of the mounting seat are determined; comparing the deviation of the actual position and the theoretical position of the mounting seat, determining the qualified range of the wall thickness of the mounting seat hole and the qualified range of the position, taking an intersection, solving the qualified machining range meeting the wall thickness requirement and the position requirement at the same time, and taking the midpoint of a simplified line of the qualified machining range as the preliminary machining position of the mounting seat hole; considering the relative position requirements of adjacent mounting seat holes in the same group, adjusting the preliminary processing position of the mounting seat holes in a qualified processing range, and solving the final processing position of the mounting seat holes; in engineering practice, the final machining position of the mounting seat hole is considered to meet all space position constraints, and final machining position coordinates are output to generate a self-adaptive machining program; the automatic tool setting device is used for realizing automatic tool setting in the machining process by adopting a laser automatic tool setting instrument, monitoring the machining state by adopting a method for monitoring the cutting force of a machine tool spindle, avoiding damaging a workpiece matrix while efficiently making holes, and completing the self-adaptive efficient machining of the mounting seat holes.
The technical scheme adopted by the invention is as follows:
the method comprises the steps of firstly, scanning a workpiece by using a line laser measuring method, extracting boundary points and fitting contours based on measured data, obtaining actual pose information of the thin-wall shell and an installation seat, and determining an axial positioning reference and a radial positioning reference of the installation seat; comparing the deviation of the actual position and the theoretical position of the mounting seat, determining the qualified range of the wall thickness of the mounting seat hole and the qualified range of the position, judging whether the two meet each other, namely the qualified machining range meeting the position requirement and the wall thickness requirement at the same time, and dividing the judging result into two cases; taking the midpoint of the simplified line of the qualified machining range as a preliminary machining position of the mounting seat hole under the condition that the intersection exists; considering the relative position requirements of adjacent symmetrical mounting seat holes, judging whether further trimming can be carried out, and dividing the judging result into three cases; for the condition that the adjustment can be further carried out, the initial machining position of the mounting seat hole is adjusted in a qualified machining range, and the intersection center point of a relative position tolerance zone and a qualified machining range simplification line is taken as the final machining position of the mounting seat hole; in engineering practice, the optimal machining position of the hole meets all space position constraints, the optimal machining position coordinates are output, a machining G code is generated, the machining state is monitored by adopting a machine tool spindle cutting force monitoring method, the damage to a thin-wall shell is avoided, and a laser automatic tool setting instrument is used for realizing quick and accurate tool changing, so that the self-adaptive efficient machining of the mounting seat hole is realized.
The method comprises the following specific steps:
first step, array characteristic information based on online measurement of line laser is extracted rapidly
The rapid and accurate extraction of the actual pose information of the array features is a precondition for high-quality and high-efficiency processing of the parts, and the surface contour information of the parts is rapidly and accurately extracted by using a linear laser on-machine measurement method, so that a foundation can be laid for the next array hole processing position calculation.
The part consists of a thin-wall shell and an array mounting seat on the outer surface of the thin-wall shell. Two rows of mounting seats are axially distributed on the outer surface of the thin-wall shell, two radially adjacent mounting seats are a group, and each mounting seat is required to be provided with a threaded hole. When the mounting seats are used for making holes, the holes are required to meet the axial size requirement and the radial size requirement relative to the thin-wall rotary shell, the holes of the two adjacent mounting seats in the same group are required to meet the relative position requirement, and the holes on the mounting seats are required to meet the axial size requirement and the radial size requirement relative to the mounting seats, namely the wall thickness requirement. Meanwhile, because a gap exists between the mounting seat and the thin-wall shell, the thin-wall shell cannot be damaged after the cutter penetrates through the mounting seat during machining.
In view of the small size of the mounting seat relative to the thin-wall shell, the contact type on-machine measuring method is difficult to use, so that the non-contact type line laser on-machine measuring method is adopted to measure the parts. Firstly, the thin-wall shell 4 is clamped on the processing machine tool 1, a special knife handle type line laser measuring tool is developed, a line laser scanner is arranged on the processing machine tool, and the processing machine tool drives the line laser scanner to finish workpiece measurement. The tool for measuring the knife handle type line laser comprises a special knife handle 6, an upper connecting plate 7, a lower connecting plate 9, a three-dimensional precise fine adjustment platform 8 and a line laser scanner 10; the special knife handle 6 is arranged on a main shaft of the processing machine tool and is connected with the three-dimensional precise fine adjustment platform 8 through the upper connecting plate 7; the three-dimensional precise fine adjustment platform 8 is connected with the line laser scanner 10 through a lower connecting plate 9 and is used for calibrating the measuring pose of the line laser scanner 10. The non-contact line laser on-machine measurement method is used for acquiring measurement point cloud data of the surface profile of the thin-wall shell part, and further feature boundary extraction and gap solving are needed after preprocessing such as noise rejection, data reduction and repair are carried out on the measurement point data.
The curvature is taken as an important geometric feature of the point cloud data, and the change condition of the curve can be reflected to a certain extent, so that the curvature is taken as a measurement parameter of the edge feature point. And calculating the approximate curvature of each position data point of the surface profile measurement point cloud data of the thin-wall shell by adopting a three-point method, and calculating the point with the maximum curvature, namely the edge characteristic point of the mounting seat to be detected. After the edge characteristic points of the mounting seat are obtained, interpolation fitting is carried out on the edge characteristic points of the mounting seat by using a secondary B spline curve, and a fitting curve is obtained. FittingThe curve is formed by a semicircle A and a straight line L 1 Semi-circular arc B and straight line L 2 Four lines are connected end to end in turn, wherein a semicircular arc A and a straight line L 1 Intersecting with the end point a 1 (x a1 ,y a1 ) And straight line L 2 Intersecting with the end point a 3 (x a3 ,y a3 ) Semi-circular arc B and straight line L 1 Intersecting with the end point a 2 (x a2 ,y a2 ) And straight line L 2 Intersecting with the end point a 4 (x a4 ,y a4 ). The fitting curve is the positioning reference of the mounting seat hole relative to the mounting seat.
Solving straight line L 1 The perpendicular bisector of (2) is:
similarly, straight line L can be solved 3 For the intersection of two perpendicular bisectors, i.e. the centre point O of the mount 2 The method comprises the steps of carrying out a first treatment on the surface of the Repeating the above steps to obtain a straight line L 2 Perpendicular bisector and straight line L of (2) 4 Another intersection point O of the perpendicular bisector of (2) 1 ，O 1 With O 2 The midpoint of the two-point connecting line is the actual center point 2a of the mounting seat.
Because the thin-wall shell cannot be damaged in the hole machining process, the actual height and the actual clearance value of the mounting seat need to be accurately calculated, and a basis is provided for the cutting feed of the machine tool. The deformation of the thin-wall shell is uneven, and the gap between the mounting seat and the thin-wall shell needs to be fitted in a difference value. For the clearance area, the deformation is smaller, the actual deformation condition can be approximately solved after the quadratic interpolation fitting, the approximation degree is higher, and the judgment of the actual change state of the clearance of the mounting seat is accurate enough. Taking a radial section of the mounting seat as an example for illustration, after quadratic interpolation fitting, the fitted gap can represent the actual gap. After fitting, the actual height D at different positions of the mounting base j The conic representation can be approximated:
D j ＝k 1 ·x 2 +k 2 ·x+b(2)
wherein the abscissa x is the cross-section abscissa value; d (D) j An actual height value at mount location j; k (k) 1 ，k 2 B is the fitting constant.
The actual gap can be expressed as:
η＝D j -d＝k 1 ·x 2 +k 2 ·x+b-d(3)
wherein eta is the actual gap value; d is the actual thickness of the mount.
The method of curvature calculation and secondary B spline curve fitting can be used for obtaining the boundary expression of the end face of the thin-wall shell, and the vertex is taken, namely the axial positioning reference of the array mounting seat hole relative to the thin-wall shell. And (3) taking position data points on the connecting lines of the actual center points of the same group of radially adjacent mounting seats, fitting by using a quadratic B spline curve, obtaining an expression, and taking the vertexes as radial positioning references of the holes of the same group of radially adjacent mounting seats relative to the thin-wall shell.
Second step, based on measuring point cloud, calculating hole making position of thin-wall shell surface mounting seat
The method comprises the steps of comprehensively considering multiple constraints of the array holes based on the pose information and the positioning reference of the surface of the thin-wall shell obtained in the first step, and solving the processing position coordinates of the array holes.
When the array mounting base is used for making holes, a plurality of constraints need to be considered in a coordinated manner: l (L) Z ±D WZ And L d ±D Wd The position of the hole on the thin-wall substrate is restricted, so that the position requirement is ensured; l (L) bd ±D bd And L bz ±D bz The positions of the holes on the mounting seat are restricted, so that the wall thickness requirement is ensured; l (L) dL ±D WdL And restraining the relative position requirement between the radial adjacent mounting seat holes in the same group.
The actual end face center 2a of the mounting base body is not coincident with the theoretical end face center 1a of the mounting base body, and the axial deviation d exists between the two z And a radial deviation d d . All points meeting the wall thickness processing requirements are a rectangular area, i.e. wall thickness tolerance range Q b The center of which is the actual end face center 2a of the mount base. All points meeting the position requirement are also oneRectangular areas, i.e. position tolerance ranges Q w The center of the base body is the theoretical end face center 1a of the base body. Wall thickness tolerance range Q b And a position tolerance range Q w The intersection of the two is the qualified processing range Q of a single hole h That is, when the hole is machined in this range, the wall thickness requirement and the position requirement can be satisfied at the same time. According to the axial deviation d of the wall thickness tolerance range central point and the position tolerance range central point z And a radial deviation d d Axial wall thickness tolerance value D bz And radial wall thickness tolerance value D bd Axial position tolerance value D wz And a radial position tolerance value D wd The acceptable processing range can be divided into two cases:
when d z ＜D wz +D bz And d d ＜D wd +D bd When the method is used, the qualified machining range of the hole exists, and the machining position of the hole can be coordinated and compensated based on the relative position requirement of the adjacent mounting seat holes on the premise that the wall thickness requirement and the position requirement are simultaneously met. For easy processing, simplifying the qualified processing range, taking the connecting line L of the wall thickness tolerance range center point 2a and the position tolerance range center point 1a, and taking the intersection line of the straight line L and the qualified processing range as the adjustable range L T And taking the midpoint O of the adjustable range as a preliminary machining position of the hole.
When d z ≥D wz +D bz Or d d ≥D wd +D bd And when the hole is in a qualified machining range, the wall thickness requirement and the position requirement cannot be met at the same time, and the part is scrapped.
Considering the relative position requirement between the radial adjacent mounting seat holes, the preliminary machining positions of the radial adjacent mounting seat holes need to be further coordinated, repaired and compensated. Radial minimum distance d according to qualified machining range Lmin And a maximum radial distance d Lmax Radial distance d of preliminary machining position of radially adjacent mounting seat holes Lmid Relative position requirement L of radially adjacent mounting seat holes dL ±D WdL The relationship between them is further divided into three cases:
when the radial adjacent mounting seat holes are preliminarily machinedThe radial distance of the position satisfies L dL ±D WdL Is not required to be modified. The preliminary machining position of the radial adjacent mounting seat hole is the final machining position of the hole.
When the radial distance between the primary machining positions of the radially adjacent mounting seat holes does not meet L dL ±D WdL Requirement d Lmax ≥L dL +D wdL Or d Lmin ≤L dL -D wdL When the adjustment range is adjusted, all points do not meet the relative position requirements of radial adjacent mounting seat holes, the compensation cannot be coordinated, and the parts are scrapped.
When the radial distance between the primary machining positions of the radially adjacent mounting seat holes does not meet L dL ±D WdL Requirement d Lmax ∈L dL ±D wdL Or d Lmin ∈L dL ±D wdL And when the part of points in the trimming range meet the radial relative position requirement, trimming the preliminary machining positions of the radially adjacent mounting seat holes on the basis. Taking intersection L of adjustable range of radial adjacent mounting seat holes and tolerance zone required by relative position TZ The points in the intersection can meet the wall thickness requirement, the position requirement and the relative position requirement, and at the moment, the midpoint O of the intersection is respectively taken Z As the final machining location for radially adjacent mount holes.
And finally, outputting the final machining position coordinates of the array mounting seat holes, generating a machining G code, and preparing for machining.
Third step high-efficiency automatic processing of screw hole with controllable depth
According to the processing position coordinates of the array mounting seat holes solved in the previous step, the high-quality and high-efficiency processing of the array mounting seat holes is completed under the condition that the shell is not damaged.
Firstly, in order to ensure the processing quality of the holes of the array mounting seat, drilling and thread processing are needed to be respectively carried out in two working procedures, after the tool is changed between different working procedures, the dimension deviation and the position deviation of the tool exist, and only after the tool is set, the radius, the length and the position deviation of the tool are compensated into a self-adaptive processing program, the tool can be accurately processed at the position after the trimming and the compensation, and meanwhile, the damage to a shell is avoided. When the method is used for tool setting by using the automatic laser tool setting instrument, firstly, the actual position of the laser tool setting instrument under a machine tool coordinate system is obtained by using a standard tool for tool setting; the actually used tool is then brought close to the laser beam from multiple directions, thereby accurately determining the tool geometry and the positional deviation of the tool relative to the spindle after installation. After the actual length H of the cutter is obtained by tool setting, the height deviation of the machining position can be carried out by updating the cutter length compensation instruction G43; for the deviation of the tool in the direction X, Y, the position deviation accumulation compensation can be performed by using a coordinate system deviation command such as TRANS or an R parameter, so that an array mount hole machining program of different tools (different processes) can be further generated on the basis of the adaptive machining code.
Secondly, considering the clearance of the mounting seat, the solid rocket shell cannot be damaged during processing, and two measures are taken to ensure the safe processing of the mounting seat hole. And the actual height and clearance value of the mounting seat are solved through the line laser measurement data, so that the drilling depth of the G code processed by the mounting seat is controlled, and the shell is prevented from being damaged. Meanwhile, when the cutter cuts into and cuts out a workpiece, the cutting force can generate periodic mutation, the cutting force monitoring function of the main shaft of the machine tool is used for capturing the axial cutting force mutation point of the cutter in the moment of penetrating through the mounting seat, when the cutter continues to feed after penetrating is completed, the system alarms and controls the machine tool to stop running, so that the safety monitoring of the processing state in the processing process is realized, the abnormal condition is avoided, and the safety processing is ensured.
And finally, starting the machine tool, and executing an array mounting seat hole machining program on the premise of monitoring the stress of a main shaft of the machine tool to finish high-quality and high-efficiency machining of the array holes of the mounting seat of the thin-wall shell.
The invention has the beneficial effects that: the invention provides a high-efficiency processing method for array holes on the outer surface of a thin-wall shell, which is used for acquiring actual pose information of an array mounting seat based on a line laser measurement method, solving the final processing position of adjacent symmetrical mounting seat holes, realizing high-efficiency automatic processing of threaded holes with controllable depth and solving the problems of difficult positioning, low efficiency and insufficient precision of the array mounting seat hole processing. The method is suitable for the condition of automatic position trimming by programming in the self-adaptive machining system of the array holes on the outer surface of the thin-wall shell part, the trimming process is simple, the coupling influence between the array holes and the safe machining requirement are considered, and the result is reliable. The method can meet the demand of self-adaptive machining of the characteristics of the mounting seat hole facing the manufacturing site environment.
Drawings
FIG. 1 (a) is a schematic diagram of the hardware assembly of the present invention.
Fig. 1 (b) is a schematic diagram of the knife handle type linear laser measuring tool.
FIG. 2 is a schematic diagram of the array hole feature processing requirements according to the present invention.
FIG. 3 is a flow chart of a multi-source constrained array hole self-adaptive processing method according to the invention.
Fig. 4 is a schematic diagram of fitting of actual pose information of the mounting seat.
FIG. 5 is a schematic diagram of a solution for a preliminary processing location of a hole.
Fig. 6 is a schematic diagram when the mounting seat deviation is too large to cause no solution.
Fig. 7 is a schematic view of the hole at the point of preliminary processing for further trimming.
In the figure: 1, a machine tool; 2, specially-made cutters; 3, a mounting seat; 4, a thin-wall shell; 5, a laser tool setting gauge; 6, a cutter handle is specially manufactured; 7, connecting a plate; 8, a three-dimensional precise fine adjustment platform; 9, a lower connecting plate; a 10-line laser scanner; i is the mounting seat of the ith group; z is Z J Positioning a reference for the axial direction of the workpiece; l (L) Z Is the central axis of the workpiece; l (L) Z ±D WZ The axial position requirement of the mounting seat hole relative to the thin-wall shell is met; l (L) d ±D Wd The radial relative position requirement of the mounting seat hole relative to the thin-wall shell is met; l (L) dL ±D WdL The requirements for the relative positions between the adjacent mounting seat holes are met; l (L) bd ±D bd The radial position requirement of the mounting seat hole relative to the mounting seat is met; l (L) bz ±D bz The axial position requirement of the mounting seat hole relative to the mounting seat is met;
L S the theoretical position boundary of the base body of the mounting seat; l (L) C The actual position boundary of the base body of the mounting seat; 1a is the theoretical end face center (the center point of the position tolerance range) of the base body of the mounting seat; 2a is the actual end face center of the base body of the mounting seat(wall thickness tolerance range center point); d, d z The axial deviation amount is the axial deviation amount between the theoretical end face center of the mounting base body and the actual end face center of the mounting base body; d, d d The radial deviation amount is the radial deviation amount of the theoretical end face center of the installation base body and the actual end face center of the installation base body; l is a connecting line between the center of the theoretical end face of the mounting base body and the center of the actual end face of the mounting base body; l (L) T Is a tunable range; d (D) bz The dimensional tolerance value of the axial position of the mounting seat hole relative to the mounting seat is set; d (D) bd The radial position dimension tolerance value of the mounting seat hole relative to the mounting seat is set; d (D) wz The dimensional tolerance value of the axial position of the mounting seat hole relative to the thin-wall matrix is set; d (D) wd The radial position dimension tolerance value of the mounting seat hole relative to the thin-wall matrix is set; q (Q) w Is a position tolerance range; q (Q) b Is a wall thickness tolerance range; q (Q) h Is a qualified processing range; o is the preliminary machining position of the hole; q (Q) L A tolerance band is required for the relative position; d, d Lmin The radial minimum distance is the qualified machining range; d, d Lmax Radial maximum distance for qualified processing range; d, d Lmid Radial distances are reserved for the preliminary machining positions of adjacent mounting seat holes. L (L) TZ Intersection of the adjustable range and the relative position required tolerance zone for adjacent mounting seat holes; o (O) Z Is the final machining position of the adjacent mounting seat holes.
Detailed Description
The invention is further described with reference to the drawings and the technical scheme.
FIG. 2 is a schematic diagram of the processing requirements of the array holes according to the present invention, and the specific requirements are as follows:
a rotary part consists of a thin-wall shell and an array mounting seat on the outer surface of the thin-wall shell. Two rows of mounting seats are axially distributed on the outer surface of the thin-wall shell, and 10 mounting seats are arranged in each row, and 20 mounting seats are arranged in total; wherein two radial adjacent mount pads are a set of, and every mount pad all need processing screw hole. The axial dimension requirement L of the axial positioning reference of the hole to the thin-wall shell is required to be met in hole machining Z ±D WZ Radial dimension requirement L to the central axis of a thin-walled housing d ±D Wd Dimensional requirements L between adjacent mounting seat holes dL ±D WdL . At the same time, the axial dimension requirement L of the hole on the mounting seat needs to be met bz ±D bz And radial dimension requirement L bd ±D bd The wall thickness requirement is ensured.
Fig. 3 is a flowchart of a method for adaptive hole processing, and the specific steps of the method for adaptive hole position trimming are as follows:
first step, array characteristic information based on online measurement of line laser is extracted rapidly
In view of the small size of the mounting seat relative to the thin-wall shell, the contact type on-machine measuring method is difficult to use, so that the non-contact type line laser on-machine measuring method is adopted to measure the parts.
The thin-wall shell 4 is clamped on the processing machine tool 1, a special knife handle type line laser measuring tool is developed, a line laser scanner is arranged on the processing machine tool and driven by the processing machine tool, and the workpiece measurement is completed. The tool for measuring the knife handle type line laser comprises a special knife handle 6, an upper connecting plate 7, a lower connecting plate 9, a three-dimensional precise fine adjustment platform 8 and a line laser scanner 10; the special knife handle 6 is arranged on a main shaft of a processing machine tool, is connected with the three-dimensional precise fine adjustment platform 8 through the upper connecting plate 7, and the three-dimensional precise fine adjustment platform 8 is connected with the line laser scanner 10 through the lower connecting plate 9 and is used for calibrating the measuring pose of the line laser scanner 10. The non-contact line laser on-machine measurement method is used for acquiring measurement point cloud data of the surface profile of the thin-wall shell part, and further feature boundary extraction and gap solving are needed after preprocessing such as noise rejection, data reduction and repair are carried out on the measurement point data.
The curvature is taken as an important geometric feature of the point cloud data, and the change condition of the curve can be reflected to a certain extent, so that the curvature is taken as a measurement parameter of the edge feature point. And calculating the approximate curvature of each position data point of the surface profile measurement point cloud data of the thin-wall shell by adopting a three-point method, and calculating the point with the maximum curvature, namely the edge characteristic point of the mounting seat to be detected. After the edge characteristic points of the mounting seat are obtained, interpolation fitting is carried out on the edge characteristic points of the mounting seat by using a secondary B spline curve, and a fitting curve is obtained. The fitting curve is formed by a semicircular arc A and a straight line L 1 Semi-circular arc B and straight line L 2 Four lines are connected end to end in turn, wherein a semicircular arc A and a straight line L 1 Intersecting with the end point a 1 (x a1 ,y a1 ) And straight line L 2 Intersecting with the end point a 3 (x a3 ,y a3 ) Semi-circular arc B and straight line L 1 Intersecting with the end point a 2 (x a2 ,y a2 ) And straight line L 2 Intersecting with the end point a 4 (x a4 ,y a4 ). The fitting curve is the positioning reference of the mounting seat hole relative to the mounting seat.
Solving straight line L 1 The perpendicular bisector of (2) is:
similarly, straight line L can be solved 3 For the intersection of two perpendicular bisectors, i.e. the centre point O of the mount 2 The method comprises the steps of carrying out a first treatment on the surface of the Repeating the above steps to obtain a straight line L 2 Perpendicular bisector and straight line L of (2) 4 Another intersection point O of the perpendicular bisector of (2) 1 ，O 1 With O 2 The midpoint of the two-point connecting line is the actual center point 2a of the mounting seat.
Because the thin-wall shell cannot be damaged in the hole machining process, the actual height and the actual clearance value of the mounting seat need to be accurately calculated, and a basis is provided for the cutting feed of the machine tool. The deformation of the thin-wall shell is uneven, and the gap between the mounting seat and the thin-wall shell needs to be fitted in a difference value. For the clearance area, the deformation is smaller, the actual deformation condition can be approximately solved after the quadratic interpolation fitting, the approximation degree is higher, and the judgment of the actual change state of the clearance of the mounting seat is accurate enough. Taking a radial section of the mounting seat as an example for illustration, after quadratic interpolation fitting, the fitted gap can represent the actual gap. After fitting, the actual height D at different positions of the mounting base j The conic representation can be approximated:
D j ＝k 1 ·x 2 +k 2 ·x+b (2)
in which the abscissa x is the cross-sectionCoordinate values; d (D) j An actual height value at mount location j; k (k) 1 ，k 2 B is the fitting constant.
The actual gap can be expressed as:
η＝D j -d＝k 1 ·x 2 +k 2 ·x+b-d (3)
wherein eta is the actual gap value; d is the actual thickness of the mount.
The method of curvature calculation and secondary B spline curve fitting can be used for obtaining the boundary expression of the end face of the thin-wall shell, and the vertex is taken, namely the axial positioning reference of the array mounting seat hole relative to the thin-wall shell. And (3) taking position data points on the connecting lines of the actual center points of the same group of radially adjacent mounting seats, fitting by using a quadratic B spline curve, obtaining an expression, and taking the vertexes as radial positioning references of the holes of the same group of radially adjacent mounting seats relative to the thin-wall shell.
Second step, based on measuring point cloud, calculating hole making position of thin-wall shell surface mounting seat
When the array mounting base is used for making holes, a plurality of constraints need to be considered in a coordinated manner: l (L) Z ±D WZ And L d ±D Wd The position of the hole on the thin-wall substrate is restricted, so that the position requirement is ensured; l (L) bd ±D bd And L bz ±D bz The positions of the holes on the mounting seat are restricted, so that the wall thickness requirement is ensured; l (L) dL ±D WdL And restraining the relative position requirement between the radial adjacent mounting seat holes in the same group.
The actual end face center 2a of the mounting base body is not coincident with the theoretical end face center 1a of the mounting base body, and the axial deviation d exists between the two z And a radial deviation d d . All points meeting the wall thickness processing requirements are a rectangular area, i.e. wall thickness tolerance range Q b The center of which is the actual end face center 2a of the mount base. All points meeting the position requirement are also a rectangular area, i.e. the position tolerance range Q w The center of the base body is the theoretical end face center 1a of the base body. Wall thickness tolerance range Q b And a position tolerance range Q w The intersection of the two is the qualified processing range Q of a single hole h I.e. when working holes in this rangeThe wall thickness requirement and the position requirement can be simultaneously met. According to the axial deviation d of the wall thickness tolerance range central point and the position tolerance range central point z And a radial deviation d d Axial wall thickness tolerance value D bz And radial wall thickness tolerance value D bd Axial position tolerance value D wz And a radial position tolerance value D wd The acceptable processing range can be divided into two cases:
when d z ＜D wz +D bz And d d ＜D wd +D bd When the method is used, the qualified machining range of the hole exists, and the machining position of the hole can be coordinated and compensated based on the relative position requirement of the adjacent mounting seat holes on the premise that the wall thickness requirement and the position requirement are simultaneously met. For easy processing, simplifying the qualified processing range, taking the connecting line L of the wall thickness tolerance range center point 2a and the position tolerance range center point 1a, and taking the intersection line of the straight line L and the qualified processing range as the adjustable range L T And taking the midpoint O of the adjustable range as a preliminary machining position of the hole.
When d z ≥D wz +D bz Or d d ≥D wd +D bd And when the hole is in a qualified machining range, the wall thickness requirement and the position requirement cannot be met at the same time, and the part is scrapped.
Considering the relative position requirement between the radial adjacent mounting seat holes, the preliminary machining positions of the radial adjacent mounting seat holes need to be further coordinated, repaired and compensated. Radial minimum distance d according to qualified machining range Lmin And a maximum radial distance d Lmax Radial distance d of preliminary machining position of radially adjacent mounting seat holes Lmid Relative position requirement L of radially adjacent mounting seat holes dL ±D WdL The relationship between them is further divided into three cases:
when the radial distance between the preliminary machining positions of the radially adjacent mounting seat holes meets L dL ±D WdL Is not required to be modified. The preliminary machining position of the radial adjacent mounting seat hole is the final machining position of the hole.
When the radial distance between the preliminary machining positions of the radially adjacent mounting seat holes is not equal toSatisfy L dL ±D WdL Requirement d Lmax ≥L dL +D wdL Or d Lmin ≤L dL -D wdL When the adjustment range is adjusted, all points do not meet the relative position requirements of radial adjacent mounting seat holes, the compensation cannot be coordinated, and the parts are scrapped.
When the radial distance between the primary machining positions of the radially adjacent mounting seat holes does not meet L dL ±D WdL Requirement d Lmax ∈L dL ±D wdL Or d Lmin ∈L dL ±D wdL And when the part of points in the trimming range meet the radial relative position requirement, trimming the preliminary machining positions of the radially adjacent mounting seat holes on the basis. Taking intersection L of adjustable range of radial adjacent mounting seat holes and tolerance zone required by relative position TZ The points in the intersection can meet the wall thickness requirement, the position requirement and the relative position requirement, and at the moment, the midpoint O of the intersection is respectively taken Z As the final machining location for radially adjacent mount holes.
And finally, outputting the final machining position coordinates of the array mounting seat holes, generating a machining G code, and preparing for machining.
Third step high-efficiency automatic processing of screw hole with controllable depth
Firstly, in order to ensure the processing quality of the holes of the array mounting seat, drilling and thread processing are needed to be respectively carried out in two working procedures, after the tool is changed between different working procedures, the dimension deviation and the position deviation of the tool exist, and only after the tool is set, the radius, the length and the position deviation of the tool are compensated into a self-adaptive processing program, the tool can be accurately processed at the position after the trimming and the compensation, and meanwhile, the damage to a shell is avoided. The method uses the laser automatic tool setting gauge 5 to carry out tool setting, and when the tool setting is carried out, firstly, the actual position of the laser tool setting gauge under the coordinate system of the machine tool is obtained by using a standard tool for tool setting; the actually used tool is then brought close to the laser beam from multiple directions, thereby accurately determining the tool geometry and the positional deviation of the tool relative to the spindle after installation. After the actual length H of the cutter is obtained by tool setting, the height deviation of the machining position can be carried out by updating the cutter length compensation instruction G43; for the deviation of the tool in the direction X, Y, the position deviation accumulation compensation can be performed by using a coordinate system deviation command such as TRANS or an R parameter, and the array hole machining program of a different tool (different process) can be further generated based on the adaptive machining code.
Secondly, considering the clearance of the mounting seat, the solid rocket shell cannot be damaged during processing, and two measures are taken to ensure the safe processing of the mounting seat hole. And the actual height and clearance value of the mounting seat are solved through the line laser measurement data, so that the drilling depth of the G code processed by the mounting seat is controlled, and the shell is prevented from being damaged. Meanwhile, when the cutter cuts into and cuts out a workpiece, the cutting force can generate periodic mutation, the cutting force monitoring function of the main shaft of the machine tool is used for capturing the axial cutting force mutation point of the cutter in the moment of penetrating through the mounting seat, when the cutter continues to feed after penetrating is completed, the system alarms and controls the machine tool to stop running, so that the safety monitoring of the processing state in the processing process is realized, the abnormal condition is avoided, and the safety processing is ensured.
And finally, starting the machine tool, and executing an array mounting seat hole machining program on the premise of monitoring the stress of a main shaft of the machine tool to finish high-quality and high-efficiency machining of the array holes of the mounting seat of the thin-wall shell.
Claims (3)
1. The efficient processing method of the array holes on the outer surface of the thin-wall shell is characterized by comprising the following steps of:
first step, array characteristic information based on online measurement of line laser is extracted rapidly
The thin-wall shell part consists of a thin-wall shell and an array mounting seat on the outer surface of the thin-wall shell; two rows of mounting seats are axially distributed on the outer surface of the thin-wall shell, two radially adjacent mounting seats are in a group, and each mounting seat is required to be provided with a threaded hole;
acquiring measurement point cloud data of the surface profile of the thin-wall shell part by using a non-contact line laser on-machine measurement method, performing noise rejection, data reduction and repair pretreatment on the measurement point data, and performing further feature boundary extraction and gap solving on the measurement point data;
calculating the approximate curvature of each position data point of the thin-wall shell surface profile measurement point cloud data by adopting a three-point method, and calculating the curvature to be the highestThe large points are edge characteristic points of the mounting seat to be detected; after obtaining the edge characteristic points of the mounting seat, performing interpolation fitting on the edge characteristic points of the mounting seat by using a secondary B spline curve to obtain a fitting curve; the fitting curve is formed by a semicircular arc A and a straight line L 1 Semi-circular arc B and straight line L 2 Four lines are connected end to end in turn, wherein a semicircular arc A and a straight line L 1 Intersecting with the end point a 1 (x a1 ,y a1 ) And straight line L 2 Intersecting with the end point a 3 (x a3 ,y a3 ) Semi-circular arc B and straight line L 1 Intersecting with the end point a 2 (x a2 ,y a2 ) And straight line L 2 Intersecting with the end point a 4 (x a4 ,y a4 ) The method comprises the steps of carrying out a first treatment on the surface of the The fitting curve is the positioning reference of the mounting seat hole relative to the mounting seat;
solving straight line L 1 The perpendicular bisector of (2) is:
solving straight line L by the same method 3 For the intersection of two perpendicular bisectors, i.e. the centre point O of the mount 2 The method comprises the steps of carrying out a first treatment on the surface of the Repeating the above steps to obtain a straight line L 2 Perpendicular bisector and straight line L of (2) 4 Another intersection point O of the perpendicular bisector of (2) 1 ，O 1 With O 2 The midpoint of the two-point connecting line is the actual center point 2a of the mounting seat;
because the thin-wall shell cannot be damaged in the hole machining process, the actual height and the actual clearance value of the mounting seat need to be accurately calculated, and a basis is provided for the cutting feed of the machine tool; taking a radial section of the mounting seat as an example, after secondary interpolation fitting, the fitted gap represents the actual gap; after fitting, the actual height D at different positions of the mounting base j Represented using a quadratic curve:
D j ＝k 1 ·x 2 +k 2 ·x+b(2)
wherein the abscissa x is the cross-section abscissa value; d (D) j An actual height value at mount location j; k (k) 1 ，k 2 B is a fitting constant;
the actual gap is expressed as:
η＝D j -d＝k 1 ·x 2 +k 2 ·x+b-d(3)
wherein eta is the actual gap value; d is the actual thickness of the mounting seat;
obtaining an end face boundary expression of the thin-wall shell by using a curvature calculation and secondary B spline curve fitting method, and taking a vertex to obtain an axial positioning reference of the array mounting seat hole relative to the thin-wall shell; the method comprises the steps of taking position data points on the connecting line of actual center points of the same group of radially adjacent mounting seats, fitting by using a quadratic B spline curve, obtaining an expression, and taking the vertex as a radial positioning reference of the holes of the same group of radially adjacent mounting seats relative to a thin-wall shell; second step, based on measuring point cloud, calculating hole making position of thin-wall shell surface mounting seat
When the array mounting base is used for making holes, a plurality of constraints need to be considered in a coordinated manner: l (L) Z ±D WZ And L d ±D Wd The position of the hole on the thin-wall substrate is restricted, so that the position requirement is ensured; l (L) bd ±D bd And L bz ±D bz The positions of the holes on the mounting seat are restricted, so that the wall thickness requirement is ensured; l (L) dL ±D WdL Restraining the relative position requirements between the radial adjacent mounting seat holes in the same group; wherein L is Z ±D WZ For the axial position requirement of the mounting seat hole relative to the thin-walled shell, L d ±D Wd For radial relative position requirement of mounting seat hole relative to thin-wall shell, L bd ±D bd For radial position requirement of mount hole relative to mount, L bz ±D bz The axial position requirement of the mounting seat hole relative to the mounting seat is met;
the actual end face center 2a of the mounting base body is not coincident with the theoretical end face center 1a of the mounting base body, and the axial deviation d exists between the two z And a radial deviation d d The method comprises the steps of carrying out a first treatment on the surface of the All points meeting the wall thickness processing requirements are a rectangular area, i.e. wall thickness tolerance range Q b The center of the mounting base body is the actual end face center 2a of the mounting base body; all points meeting the position requirement are also a rectangular area, i.e. a position tolerance rangeQ w The center of the base body is the theoretical end face center 1a of the base body of the mounting seat; wall thickness tolerance range Q b And a position tolerance range Q w The intersection of the two is the qualified processing range Q of a single hole h Namely, when the hole is machined in the range, the wall thickness requirement and the position requirement can be met at the same time; according to the axial deviation d of the wall thickness tolerance range central point and the position tolerance range central point z And a radial deviation d d Axial wall thickness tolerance value D bz And radial wall thickness tolerance value D bd Axial position tolerance value D wz And a radial position tolerance value D wd The relationship between the processing ranges is divided into two cases:
when d z ＜D wz +D bz And d d ＜D wd +D bd When the method is used, the qualified machining range of the hole exists, and the machining position of the hole can be coordinated and compensated based on the relative position requirement of the adjacent mounting seat hole on the premise that the wall thickness requirement and the position requirement are simultaneously met; for easy processing, simplifying the qualified processing range, taking the connecting line L of the wall thickness tolerance range center point 2a and the position tolerance range center point 1a, and taking the intersection line of the straight line L and the qualified processing range as the adjustable range L T Taking the adjustable range L T Taking the midpoint O of the hole as a preliminary machining position of the hole;
when d z ≥D wz +D bz Or d d ≥D wd +D bd When the qualified machining range of the hole does not exist, the wall thickness requirement and the position requirement cannot be met at the same time, and the part is scrapped;
considering the relative position requirement between the radial adjacent mounting seat holes, the preliminary machining positions of the radial adjacent mounting seat holes need to be further coordinated, repaired and compensated; radial minimum distance d according to qualified machining range Lmin And a maximum radial distance d Lmax Radial distance d of preliminary machining position of radially adjacent mounting seat holes Lmid Relative position requirement L of radially adjacent mounting seat holes dL ±D WdL The relationship between them is further divided into three cases:
when the radial distance between the preliminary machining positions of the radially adjacent mounting seat holes meets L dL ±D WdL When the requirements are met, the maintenance is not needed; the preliminary machining position of the radial adjacent mounting seat hole is the final machining position of the hole;
when the radial distance between the primary machining positions of the radially adjacent mounting seat holes does not meet L dL ±D WdL Requirement d Lmax ≥L dL +D wdL Or d Lmin ≤L dL -D wdL When the adjustment range is adjusted, all points do not meet the relative position requirements of radial adjacent mounting seat holes, the coordination compensation cannot be performed, and the parts are scrapped;
when the radial distance between the primary machining positions of the radially adjacent mounting seat holes does not meet L dL ±D WdL Requirement d Lmax ∈L dL ±D wdL Or d Lmin ∈L dL ±D wdL When the radial relative position requirement is met by partial points in the trimming range, trimming the preliminary machining positions of the radial adjacent mounting seat holes on the basis; taking intersection L of adjustable range of radial adjacent mounting seat holes and tolerance zone required by relative position TZ The points in the intersection can meet the wall thickness requirement, the position requirement and the relative position requirement, and at the moment, the midpoint O of the intersection is respectively taken Z As a final machining location for radially adjacent mount holes;
finally, outputting final machining position coordinates of the array mounting seat holes, generating a machining G code, and preparing for machining;
third step high-efficiency automatic processing of screw hole with controllable depth
Firstly, in order to ensure the processing quality of the holes of the array mounting seat, drilling and thread processing are needed to be respectively carried out in two working procedures, after the tool is changed between different working procedures, the dimension deviation and the position deviation of the tool exist, and only after the tool is set, the radius, the length and the position deviation of the tool are compensated into a self-adaptive processing program, the tool can be accurately processed at the position after the adjustment and the compensation, and meanwhile, the damage to a shell is avoided;
secondly, considering the clearance of the mounting seat, the solid rocket shell cannot be damaged during processing, and controlling the G code drilling depth of the mounting seat to be processed according to the actual height and clearance value of the mounting seat obtained by line laser measurement data, so that the shell is prevented from being damaged; meanwhile, when the cutter cuts into and cuts out a workpiece, the cutting force can generate periodic mutation, the cutting force monitoring function of the main shaft of the machine tool is used for capturing the axial cutting force mutation point at the moment that the cutter penetrates through the mounting seat, when the cutter continues to feed after penetration is completed, the system alarms and controls the machine tool to stop running, so that the safety monitoring of the processing state in the processing process is realized, the abnormal situation is avoided, and the safety processing is ensured;
and finally, starting the machine tool, and executing an array mounting seat hole machining program on the premise of monitoring the stress of a main shaft of the machine tool to finish machining of the array holes of the mounting seat of the thin-wall shell.
2. The method for efficiently machining the array holes on the outer surface of the thin-wall shell according to claim 1, wherein in the first step, when the non-contact line laser is used for measuring the part in the on-machine measuring method, the thin-wall shell is clamped on a machining machine tool, a knife handle type line laser measuring tool is designed, a line laser scanner is arranged on the machining machine tool, and the machining machine tool drives the line laser measuring tool to finish workpiece measurement; the tool comprises a special tool handle, an upper connecting plate, a lower connecting plate, a three-dimensional precise fine adjustment platform and a line laser scanner; the special cutter handle is arranged on a main shaft of the processing machine tool and is connected with the three-dimensional precise fine adjustment platform through an upper connecting plate; the three-dimensional precise fine adjustment platform is connected with the line laser scanner through a lower connecting plate and is used for calibrating the measuring pose of the line laser scanner.
3. The method for efficiently machining the array holes on the outer surface of the thin-wall shell according to claim 1 or 2, wherein in the third step, after tool changing is performed between two working procedures of drilling and thread machining, a laser automatic tool setting instrument is used for tool setting; when the tool is set, firstly, the actual position of the laser tool setting gauge under the coordinate system of the machine tool is obtained by using a standard tool for tool setting; then, approaching the actually used tool to the laser beam from multiple directions, so as to accurately determine the geometric dimension of the tool and the position deviation of the tool relative to the spindle after installation; after the actual length H of the cutter is obtained by tool setting, updating the cutter length compensation instruction G43 to carry out the height deviation of the machining position; for the deviation of the tool in the direction X, Y, the coordinate system deviation instruction or the R parameter is utilized to carry out the deviation accumulation compensation of the position, so that the array mounting seat hole machining program of different tools is further generated on the basis of the self-adaptive machining codes.
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