WO2013088849A1 - Dispositif de coupe et procédé de traitement utilisant celui-ci - Google Patents

Dispositif de coupe et procédé de traitement utilisant celui-ci Download PDF

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Publication number
WO2013088849A1
WO2013088849A1 PCT/JP2012/078011 JP2012078011W WO2013088849A1 WO 2013088849 A1 WO2013088849 A1 WO 2013088849A1 JP 2012078011 W JP2012078011 W JP 2012078011W WO 2013088849 A1 WO2013088849 A1 WO 2013088849A1
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WIPO (PCT)
Prior art keywords
cutting
tool
machining
signal
vibration
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PCT/JP2012/078011
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English (en)
Japanese (ja)
Inventor
中須　信昭
英明 小野塚
武尚 吉川
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株式会社日立製作所
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Priority to JP2013549156A priority Critical patent/JP5809709B2/ja
Publication of WO2013088849A1 publication Critical patent/WO2013088849A1/fr

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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
    • B23Q17/09—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool
    • B23Q17/0952—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool during machining
    • B23Q17/0971—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool during machining by measuring mechanical vibrations of parts of the machine
    • B23Q17/0976—Detection or control of chatter
    • 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
    • B23Q17/09—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool
    • B23Q17/0952—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool during machining
    • B23Q17/0966—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool during machining by measuring a force on parts of the machine other than a motor
    • 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
    • B23Q17/09—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool
    • B23Q17/0952—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool during machining
    • B23Q17/0971—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool during machining by measuring mechanical vibrations of parts of the machine
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00—Programme-control systems
    • G05B19/02—Programme-control systems electric
    • G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
    • G05B19/404—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by control arrangements for compensation, e.g. for backlash, overshoot, tool offset, tool wear, temperature, machine construction errors, load, inertia
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/37—Measurements
    • G05B2219/37351—Detect vibration, ultrasound
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/37—Measurements
    • G05B2219/37355—Cutting, milling, machining force
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/49—Nc machine tool, till multiple
    • G05B2219/49061—Calculate optimum operating, machining conditions and adjust, adapt them

Definitions

  • the present invention relates to a cutting apparatus that performs cutting under conditions that do not cause machining abnormalities by monitoring a machining state during cutting and sequentially changing the machining conditions, and a machining method using the same.
  • Cutting is a general processing method used for various metal processing, and a cutting blade attached to a rotary tool is cut into a work material and processed into various shapes by removing the material.
  • the removal amount increases, so that the cutting efficiency, the feed speed, and the tool rotation speed are increased to increase the efficiency.
  • Patent Document 1 discloses a method of measuring the vibration amplitude of a tool and changing the tool rotation speed when the vibration amplitude exceeds a preset threshold value.
  • the tool vibration is described in Patent Document 1 because the vibration amplitude changes as the cutting depth changes.
  • the method of setting the abnormality detection threshold in advance is applicable only when the cutting amount is constant, and cannot be applied when the tool vibration amplitude changes with the change of the cutting amount.
  • An object of the present invention is to provide a cutting apparatus capable of reliably detecting an abnormality even in a machining path in which the cutting amount changes from moment to moment, and a machining method using the same.
  • the vibration or cutting force of the cutting apparatus is measured to sequentially change the processing conditions.
  • a first step of setting a machining condition for cutting the workpiece with the cutting tool, and cutting the workpiece based on the set machining condition A second step of detecting vibration or cutting force of the cutting device and converting it to an electrical signal; a third step of separating the converted electrical signal into the cutting component signal and a tool vibration component signal; A fourth step of calculating a determination index value for determining a machining state during machining with the cutting tool using the information of the separated cutting component signal and the information of the tool vibration component signal; and the calculated determination index
  • a determination threshold value set in advance and determining whether or not there is an abnormality during the cutting of the workpiece with the cutting tool, a determination result of whether or not there is an abnormality during the cutting, and the The sixth step for storing the set
  • the machining method using the cutting apparatus is characterized in that the new machining condition including an override rate for the machining condition set in the first step is set based on the index value.
  • a processing condition for cutting a work material using a cutting tool in the cutting apparatus is set, and the setting is performed. Cutting the workpiece with the cutting tool based on the machining conditions, detecting vibration or cutting force of the cutting device while cutting the workpiece, and processing the detected signal to obtain a cutting component A signal and a tool vibration component signal, and using the information of the separated cutting component signal and the information of the tool vibration component signal, a determination index value for determining a state of machining during machining by the cutting tool is calculated.
  • the calculated determination index value is compared with a predetermined determination threshold value, and a new processing condition including an override rate for the set processing condition according to the magnitude of the determination index value with respect to the determination threshold value Calculate And so cutting the workpiece by the cutting apparatus by changing the processing conditions described above set the new machining conditions said calculated.
  • a cutting apparatus that sequentially changes machining conditions by measuring vibration or cutting force of the apparatus while cutting a work material using a cutting tool.
  • Machining condition setting means for setting a machining condition for cutting a work material using a tool
  • the cutting apparatus for cutting the work material based on the machining conditions set by the machining condition setting means
  • Signal converting means for detecting the vibration or cutting force of the tool and converting it into an electric signal
  • signal separating means for separating the electric signal converted by the signal converting means into a cutting component signal and a tool vibration component signal
  • the signal separating means A determination index calculation means for calculating a determination index value for determining the state of machining during cutting with the cutting tool using the information on the cutting component signal and the information on the tool vibration component signal separated in Step 1
  • the determination index Calculation means An abnormality determination unit that compares the calculated determination index value with a preset determination threshold value to determine the presence or absence of abnormality, a determination result of the presence or
  • Machining condition calculation means for calculating a new machining condition including an override rate for the set machining condition, and the machining condition setting means sets the set machining condition during the cutting of the work material.
  • the machining conditions are changed to new machining conditions calculated by the machining condition calculation means.
  • the vibration or cutting force of the cutting apparatus is measured and the processing conditions are sequentially changed.
  • the amplitude of the vibration of the cutting device derived from the vibration of the cutting tool is derived from the cutting as an index value for determining the state of machining during the machining with the cutting tool. The information based on the value obtained by dividing by the amplitude of vibration of the cutting device is used.
  • the vibration or cutting force of the cutting apparatus is measured and the processing conditions are sequentially changed.
  • the vibration of the cutting device derived from the vibration of the cutting tool is frequency-converted as an index value for determining the state of processing during processing with the cutting tool, and the side Information based on a value obtained by dividing the lobe amplitude by the main lobe amplitude is used.
  • a data input support device that supports data input in a processing device having a function of measuring a cutting state amount accompanying processing for rotating a cutting tool and detecting processing abnormality
  • a machining condition input unit that presents a library item of machining conditions for machining a workpiece with the cutting tool to the user and receives designation of the library item of machining conditions from the user, and a workpiece with the cutting tool
  • a machining path input unit that presents a machining path library item for machining to the user and receives designation of the machining path library item from the user, and characteristics of the tool for machining the workpiece with the cutting tool
  • Tool / work material characteristics input unit that presents the library items of workpiece characteristics to the user and receives specification of the tool characteristics and workpiece characteristics library items from the user , Presenting a library item of conditions for determining machining abnormalities from data obtained by measuring a cutting state amount when machining a workpiece with the cutting tool, and specifying the library items of the determination conditions from
  • the abnormality detection accuracy can be improved and the machining accuracy can be improved.
  • FIG. 16 is a diagram showing an example of file information when “Acquire from file” is selected in “Diameter cutting input method” on the input screen for inputting the machining path setting method shown in FIG. 15.
  • FIG. 16 is a diagram showing an example of file information when “Acquire from file” is selected in “Diameter cutting input method” on the input screen for inputting the machining path setting method shown in FIG. 15.
  • 16 is a diagram showing an example of file information when “Acquire from file” is selected in “Work material thickness input method” on the input screen for inputting the machining path setting method shown in FIG. 15. It is a front view of the screen which selects the tool characteristic input method or the work material characteristic input method in the Example of this invention. It is a figure which shows an example of the file format of the library information in the input screen which inputs the tool characteristic input method in the Example of this invention, or a workpiece characteristic input method. It is a front view of the screen which inputs the tool specification in the Example of this invention. It is a figure which shows an example of the file format of the library information of the tool specification in the Example of this invention.
  • FIG. 19 is a screen showing an example of a table displayed when “Acquire from table” is selected as the work material property input method on the input screen for inputting the tool property input method or the work material property input method shown in FIG. 18. .
  • FIG. 2 shows a configuration of a cutting apparatus 500 according to the present embodiment.
  • a three-axis control machining apparatus will be described as an example, but the number of control axes and the apparatus configuration are not limited thereto.
  • the cutting device 500 holds and moves a housing 501, a machining tool 504, a spindle 503 that rotates the machining tool 504, a spindle stage 502 that moves the spindle 503, a work material 505, and a work material 505.
  • a cutting condition calculation device 510 that obtains information such as material characteristics and a machining path of a work material to plan cutting conditions, and performs machining abnormality determination based on information on the cutting force measured by the cutting force measuring device 509.
  • an input unit 512 for inputting data such as an abnormality determination threshold value.
  • the machining apparatus 500 processes the shape of the work material 505 by rotating the work tool 504, cutting it into the work material 505, and removing it.
  • the machining tool 504 vibrates the machining tool 504, the housing 501 and the like due to the force received from the work material 505. When the amplitude of this vibration increases, the surface roughness of the work surface of the work material 505 decreases, Problems such as breakage of the tool 504 occur.
  • a signal from the force sensor 508 built in the table 506 is processed by the cutting force measuring device 509 to obtain a cutting force, and the machining tool 504 and the casing are obtained using the obtained cutting force.
  • the cutting condition calculation apparatus 510 calculates the cutting conditions that detect vibrations such as 501 and suppress the vibrations.
  • the output signal of the force sensor 508 built in the table 506 is used.
  • the force sensor is built in the spindle 503, and the output signal of the built-in force sensor, or the acceleration sensor is installed in the table 506 or the spindle stage 502.
  • the output signal of this acceleration sensor or the like can also be used.
  • FIG. 3 is a functional block diagram showing the internal configuration of the cutting force measuring device 509, the cutting condition calculating device 510, the controller 507, the storage unit 511, and the input unit 512 of the cutting device 500 as functional blocks.
  • the cutting condition calculation device 510 includes an abnormality determination unit 140 and a condition calculation unit 150.
  • the storage unit 511 includes a machining condition history storage unit 181 that stores a history of machining conditions, a chatter determination history storage unit 182 that stores a history of chatter determination results, and material characteristics and dynamic characteristics of the machining tool 504 and the work material 505. , A tool / work material characteristic storage unit 184 that stores a shape, a machining path storage unit 183 that indicates a path for moving the processing tool 504 during processing, and a threshold value that is used to determine a processing abnormality determination threshold. A value storage unit 185 and a signal separation condition setting storage unit 186 that separates signals detected by the force sensor 508 are configured.
  • the machining condition history storage unit 181 and the machining abnormality determination history storage unit 182 are stored in association with each other so that it can be understood which machining condition has occurred when a machining abnormality has occurred.
  • the controller 507 chucks and moves the machining apparatus control unit 101 that controls the operation of the entire cutting apparatus 500, the spindle control unit 102 that controls the operation of the spindle 503 that rotates the machining tool 504, and the work material 505.
  • the table control unit 103 controls the operation of the table 506, and a general technique of a cutting apparatus can be used.
  • the cutting force measuring device 509 receives a signal output from the force sensor 508 and measures a cutting force, and a signal separating unit 132 that separates the measured cutting force into a cutting component force and a tool vibration component force. It has.
  • the cutting force measuring device 509 will be described with a configuration in which an output signal from the force sensor 508 is input and processed, but the force sensor 508 may be replaced with a sensor that measures vibration, such as an acceleration sensor, a displacement sensor, or a magnetostrictive sensor.
  • the signal separation unit 132 separates the low frequency component and the high frequency component by calculating a moving average value by focusing on the difference in frequency between the cutting component force and the tool vibration component force after frequency conversion.
  • the separation method is changed by switching circuits according to the separation method calculated by the signal separation condition calculation unit 153, and the threshold value used in the separation also uses the value calculated by the signal separation condition calculation unit 183.
  • the abnormality determination unit 140 of the cutting condition calculation device 510 includes a determination index value calculation unit 141 that calculates a determination index value from the cutting component force and the tool vibration component force separated by the signal separation unit 132, and a threshold value for the calculated chatter index value. It is provided with a machining abnormality determination unit 142 that determines the presence or absence of chatter vibration by comparing with a value and determines machining abnormality such as tool wear by comparing the maximum value of cutting component force with another threshold value. .
  • the machining abnormality determination unit 142 is an electronic circuit that implements a method of determining the presence or absence of chatter vibration by comparing the calculated chatter index value and the threshold value stored in the threshold value storage unit 185. The determination result is stored in the machining abnormality determination history storage unit 182.
  • the condition calculation unit 150 includes a machining condition calculation unit 151 that calculates a machining condition, a threshold value calculation unit 152 that calculates a threshold value used in processing abnormality determination, and a signal separation condition calculation unit 153 that calculates a signal separation condition. It is configured with.
  • the machining condition calculation unit 151 acquires the machining conditions set in the past from the machining condition history storage unit 181, acquires the machining abnormality determination result determined in the past from the machining abnormality determination history storage unit 182, and further acquires the tool / cover.
  • Information such as material characteristics, dynamic characteristics, and shapes of the processing tool 504 and the work material 505 is acquired from the cutting material characteristic storage unit 184, processing path information is acquired from the processing path storage unit 183, and the processing conditions to be changed are calculated. Is an electronic circuit.
  • the calculated machining conditions are stored in the machining condition history storage unit 181.
  • the threshold calculation unit 152 obtains information such as material characteristics, dynamic characteristics, and shapes of the machining tool 504 and the work material 505 from the tool / work material characteristic storage unit 184, and a threshold setting condition storage unit.
  • the electronic circuit obtains a threshold setting method and the like from 187 and calculates a processing abnormality determination threshold.
  • the threshold value calculated by the threshold value calculation unit 152 is stored in the threshold value storage unit 185.
  • the signal separation condition calculation unit 153 obtains machining conditions from the machining condition history storage unit 181, obtains machining path information from the machining path storage unit 183, and further obtains a machining tool 504 from the tool / work material property storage unit 184.
  • an electronic circuit that obtains information such as material characteristics, dynamic characteristics, and shape of the work material 505 and calculates signal separation conditions.
  • the condition calculation unit 150 can also be implemented by an electronic circuit independent of the cutting apparatus 500 or a program in a computer.
  • the input unit 512 includes a machining condition input unit 191, a tool / work material characteristic input unit 192, a machining path input unit 193, and a determination condition input unit 194.
  • the machining condition input unit 191 is an input device that inputs machining conditions such as the spindle rotation speed and stores the machining conditions in the machining condition history storage unit 181.
  • the tool / work material characteristic storage unit 184 is an input device that inputs information such as material characteristics, dynamic characteristics, and shapes of the machining tool 504 and the work material 505 and stores the information in the tool / work material characteristic storage unit 184.
  • the machining path input unit 193 is an input device that inputs a machining path and a machining order and stores them in the machining path storage unit 183.
  • the determination condition input unit 194 is an input device that inputs a method for calculating a signal separation condition and an abnormality detection threshold value and stores them in the signal separation condition setting storage unit 186 and the threshold setting condition storage unit 187.
  • the input unit 512 can also be implemented by an electronic circuit independent of the cutting apparatus 500 or a program in a computer.
  • FIG. 1 shows a processing flow in this embodiment.
  • the machining condition calculation unit 151 of the machining condition calculation device 510 performs machining initial condition derivation (S1), and performs machining initial condition storage (S2) for storing the derived machining initial condition in the machining condition history storage unit 181.
  • the machining condition calculation unit 151 of the cutting condition calculation device 510 uses the tool / work material characteristic storage unit 184 of the storage unit 511 to determine the material characteristics, dimensions, and motions of the machining tool 504 and the work material 505.
  • Information such as characteristics and machining dimensions is acquired and the machining path and cutting conditions are derived from the result of simulation or from a table stored in advance in the machining path storage unit 183.
  • the machining path is a path for moving the machining tool 504 when the machining tool 504 cuts the work material 505, and is determined along with the diameter cutting amount, the shaft cutting amount, the feed speed, and the like.
  • the machining condition setting (S3) information on the machining path and the cutting condition derived by the machining condition calculation unit 151 of the cutting condition calculation device 510 is transmitted to the processing machine control unit 101 of the controller 507, and the processing machine control unit 101
  • the machining is started by controlling with the spindle control unit 102 and the table control unit 103 (S4).
  • the cutting force measurement (S5) is performed by the force sensor 508 during processing, and the cutting force signal output from the force sensor 508 is input to the cutting force measuring unit 131 of the cutting force measuring device 509 and processed.
  • Signal separation (S6) is performed in which the signal processed by the measurement unit 131 is received by the signal separation unit 132 and separated into a cutting component force signal and a tool vibration component force signal.
  • the cutting component force signal and the tool vibration component force signal separated by the signal separation unit 132 of the cutting force measurement device 509 are input to the determination index calculation unit 141 of the abnormality determination unit 140 of the cutting condition calculation device 510, and this input is performed.
  • Determination index calculation (S7) for calculating a determination index using the cutting component force signal and the tool vibration component force signal is performed.
  • information on the determination index calculated by the determination index calculation unit 141 is input to the processing abnormality determination unit 142, and the determination stored in the threshold storage unit 185 of the storage unit 511 in the processing abnormality determination unit 142 in advance.
  • the processing machine control unit 101 of the controller 507 performs a processing end determination (S10) for determining whether or not the predetermined cutting has been completed. If it is determined that the processing has been completed, the processing is ended (S11).
  • the processing condition calculation unit 151 of the cutting condition calculation device 510 determines the processing abnormality in the chatter determination storage (S9).
  • the machining condition calculation (S12) for calculating the next machining condition is performed from the chatter determination result stored in the history storage unit 182 and the machining condition stored in the machining condition history storage unit 181 in the machining initial condition storage (S2).
  • the machining condition storage (S13) for storing the calculated condition in the machining condition history storage unit 181 is performed.
  • the controller 507 performs a machining condition change (S14) for setting the control amounts of the spindle control unit 102 and the table control unit 103 based on the machining conditions calculated by the machining condition calculation unit 151. Thereafter, the cutting force measurement (S5) to the machining condition change (S14) are repeatedly performed, and the process is repeated until it is determined that the machining is finished.
  • S14 a machining condition change
  • FIG. 4 is a view of a state in which the work material 505 is being processed by the processing tool 504 as viewed from above the cutting apparatus 500.
  • the processing tool 504 has a structure in which a plurality of chips 516 each having a cutting edge formed on a rotating shaft 515 are attached.
  • a processing method is shown in which the processing tool 504 is rotated and the chips 516 are cut into the work material 505 to scrape the work material 505.
  • the number of the chips 516 attached to the processing tool 504 is illustrated. The number is not limited to two, and may be three or more. Further, it is possible to use a processing method in which the processing tool 504 is fixed and the work material 505 is rotated.
  • Ft is a force applied from the work material 505 to the chip 516 when the work material 505 is cut with the chip 516 by feeding the work tool 504 in the direction of the tool while rotating in the direction of the arrow.
  • the cutting component force that is a force component in the tangential direction of the machining tool 504 is represented.
  • Fr represents a tool vibration component that is a force component in the radial direction of the machining tool 504 of the force applied from the work material 505 to the tip 516.
  • FIG. 5A shows an output signal from the force sensor 508.
  • the force applied to the force sensor 508 is the resultant force of the cutting component force (Ft), which is the force for the chip 516 to scrape the workpiece 505, and the tool vibration component force (Fr) resulting from the tool vibration.
  • the output signal includes a cutting component force signal and a tool vibration component force signal.
  • FIG. 5B shows a diagram obtained by frequency-converting the output signal from the force sensor 508.
  • the cutting component force frequency is easily estimated from the tool rotation speed, and generally, the tool vibration component frequency is 10 times or more of the cutting component force frequency, so that the cutting component and the tool vibration component are easily separated from FIG. 5B. be able to.
  • FIGS. 6A and 6B The separated results are shown in FIGS. 6A and 6B.
  • 6A shows the frequency of the cutting component force
  • FIG. 6B shows the frequency of the tool vibration component force.
  • FIGS. 6C and 6D The results of inverse frequency conversion of these signals are shown in FIGS. 6C and 6D.
  • the output signal from the force sensor 508 shown in FIG. 5A is separated into a cutting component (FIG. 6C) and a tool vibration component (FIG. 6D). Become.
  • the moving average line 520 of the output signal from the force sensor 508 shown in FIG. 5A is calculated.
  • the moving average width is set to be not less than the tool vibration period (T1) and less than the cutting period (T2).
  • the moving average line 520 is a low frequency component and indicates a cutting component force having a low frequency.
  • a process of calculating a difference between the original signal (output signal component from the force sensor 508) and the calculated moving average line 520 is performed.
  • This value (a signal component obtained by subtracting the component of the moving average line 520 from the output signal component from the force sensor 508) is a high-frequency component and indicates a tool vibration component force having a high frequency. Also by this method, it is possible to separate the signal from the force sensor 508 into the cutting component force and the tool vibration component force.
  • a cutting component force profile is obtained by using a simulation or the like from the material characteristics, dynamic characteristics, and shape information of the machining tool 504 and the work material 505 stored in the tool / work material characteristic storage unit 184, pattern matching, etc.
  • the signal separation can also be performed by adjusting the waveform of the low frequency component to the cutting force signal by calculating the difference from the cutting force signal and obtaining the high frequency component.
  • the tool When obtaining the tool vibration component force, especially when starting to cut into the work material and at the end of cutting, the tool may vibrate and may be erroneously determined as chatter vibration.
  • a waveform example at that time is shown in FIG. 26A. Since the beginning and end of cutting are in an unsteady state, it is considered that tool vibration is induced. However, since it is not in a chatter vibration state, the tool vibration is quickly attenuated, and the vibration converges before the next blade cuts.
  • the result of frequency conversion of the waveform of FIG. 26A is shown in FIG. 26B.
  • Another frequency 1303 is generated at a position h [Hz] away from the frequency 1302 of the peak value Va of the tool vibration component force.
  • the signal separation unit 132 changes the tool vibration magnitude Fc to zero.
  • the frequency of the cutting component force and the frequency of the tool vibration component are separated, but the range of each frequency can be acquired from the signal separation condition calculation unit 153.
  • the example of separation into the frequency of the cutting component force and the frequency of the tool vibration component force has been described.
  • the vibration of the work material may be larger than the tool vibration, and the frequency of the work material vibration may be used instead of the frequency of the tool vibration component.
  • the magnitude of the tool vibration component force varies depending on the machining conditions. For example, even if the amplitude of the tool vibration is the same, the area of contact between the tip 516 and the work material 505 is doubled when the amount of axial cut is doubled, so the tool vibration component force applied to the processing tool 504 is also doubled. It becomes. Therefore, when determining the presence or absence of chatter vibration from the magnitude of the tool vibration component force, a certain threshold value cannot be used.
  • chatter index value Fv / Fc (Expression 1)
  • Fc is the magnitude of the cutting component force (corresponding to Fc in FIG. 6C)
  • Fv is the amplitude of the tool vibration component force (corresponding to Fv in FIG. 6D).
  • FIG. 8 shows a simulation result of the relationship between the tool vibration amplitude and the chatter index value.
  • ⁇ indicates the relationship of the chatter index value to the tool vibration amplitude when machining is performed under the condition that the shaft depth is 0.4 mm and the rotational speed of the machining tool 504 is 3120 rpm.
  • FIG. 78 there is a linear relationship between the tool vibration amplitude and the chatter index value, and the data are arranged on the same straight line even if the machining conditions change. Since the tool vibration amplitude and the chatter index value have a unique relationship, the same threshold value can be used regardless of the machining conditions.
  • the threshold value of the chatter index value can be obtained from the allowable tool vibration amplitude.
  • the machining condition calculation unit 151 determines the machining condition by specifying the allowable tool vibration amplitude in the derivation of the machining initial condition in S1.
  • the shaft cut amount is set based on the relationship of the chatter index value with respect to the tool vibration amplitude as shown in FIG. 8 stored in the history storage unit 181.
  • the processing abnormality determination unit 142 compares the chatter index value calculated by the determination index calculation unit 141 with the determination index calculation (S7) and the threshold value preset in the threshold storage unit 185. Based on this, the presence or absence of chatter vibration is determined. Further, the presence / absence of machining abnormality such as tool wear is determined by comparing the maximum value of the cutting component force signal with a preset machining abnormality determination threshold value.
  • the cutting apparatus 500 can dynamically control the machining conditions by multiplying the initially set machining conditions by an override rate.
  • parameters for multiplying the override rate there are generally a spindle rotation speed and a tool feed speed, and the override rate can be changed in a range of 0 to 200%.
  • a method of changing the machining condition by changing the override amount will be described as an example, but a method of directly changing the machining condition may be used.
  • the chatter determination threshold value is set to c1.
  • the machining abnormality determination unit 142 determines that chatter has occurred in the machining abnormality determination (S8), and the machining condition calculation unit 151 calculates the override change amount in the machining condition calculation (S12) process.
  • the machining condition change (S14) step the machining tool control unit 101 of the controller 507 controls the spindle control unit 102 and the table control unit 103 on the basis of the override rate calculated by the machining condition calculation unit 151.
  • the override ratio is changed by driving 504 and the table 506.
  • the machining condition calculation unit 151 obtains the override rate from FIG. 9A or FIG. 9B, and calculates the new override rate by multiplying the current override rate. Further, the machining condition is calculated by multiplying the calculated new override rate by the initial setting value of the machining condition.
  • chatter index value calculated by the determination index calculation unit 141 greatly exceeds the chatter determination threshold value c1, the override rate is increased. When the excess index value is small, the override rate is decreased to quickly chatter vibration. Can be converged. Further, when the chatter index value is smaller than the threshold value c2, a positive override rate is set, and control is performed to further increase the machining efficiency. At this time, chattering of the control can be prevented by setting the range between the chatter index values c1 and c2 to 0% override rate. A positive override rate is set such that a large change rate is set when the chatter index value is significantly below c2, and a small change rate is set when close to c2.
  • FIG. 9A shows an example in which the override rate is changed stepwise, but a straight line or a curved line can also be used as shown in FIG. 9B.
  • the rate of change is small where the chatter index value is close to c1 or c2, and there is an effect that chattering of control can be further prevented.
  • FIG. 10 shows a stability limit diagram regarding the relationship between the amount of shaft cutting and the tool rotation speed under general cutting conditions.
  • the condition below the stability limit line 530 is a stable condition in which chatter vibration does not occur, and the condition above the stability limit line 530 indicates that chatter vibration is generated and unstable machining is performed.
  • n is an integer of 1 or more.
  • a method of increasing the amount of removal per unit time by increasing the amount of shaft cut is effective.
  • the machining conditions can be derived by calculating FIG. 10 using simulation or the like.
  • the stability limit line 530 includes an error due to an error such as a material characteristic or a shape dimension of the processing tool 504 or the work material 505
  • the derived condition is not always optimal. Therefore, the machining conditions are guided to the peak position of the stability limit line 530 using the method described in FIGS. 9A and 9B.
  • the step width ST of the override rate in FIG. 9A is preferably set to be about a fraction (for example, 1/5 or less) of the peak position interval PW shown in the graph of FIG.
  • FIG. 11 is a diagram showing the change over time of the override rate when the override change rate is determined using FIG. 9A. Machining is started under the initial machining conditions, and from time 0 to T3, it is determined that chatter vibration has not occurred, so the override rate becomes positive and the override rate increases. When the override rate increases, chatter vibration is likely to occur. When the chatter index value exceeds the determination threshold (c1 in FIG. 9A or 9B), it is determined that chatter vibration has occurred. The override rate v3 at this time is stored.
  • the processing condition calculation unit 151 changes the processing condition so as to reduce the override rate. If the machining abnormality determination unit 142 determines that chatter vibration has not recurred after a predetermined time has elapsed, the machining condition calculation unit 151 changes the machining condition to increase the override rate, but chatter vibration occurs.
  • the upper limit is a value smaller than the override rate v3 stored in the machining condition history storage unit 181 (for example, 90% of p3). Thus, stable machining can be realized by avoiding the use of the condition that once generated chatter vibration.
  • FIG. 12A shows an algorithm for realizing the control of FIG. 9A.
  • the initial value of the override rate (OV) and override change rate ( ⁇ OV) is set to 100, and the maximum value that can be taken by the override rate is set to the upper limit value (OV_c) of the override rate (S1101).
  • a chatter index value is calculated (S1102).
  • the chatter index value calculated by the determination index calculation unit 141 is compared with the threshold c1 in the machining abnormality determination unit 142 (S1103), and when the chatter index value is equal to or greater than the threshold c1 (Yes in (S1103)).
  • the machining condition calculation unit 151 determines a value in a flow that branches the step-like override change rate setting condition shown in FIG. 9A according to the size of the chatter index value.
  • the machining condition calculation unit 151 determines whether or not the chatter index value stored in the machining abnormality determination history storage unit 182 is smaller than c5 (S1104). If it is smaller (Yes), the override change rate ( ⁇ OV) is set to p4. Setting is performed (S1105). If the chatter index value is larger than c5 (No in (S1104)), it is determined whether the chatter index value is smaller than c6 (S1106), and if it is smaller (Yes), the override change rate ( ⁇ OV) is set to p3. It sets (S1107).
  • chatter index value When the chatter index value is larger than c6 (in the case of No in (S1106)), it is determined whether the chatter index value is smaller than c7 (S1108), and when it is smaller (Yes), the override change rate ( ⁇ OV) is set to p2. Set (S1109). If the chatter index value is larger than c7 (No in (S1108)), the chatter index value is set to c1 (S1110).
  • the machining condition calculation unit 151 substitutes the current override rate for the override upper limit value to obtain a new upper limit value (S1111). Further, the current time (t) is stored in Tc (S1112). Next, a new override amount is calculated by multiplying the current override rate (OV) by the override change rate ( ⁇ OV) (S1113) and stored (S1114). The stored override rate is used to calculate new machining conditions.
  • the chatter index value is less than c1 (in the case of No in (S1103))
  • the override rate is set to 100 (S1122). If smaller than c2 (No in (S1121)), it is determined that chatter has not occurred, and it is determined whether the difference between the current time (t) and the stored Tc is equal to or greater than T1 (S1123). This is to determine the elapsed time from the time when chatter last occurred. When the elapsed time (t ⁇ Tc) is shorter than T1 (in the case of No in (S1123)), the override change rate is set. 100 (S1122).
  • the machining condition calculation unit 151 determines whether the chatter index value stored in the machining abnormality determination history storage unit 182 is larger than c3 (S1124), and if it is larger (Yes in (S1124)), the override change rate ( ⁇ OV) is set to p5 (S1125).
  • the chatter index value is smaller than c3 (No in (S1124)
  • the rate of change ( ⁇ OV) is set to p6 (S1127).
  • the override change rate ( ⁇ OV) is set to p7 (S1128).
  • a new override rate is calculated by multiplying the current override rate (OV) and the override change rate ( ⁇ OV) (S1113) and stored in the machining condition history storage unit 181 (S1114).
  • the override rate stored in the machining condition history storage unit 181 is used by the machining condition calculation unit 151 to calculate a new machining condition. The above flow is repeatedly executed until the machining of the work material 505 is completed.
  • FIG. 12B shows an algorithm for realizing the control of FIG. 9B.
  • requires an override change rate differs from the flow demonstrated in FIG. 12A that the function of a chatter parameter
  • the initial values of the override rate (OV) and override change rate ( ⁇ OV) are set to 100, and the maximum value that can be taken by the override rate is set to the upper limit value (OV_c) of the override rate (S1151).
  • a chatter index value is calculated (S1152).
  • the machining abnormality determination unit 142 determines whether the calculated chatter index value is c1 or more (S1153), and the determination result is stored in the machining abnormality determination history storage unit 182 together with the chatter index value.
  • chatter index value is greater than or equal to c1 (in the case of Yes in (S1153))
  • the machining condition calculation unit 51 sets the function f of the chatter index as an override change rate ( ⁇ OV) (S1154)
  • the current override rate (OV) is set as the upper limit value (OV_c) of the override rate (S1155), and the current time (t) is stored in Tc (S1156).
  • a new override amount is calculated by multiplying the current override rate (OV) by the override change rate ( ⁇ OV) (S1157) and stored (S1158).
  • the stored override rate is used to calculate new machining conditions.
  • the machining condition calculation unit 51 sets the override change rate ( ⁇ OV) to 100 (S1162). If the chatter index value is less than c2 (No in (S1161)), it is determined whether the difference between the current time (t) and the stored Tc is equal to or greater than T1 (S1163). This is to determine the elapsed time from the time when chatter last occurred. When the elapsed time (t-Tc) is shorter than T1 (in the case of No in (S1163)), the override change rate ( ( ⁇ OV) is set to 100 (S1162).
  • the input unit 512 includes a machining condition input unit 191, a machining path input unit 193, a tool / workpiece material characteristic input unit 192, and a determination condition input unit 194.
  • FIG. 13 is a schematic diagram showing an example of an input screen 1001 for inputting a machining condition setting method.
  • FIG. 14 is a diagram illustrating an embodiment of the file format of the library information of items displayed on the input screen 1001 illustrated in FIG. 13, and is data stored in the storage unit 511.
  • the library information corresponding to the input screen 1001 includes, for example, a library number 1005 and library items 1006 such as a spindle rotation speed input method.
  • Display items 1002 are displayed on the input screen 1001 in FIG. 13 based on the library information in FIG. 14, and a condition to be used for each item is selected by pressing a radio button 1003. After selecting all items, pressing the enter button 1004 terminates the input and stores the selected items in the machining condition history storage unit 181.
  • the value input in the input field 1010 is used as the spindle rotation speed, and the signal separation unit 132 is used. Extract the cutting force component with.
  • the spindle rotation speed acquired from the spindle control unit 102 of the controller 507 is used.
  • the spindle rotation speed of the program stored in the machining apparatus 500 or the controller 507 is acquired.
  • the machining program is composed of several steps, and it is desirable to acquire information on the spindle rotation speed for each step.
  • FIG. 15 is a schematic diagram showing an example of an input screen 1101 for inputting a machining path setting method.
  • FIG. 16 is a diagram showing an embodiment of a file format of library information of items displayed on the input screen 1101 shown in FIG.
  • the file information shown in FIG. 17A is acquired from the specified file.
  • the file information includes, for example, a library number 1107, a library first item 1108, and a library second item 1109.
  • FIG. 18 is a schematic diagram showing an example of an input screen 1201 for selecting a tool / work material characteristic input method.
  • FIG. 19 is a diagram showing an embodiment of a file format of the library information of items displayed on the input screen 1201 shown in FIG.
  • the library information corresponding to the input screen 1201 is acquired from, for example, a library number 1205, a library first item 1206 for specifying an input target such as a tool property input method and a workpiece property input method, a natural frequency input, and a table.
  • a library second item 1207 for designating a data input method such as the above is included.
  • Display items 1202 are displayed on the input screen 1201 in FIG. 18 based on the library information in FIG. 19, and a condition to be used for each item is selected by pressing a radio button 1003. After selecting all the items, pressing the enter button 1004 terminates the input, and the selected items are stored in the tool / work material characteristic storage unit 184.
  • FIG. 20 is a schematic diagram showing an example of the tool specification input screen 1021.
  • FIG. 21 is a diagram showing an embodiment of a file format of the library information of items displayed on the input screen 1021 shown in FIG.
  • the library information includes, for example, a library number 1025 and a library item 1026 for designating an input target of tool specifications such as a tool length and a tool diameter.
  • FIG. 22 is a schematic diagram showing an example of the work material specification input screen 1031.
  • FIG. 23 is a diagram illustrating an embodiment of a file format of the library information of items displayed on the input screen 1031 illustrated in FIG. When transitioning to the input screen 1031, information is input from the file describing the library information in FIG. 22 and displayed.
  • the library information includes, for example, a library number 1035 and a library item 1036 for designating an input target of work material specifications such as a work material shape model and work material composition.
  • FIG. 24 shows information described in the table.
  • the library number 1045, the library first item 1046 for designating the machining path, and the library second item 1047 for designating the natural frequency of the work material in each machining path are shown. included.
  • the table information is stored in a file and is read when “Get from table” is selected.
  • FIG. 25 is a schematic diagram illustrating an example of a determination condition input screen 1211.
  • the signal separation usage data column one of the selection items for determining whether to use the tool characteristics, the work material characteristics, or the tool characteristics and the work material characteristics as data used for the signal separation is selected.
  • the column of the abnormality detection threshold setting method one is selected from the selection items of inputting a fixed value or calculating by simulation.
  • the attenuation determination column there is a check box 1053 for selecting whether to execute or not, and it becomes effective when checked.
  • the threshold value used for attenuation determination is the value input in the input box 1054.
  • the decision button 1004 By pressing the decision button 1004 after selecting each item, the items set in “signal separation usage data” and “attenuation determination” are stored in the signal separation condition setting storage unit 186, and “anomaly detection threshold setting method” ”Is stored in the threshold setting condition storage unit 187.
  • the frequency of the cutting component force may be a tool rotation speed stored in the machining condition history storage unit 181 or a value obtained by multiplying the tool rotation speed acquired from the controller 507 by the number of blades.
  • a method for calculating the frequency of the tool vibration a method stored in the signal separation condition setting storage unit 186 is used. For example, when “input of natural frequency” is selected, the input value is used as the frequency of the cutting component force.
  • a frequency calculated by a mathematical expression or simulation from the tool length, the tool diameter, and the tool rigidity can be used.
  • the method stored in the signal separation condition setting storage unit 186 is used as a method for calculating the frequency of the workpiece vibration. For example, when “input of natural frequency” is selected, the input value is used as the frequency of the cutting component force. In addition, when “calculate from work material specifications” is selected, a frequency calculated by a mathematical formula or simulation from the shape model, the work material rigidity, the fixed jig model, and the jig rigidity can be used.
  • the frequency stored in the signal separation condition setting storage unit 186 is used to determine whether the tool vibration frequency or the workpiece vibration frequency is used. At this time, when the option of using a plurality of frequencies is selected (for example, tool vibration and workpiece vibration), after calculating the respective frequencies and amplitudes, the larger amplitude may be selected.
  • chatter vibration occurrence can be determined with a constant threshold value regardless of the machining conditions, so that the threshold value can be set appropriately and abnormality detection accuracy is improved.
  • stable machining can be performed under conditions immediately before chatter vibration occurs, and highly efficient machining can be realized.

Abstract

L'objet de la présente invention est de permettre l'utilisation d'une valeur seuil de détection de défaillance constante même dans des trajets de traitement dans lesquels la profondeur de coupe change d'un moment à l'autre. L'invention est conçue de sorte que la pièce soit coupée à l'aide d'une machine-outil par : l'établissement de conditions de traitement ; la coupe de la pièce à l'aide d'un outil de coupe sur la base des conditions de traitement établies ; la détection de la vibration ou de la force de coupe de l'outil de coupe pendant la coupe de la pièce ; le traitement et la séparation d'un signal détecté en un signal d'élément de coupe et un signal d'élément de vibration d'outil ; le calcul d'une valeur d'indice d'évaluation pour l'évaluation des conditions pendant le traitement au moyen des informations distinctes provenant du signal d'élément de coupe et du signal d'élément de vibration d'outil ; la comparaison de la valeur d'indice d'évaluation calculée à une valeur seuil d'évaluation précédemment établie ; le calcul de nouvelles conditions de traitement présentant une quantité de priorité pour les conditions de traitement établies selon l'importance de la valeur d'indice d'évaluation par rapport à la valeur seuil d'évaluation ; et la modification des conditions de traitement établies en nouvelles conditions de traitement calculées.
PCT/JP2012/078011 2011-12-16 2012-10-30 Dispositif de coupe et procédé de traitement utilisant celui-ci WO2013088849A1 (fr)

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CN110549165A (zh) * 2018-06-01 2019-12-10 乔治费歇尔加工方案公司 用于确定机床的结构特性的系统和方法
JP2020069596A (ja) * 2018-10-31 2020-05-07 株式会社三井ハイテック 加工装置及び加工方法
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WO2014115395A1 (fr) * 2013-01-23 2014-07-31 株式会社日立製作所 Procédé de suppression des vibrations de coupe, dispositif de commande de calcul, et machine-outil
EP2871547A1 (fr) * 2013-11-07 2015-05-13 The Boeing Company Adaptation de chemin d'outil de commande numérique en temps réel au moyen de rétroaction de force
JP5955479B1 (ja) * 2015-05-11 2016-07-20 三菱電機株式会社 表示装置
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TWI626111B (zh) * 2016-11-10 2018-06-11 國立中正大學 切削加工轉速調整裝置及其方法
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JP2019168315A (ja) * 2018-03-23 2019-10-03 三菱電機株式会社 測定装置、回路基板、表示装置、および測定方法
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JP2020069596A (ja) * 2018-10-31 2020-05-07 株式会社三井ハイテック 加工装置及び加工方法
JP7148361B2 (ja) 2018-10-31 2022-10-05 株式会社三井ハイテック 加工装置及び加工方法
CN111266925A (zh) * 2018-12-04 2020-06-12 双叶电子工业株式会社 一种测算装置、测算方法及存储介质
CN111266925B (zh) * 2018-12-04 2022-12-27 双叶电子工业株式会社 一种测算装置、测算方法及存储介质
JP7456219B2 (ja) 2020-03-19 2024-03-27 株式会社ジェイテクト 歯車加工装置及び歯車加工方法

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