CN117862957A - Self-adaptive adjustment method and system for technological parameters of milling of bimetal material - Google Patents
Self-adaptive adjustment method and system for technological parameters of milling of bimetal material Download PDFInfo
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- 239000000463 material Substances 0.000 title claims abstract description 124
- 238000000034 method Methods 0.000 title claims abstract description 68
- 238000003801 milling Methods 0.000 title claims abstract description 35
- 238000005520 cutting process Methods 0.000 claims abstract description 127
- 238000004088 simulation Methods 0.000 claims abstract description 24
- 239000007769 metal material Substances 0.000 claims abstract description 17
- 238000012545 processing Methods 0.000 claims abstract description 15
- 230000008569 process Effects 0.000 claims description 33
- 230000003044 adaptive effect Effects 0.000 claims description 13
- 238000004364 calculation method Methods 0.000 claims description 8
- 238000003860 storage Methods 0.000 claims description 6
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- 238000001514 detection method Methods 0.000 claims description 4
- 101000932768 Conus catus Alpha-conotoxin CIC Proteins 0.000 claims description 3
- 238000003754 machining Methods 0.000 abstract description 4
- 230000007547 defect Effects 0.000 description 6
- 230000007704 transition Effects 0.000 description 6
- 229910052782 aluminium Inorganic materials 0.000 description 4
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 4
- 238000010586 diagram Methods 0.000 description 4
- 229910001018 Cast iron Inorganic materials 0.000 description 3
- 230000006870 function Effects 0.000 description 3
- 238000005457 optimization Methods 0.000 description 3
- 238000001914 filtration Methods 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 1
- 239000004411 aluminium Substances 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000004590 computer program Methods 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 230000004069 differentiation Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
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- 239000007787 solid Substances 0.000 description 1
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- 238000012360 testing method Methods 0.000 description 1
- 238000012795 verification Methods 0.000 description 1
Abstract
The invention provides a method and a system for adaptively adjusting technological parameters of milling of a bimetal material, and relates to the technical field of numerical control machining processes. Includes material distinguishing of the to-be-machined part of the bimetal material; cutting simulation is carried out on a workpiece to be machined, a cutting force model is established, and based on the undeformed chip parameters obtained through simulation, the individual actual unit cutting force of each metal material is calculated; obtaining the actual unit cutting force of the workpiece to be machined based on the actual cutting stroke of the bimetal, and further obtaining the overall actual cutting force of the workpiece to be machined; and acquiring a preset target cutting force, so that the actual cutting force tracks the target cutting force, and reversely pushing out the thickness of the undeformed chip corresponding to the target cutting force, thereby realizing the self-adaptive adjustment of the technological parameters. The invention can keep the processing load in a stable state, thereby obtaining good cutter life and workpiece quality.
Description
Technical Field
The invention belongs to the field of numerical control machining processes, and particularly relates to a process parameter self-adaptive adjustment method and system for milling of a bimetal material.
Background
With the development of manufacturing engineering, the solid dissimilar bimetal material workpiece is widely focused in the automobile industry due to the advantages of light weight, sustainability, low cost and the like, and has wide application prospect. However, as shown in fig. 1 (a) and 1 (b), the stress state at the cutting edge of the bimetal workpiece presents local differentiation, so that the cutter is severely abraded/damaged and has poor surface quality, which presents great challenges for cutter performance and process optimization.
Identifying material boundary contours is a key to adaptive adjustment of process parameters. In the prior art, machine data and sensors can be used for detecting cutting force in real time, and real-time cutting force changes are used for identifying materials. However, this process is limited by the response time of the sensor and control system, and the process parameters are not adjusted until the material exceeds the transition zone, which can lead to damage to the milling cutter and reduced surface quality of the workpiece in rough machining with high feed rates.
In addition, the inventor also discovers that the existing bimetal cutting process making method can not solve the problems of low service life of the cutter, unstable surface quality of the workpiece and the like caused by the load difference of the cutting edge of the cutter. The existing method for self-identifying the material of the bimetal workpiece and self-adaptively adjusting the processing technological parameters still belongs to the blank.
Disclosure of Invention
In order to overcome the defects in the prior art, the invention provides a method and a system for adaptively adjusting the technological parameters of the milling processing of the bimetal material, which are used for automatically identifying the bimetal material under the numerical control processing condition and adaptively adjusting the technological parameters according to the identification result, so that the processing load is kept in a stable state, and the service life of a cutter and the quality of a workpiece are good.
To achieve the above object, one or more embodiments of the present invention provide the following technical solutions:
the first aspect of the invention provides a process parameter self-adaptive adjustment method for milling of a bimetal material.
The technological parameter self-adaptive adjustment method for milling the bimetal material comprises the following steps:
carrying out material discrimination on a to-be-machined piece of the bimetal material to obtain boundaries of different materials;
cutting simulation is carried out on a workpiece to be machined, a cutting force model is established, and based on the undeformed chip parameters obtained through simulation, the individual actual unit cutting force of each metal material is calculated; obtaining the actual unit cutting force of the workpiece to be machined based on the actual cutting stroke of the bimetal, and further obtaining the overall actual cutting force of the workpiece to be machined;
and acquiring a preset target cutting force, so that the actual cutting force tracks the target cutting force, and reversely pushing out the thickness of the undeformed chip corresponding to the target cutting force, thereby realizing the self-adaptive adjustment of the technological parameters.
The second aspect of the invention provides a process parameter self-adaptive adjustment system for milling of a bimetallic material.
A process parameter self-adaptive adjustment system for milling of a bimetal material comprises:
a material discrimination module configured to: carrying out material discrimination on a to-be-machined piece of the bimetal material to obtain boundaries of different materials;
a cutting force calculation module configured to: cutting simulation is carried out on a workpiece to be machined, a cutting force model is established, and based on the undeformed chip parameters obtained through simulation, the individual actual unit cutting force of each metal material is calculated; obtaining the actual unit cutting force of the workpiece to be machined based on the actual cutting stroke of the bimetal, and further obtaining the overall actual cutting force of the workpiece to be machined;
an adaptive adjustment module configured to: and acquiring a preset target cutting force, so that the actual cutting force tracks the target cutting force, and reversely pushing out the thickness of the undeformed chip corresponding to the target cutting force, thereby realizing the self-adaptive adjustment of the technological parameters.
A third aspect of the present invention provides a computer readable storage medium having stored thereon a program which when executed by a processor performs the steps of the method for adaptively adjusting a process parameter of a bi-metallic material milling process according to the first aspect of the present invention.
A fourth aspect of the invention provides an electronic device comprising a memory, a processor and a program stored on the memory and executable on the processor, the processor implementing the steps in the method for adaptively adjusting process parameters of milling of a bi-metallic material according to the first aspect of the invention when the program is executed.
The one or more of the above technical solutions have the following beneficial effects:
the invention provides a method and a system for adaptively adjusting technological parameters of milling of a bimetal material, and provides a cutting force model for predicting milling of workpieces made of different material combinations.
Proved by verification, the method of the invention reduces the cutting force of transition areas of different materials by up to 70.5%, and the milling cutter has balanced load and greatly prolonged service life. By distributing and storing material class information on the workpiece model, the impact of different materials on the cutting process is considered in the material cutting simulation.
The invention provides a bimetal workpiece identification method based on machine integrated detection material transition region, which uses laser measurement technology to identify the material in a processing region, and material category information is stored in an analog digital workpiece and used for self-adaptive process planning.
Additional aspects of the invention will be set forth in part in the description which follows and, in part, will be obvious from the description, or may be learned by practice of the invention.
Drawings
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the invention.
Fig. 1 (a) is a state of use diagram of a bimetal cutting edge in the prior art.
Fig. 1 (b) is a state of stress diagram at a cutting edge of a bimetal material in the prior art.
FIG. 2 is a graph showing the comparison of a parting line of a bimetal material obtained by laser scanning in a processing state with an actual parting line of the bimetal material.
FIG. 3 is a graph comparing a parting line of a bimetal material obtained by laser scanning in a raw state with an actual parting line of the bimetal material.
FIG. 4 is a diagram showing a step of identifying a boundary of a bimetal material.
Fig. 5 is a schematic diagram of a bi-metallic material.
Fig. 6 is a flow chart of a method of the first embodiment.
Detailed Description
It should be noted that the following detailed description is exemplary and is intended to provide further explanation of the invention. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs.
It is noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of exemplary embodiments according to the present invention.
Embodiments of the invention and features of the embodiments may be combined with each other without conflict.
Example 1
The embodiment discloses a process parameter self-adaptive adjustment method for milling of a bimetal material.
As shown in fig. 6, the process parameter self-adaptive adjustment method for milling the bimetal material comprises the following steps:
carrying out material discrimination on a to-be-machined piece of the bimetal material to obtain boundaries of different materials;
cutting simulation is carried out on a workpiece to be machined, a cutting force model is established, and based on the undeformed chip parameters obtained through simulation, the individual actual unit cutting force of each metal material is calculated; obtaining the actual unit cutting force of the workpiece to be machined based on the actual cutting stroke of the bimetal, and further obtaining the overall actual cutting force of the workpiece to be machined;
and acquiring a preset target cutting force, so that the actual cutting force tracks the target cutting force, and reversely pushing out the thickness of the undeformed chip corresponding to the target cutting force, thereby realizing the self-adaptive adjustment of the technological parameters.
(1) The embodiment firstly provides a bimetal self-identification method in the milling process:
by utilizing the characteristic that the optical sensor measures the surface rapidly and accurately, a method for collecting the geometric shape of the workpiece by a laser line scanner based on the principle of a laser triangulation method is provided. And integrating a laser line scanner into the numerical control milling machine to detect the shape of the workpiece, wherein the placement position of the laser line scanner ensures that the laser line is perpendicular to the boundary of the workpiece, and the laser line is scanned from the material A to the material B. It is proposed to use a scanning strategy of high sensitivity (5), low laser intensity (1-2) and long exposure time (5000 microseconds) for planar workpieces, exploiting the difference in cloud density in the scan data to distinguish material a from material B material regions.
In particular, as shown in fig. 2-3, scan data from a laser line scanner contains surface information of the combined workpiece in the form of a point cloud, and different point densities can be used to distinguish material a from material B. The material areas are dispensed by image processing and the information is transferred to simulation software.
As shown in fig. 2 to 3, the material a is aluminum, the material B is cast iron, and the point cloud density of the material a area is greater than that of the material B, so that the boundary between the material a and the material B can be easily obtained.
In this embodiment, the scanning frequency of the laser line scanner is set to 1kHZ, the acquisition density is 800 points acquired every 0.05mm in length, and the scanning length is 1mm. Small defects in the image are removed using an image processing function.
Carrying out convolution matrix processing on the image to obtain boundaries of different materials:
as shown in fig. 4, 1) in fig. 4 represents an original point cloud image;
2) in fig. 4, removing small defects in the image and ignoring local point clusters by means of an image processing function;
3) of fig. 4) convolving the image with a special convolution matrix (a Prewitt filter in the vertical direction) to create edges in the material transition region;
4) in fig. 4), using Blob filtering to remove larger defects in the binary image;
5 in fig. 4), the pixel locations representing the material boundaries are not coincident with the pixel locations in the workpiece coordinate system, as all of the actual coordinate information is lost in the gridding. Thus, an inverse transformation from the pixel to the original grid is performed.
Fig. 5 shows three regions of the workpiece created based on the boundary recognition process described above, namely region a, region B and transition region C.
In order to detect the material boundary, an industrial image processing method is used for a binary image, and small defects in the image can be removed and local point clusters can be ignored by using an image processing function. The image is convolved with a special convolution matrix to produce edges in the material transition region. The convolution matrix is a Prewitt filter in the vertical direction and is often used in image processing. And (3) removing larger defects in the binary image by using Blob filtering.
Since all the actual coordinate information is lost in gridding, the pixel locations representing the material boundaries are not consistent with the pixel locations in the workpiece coordinate system. Thus, an inverse transformation from the pixel to the original grid is performed. The points are then transferred into the original workpiece coordinate system via coordinate transformation. The final step is to parameterize the detection points representing the material boundaries. Finally, the material is divided into aluminum and steel according to the density of the points in the respective regions.
(2) The embodiment provides a bi-metal material milling process parameter self-adaptive adjustment method.
And using a cutting force model, and simulating and adjusting the cutting force by combining a simulation platform. The use of a dexel expander enables adaptive adjustment of process parameters that take into account the material properties of the workpiece during the process simulation.
As part of the process planning, predictions of cutting forces are used to automatically calculate and adjust appropriate process parameters based on the material to be processed. In order to accurately calculate the cutting force for the optimization of the machining process parameters, an empirical model of the cutting force shown in formula (1) is used.
Wherein F is c Is the cutting force; b is the cutting width, h is the undeformed chip thickness, K C1.1 For nominal specific cutting force, m c Is the index of material properties. In order to determine the specific property values of different materials, i.e. the nominal cutting force K C1.1 And a material property index m c The cutting test data can be obtained through regression calculation of cutting experiments or reference document data.
After the simulation process begins, first, a material boundary detection module locates a material boundary of a bimetal workpiece based on scan data. Then, based on the undeformed chip parameters obtained at the time of cutting simulation, a real-time cutting force and a new feed speed corresponding to the target cutting force are calculated. Finally, the numerical control editing module adjusts the numerical control program and updates the new feeding speed and the cutter position parameters into the numerical control program.
A cutting simulation cycle comprises three steps: calculation of tool motion based on NC codes, material removal of the workpiece, and undeformed chip parameters. The undeformed chip thickness h, obtained from the simulated undeformed chip cross-section, is in this embodiment aluminium (a) and cast iron (B), respectively.
The actual unit cutting force of the aluminum (a) and cast iron (B) materials is calculated from the formulas (2) and (3).
Wherein h is the thickness of the undeformed chip obtained by simulation, m cA And m cB Material property index, K, of material A and material B, respectively c1 Is the nominal unit cutting force.
Actual unit cutting force k c Calculated by equation (4).
k c ＝X A ·k cA +X B ·k cB (4)
Wherein X is A And X B The scaling factors for material a and material B, respectively, are proportional to the actual cutting stroke length of material a and material B during the cutting stroke.
Actual cutting force F c Can be calculated by equation (5).
F c ＝b·h·k c (5)
Wherein b is the cutting width. Combining the formula (4) and the undeformed chip thicknesses h and b obtained in the simulated undeformed chip cross section to obtain the actual cutting force F c 。
Cutting force F c Is used for adaptively adjusting the process parameters.
For optimization, the desired cutting force is maintained as a target value within a prescribed range for different materials. In order to achieve the target cutting forces for both materials, new process parameters need to be calculated. Undeformed chip thickness h corresponding to target cutting force Target Calculated by equation (6). Equation (6) is derived from equations (1) - (5). Then h is Target And converting the cutting force into a target feeding rate of NC codes, namely a new feeding rate corresponding to the target cutting force.
The resulting adapted process parameters are stored in a memory together with the current tool position. On the basis, the numerical control program is adjusted, and the shaft interpolator is updated. It is not feasible to achieve an adaptive adjustment of the process parameters per revolution, and it is suggested to use a distance within 0.1-0.5mm for the adaptive process parameter adjustment.
The accuracy of the simulation results depends on the one hand on the resolution of the discrete workpieces and on the other hand on the choice of the time step. Both can be specified before the simulation begins, with a resolution recommended for the discrete workpiece of 60dexel per millimeter of depth element density in each spatial direction. The time step recommended value is 5 °.
Example two
The embodiment discloses a process parameter self-adaptive adjustment system for milling of a bimetal material.
A process parameter self-adaptive adjustment system for milling of a bimetal material comprises:
a material discrimination module configured to: carrying out material discrimination on a to-be-machined piece of the bimetal material to obtain boundaries of different materials;
a cutting force calculation module configured to: cutting simulation is carried out on a workpiece to be machined, a cutting force model is established, and based on the undeformed chip parameters obtained through simulation, the individual actual unit cutting force of each metal material is calculated; obtaining the actual unit cutting force of the workpiece to be machined based on the actual cutting stroke of the bimetal, and further obtaining the overall actual cutting force of the workpiece to be machined;
an adaptive adjustment module configured to: and acquiring a preset target cutting force, so that the actual cutting force tracks the target cutting force, and reversely pushing out the thickness of the undeformed chip corresponding to the target cutting force, thereby realizing the self-adaptive adjustment of the technological parameters.
Example III
An object of the present embodiment is to provide a computer-readable storage medium.
A computer readable storage medium having stored thereon a computer program which when executed by a processor performs the steps in a method for adaptively adjusting process parameters of bi-metallic material milling as described in embodiment 1 of the present disclosure.
Example IV
An object of the present embodiment is to provide an electronic apparatus.
An electronic device comprising a memory, a processor and a program stored on the memory and executable on the processor, wherein the processor implements the steps in the process parameter adaptive adjustment method for bi-metallic material milling as described in embodiment 1 of the present disclosure when the program is executed.
The steps involved in the devices of the second, third and fourth embodiments correspond to those of the first embodiment of the method, and the detailed description of the embodiments can be found in the related description section of the first embodiment. The term "computer-readable storage medium" should be taken to include a single medium or multiple media including one or more sets of instructions; it should also be understood to include any medium capable of storing, encoding or carrying a set of instructions for execution by a processor and that cause the processor to perform any one of the methods of the present invention.
It will be appreciated by those skilled in the art that the modules or steps of the invention described above may be implemented by general-purpose computer means, alternatively they may be implemented by program code executable by computing means, whereby they may be stored in storage means for execution by computing means, or they may be made into individual integrated circuit modules separately, or a plurality of modules or steps in them may be made into a single integrated circuit module. The present invention is not limited to any specific combination of hardware and software.
While the foregoing description of the embodiments of the present invention has been presented in conjunction with the drawings, it should be understood that it is not intended to limit the scope of the invention, but rather, it is intended to cover all modifications or variations within the scope of the invention as defined by the claims of the present invention.
Claims (10)
1. The technological parameter self-adaptive adjustment method for milling the bimetal material is characterized by comprising the following steps of:
carrying out material discrimination on a to-be-machined piece of the bimetal material to obtain boundaries of different materials;
cutting simulation is carried out on a workpiece to be machined, a cutting force model is established, and based on the undeformed chip parameters obtained through simulation, the individual actual unit cutting force of each metal material is calculated; obtaining the actual unit cutting force of the workpiece to be machined based on the actual cutting stroke of the bimetal, and further obtaining the overall actual cutting force of the workpiece to be machined;
and acquiring a preset target cutting force, so that the actual cutting force tracks the target cutting force, and reversely pushing out the thickness of the undeformed chip corresponding to the target cutting force, thereby realizing the self-adaptive adjustment of the technological parameters.
2. The method for adaptively adjusting technological parameters of milling of a bimetal material according to claim 1, wherein the method for adaptively adjusting technological parameters of milling of the bimetal material comprises the following steps:
scanning two materials by utilizing laser lines, wherein the scanning data contains surface information of the combined workpiece in a point cloud form;
carrying out convolution processing on the point cloud image by using a convolution matrix to obtain boundaries of different materials:
firstly, carrying out inverse transformation from pixels to an original grid on a point cloud image, then transferring points to an original workpiece coordinate system through coordinate transformation, finally parameterizing detection points representing material boundaries, and distinguishing two materials according to the density of the points in respective areas.
3. The adaptive adjustment method of process parameters for milling of bi-metallic materials according to claim 1, wherein the calculation formula of the individual actual unit cutting force of each metallic material is:
wherein K is cA And K cB The actual unit cutting force of material a and material B, respectively; h is the thickness of the undeformed chip obtained by simulation; m is m cA And m cB Material property indexes of the material A and the material B respectively; k (K) c1.1A And K c1.1B Nominal unit cutting force for material a and material B, respectively.
4. The adaptive adjustment method of processing parameters for milling of a bi-metallic material according to claim 3, wherein the actual unit cutting force of the workpiece to be processed is calculated by the following formula:
k c ＝X A ·k cA +X B ·k cB
wherein X is A And X B The ratio coefficients of the material A and the material B are respectively determined by the actual cutting stroke length ratio of the material A and the material B in the cutting stroke process; k (k) c K is the actual unit cutting force cA For the actual unit cutting force, k, of material A cB Is the actual unit cutting force of material B.
5. The method for adaptively adjusting the process parameters of the milling process of the bimetallic material as set forth in claim 4, wherein the actual cutting force F c The calculation formula is as follows:
F c ＝b·h·k c
wherein b is the cutting width; h is the undeformed chip thickness obtained in the simulated undeformed chip cross section.
6. The method for adaptively adjusting the process parameters of the milling process of the bimetal material according to claim 5, wherein the undeformed chip thickness h corresponding to the target cutting force Target The calculation formula is as follows:
wherein K is C1.1 For nominal unit cutting force, m c Is the index of material properties.
7. The adaptive adjustment method of the technological parameters for milling of the bimetallic material as set forth in claim 6, wherein the cutter is a rotary cutterWith undeformed chip thickness h corresponding to the target cutting force at a set distance before reaching the boundary of the bimetallic material Target Calculate and let h Target Converting to a target feed rate.
8. The technological parameter self-adaptive adjustment system for milling the bimetal material is characterized in that: comprising the following steps:
a material discrimination module configured to: carrying out material discrimination on a to-be-machined piece of the bimetal material to obtain boundaries of different materials;
a cutting force calculation module configured to: cutting simulation is carried out on a workpiece to be machined, a cutting force model is established, and based on the undeformed chip parameters obtained through simulation, the individual actual unit cutting force of each metal material is calculated; obtaining the actual unit cutting force of the workpiece to be machined based on the actual cutting stroke of the bimetal, and further obtaining the overall actual cutting force of the workpiece to be machined;
an adaptive adjustment module configured to: and acquiring a preset target cutting force, so that the actual cutting force tracks the target cutting force, and reversely pushing out the thickness of the undeformed chip corresponding to the target cutting force, thereby realizing the self-adaptive adjustment of the technological parameters.
9. A computer readable storage medium, having stored thereon a program, characterized in that the program, when executed by a processor, realizes the steps in the process parameter adaptive adjustment method for milling of a bimetal material according to any of claims 1-7.
10. Electronic device comprising a memory, a processor and a program stored on the memory and executable on the processor, characterized in that the processor implements the steps of the process parameter adaptive adjustment method for milling of a bi-metallic material according to any of the claims 1-7 when executing the program.
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