WO2020107613A1 - 一种轧辊激光毛化加工设备及其加工方法 - Google Patents

一种轧辊激光毛化加工设备及其加工方法 Download PDF

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Publication number
WO2020107613A1
WO2020107613A1 PCT/CN2018/124564 CN2018124564W WO2020107613A1 WO 2020107613 A1 WO2020107613 A1 WO 2020107613A1 CN 2018124564 W CN2018124564 W CN 2018124564W WO 2020107613 A1 WO2020107613 A1 WO 2020107613A1
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Prior art keywords
laser
point
processing
center
distribution
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English (en)
French (fr)
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符永宏
陈天阳
纪敬虎
汤发全
张航成
符昊
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Jiangsu University
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Jiangsu University
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Priority to US16/627,423 priority patent/US20210331276A1/en
Publication of WO2020107613A1 publication Critical patent/WO2020107613A1/zh
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/352—Working by laser beam, e.g. welding, cutting or boring for surface treatment
    • B23K26/355—Texturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/0006—Working by laser beam, e.g. welding, cutting or boring taking account of the properties of the material involved
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/0093—Working by laser beam, e.g. welding, cutting or boring combined with mechanical machining or metal-working covered by other subclasses than B23K
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
    • B23K26/06—Shaping the laser beam, e.g. by masks or multi-focusing
    • B23K26/0604—Shaping the laser beam, e.g. by masks or multi-focusing by a combination of beams
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
    • B23K26/06—Shaping the laser beam, e.g. by masks or multi-focusing
    • B23K26/062—Shaping the laser beam, e.g. by masks or multi-focusing by direct control of the laser beam
    • B23K26/0622—Shaping the laser beam, e.g. by masks or multi-focusing by direct control of the laser beam by shaping pulses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/08—Devices involving relative movement between laser beam and workpiece
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/08—Devices involving relative movement between laser beam and workpiece
    • B23K26/0823—Devices involving rotation of the workpiece
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/352—Working by laser beam, e.g. welding, cutting or boring for surface treatment
    • B23K26/354—Working by laser beam, e.g. welding, cutting or boring for surface treatment by melting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/352—Working by laser beam, e.g. welding, cutting or boring for surface treatment
    • B23K26/3568—Modifying rugosity
    • B23K26/3584—Increasing rugosity, i.e. roughening
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K37/00—Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass
    • B23K37/02—Carriages for supporting the welding or cutting element
    • B23K37/0211—Carriages for supporting the welding or cutting element travelling on a guide member, e.g. rail, track
    • B23K37/0229—Carriages for supporting the welding or cutting element travelling on a guide member, e.g. rail, track the guide member being situated alongside the workpiece
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K37/00—Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass
    • B23K37/04—Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass for holding or positioning work
    • B23K37/053—Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass for holding or positioning work aligning cylindrical work; Clamping devices therefor
    • B23K37/0538—Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass for holding or positioning work aligning cylindrical work; Clamping devices therefor for rotating tubes, e.g. rollers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2101/00—Articles made by soldering, welding or cutting
    • B23K2101/04—Tubular or hollow articles
    • B23K2101/06—Tubes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2101/00—Articles made by soldering, welding or cutting
    • B23K2101/20—Tools
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/70—Auxiliary operations or equipment
    • B23K26/702—Auxiliary equipment

Definitions

  • the invention relates to laser texturing processing technology in the field of surface treatment, in particular to a laser texturing processing device for rollers and a processing method thereof.
  • Certain morphological parameters of the surface of the cold-rolled sheet have an important influence on the stamping properties and surface coating performance of the steel sheet, and the surface morphology of the cold-rolled sheet depends to a large extent on the work rolls and finishing of the rolling mill during the cold rolling production process.
  • the surface morphology of the work roll of the unit In essence, the surface morphology of the cold-rolled sheet is an attenuating "copy" of the surface morphology of the roll.
  • the method of roughening the surface of the roll is generally adopted.
  • the main methods used for roller texturing are shot peening, electric spark texturing, and laser texturing.
  • Shot peening is based on the impact of hard particles on the surface of the roll to form a concave texture.
  • the obvious defects of this technology are: 1) The formed texture is single, and the microscopic size of the texture is difficult to adjust, and it cannot adapt to different types of steel plates Rolling requirements; 2) The processing environment is harsh, and it is difficult to integrate into the cold rolled plate production line.
  • EDM is to produce a pulsed spark discharge between the electrode and the surface of the roller in the insulating liquid. The instantaneous high temperature generated by the partial discharge etches the surface of the roller to form the texture of the texture. The arrangement of the shape is random.
  • the defects are: 1) The roughening morphology formed by the thermal effect ablation of the roll surface, with four layers of recast layer, re-quenched layer, heat-affected layer and substrate, of which the recast layer roughened on the roll surface is easy to peel off and form Poor appearance retention and short lifespan seriously affect the consistency of the surface quality of the same batch of rolled steel plates; 2) Electrode wear during texturing, although electrode compensation feedback is provided, it is difficult to ensure consistent and controllable microscopic dimensions of the roll surface texture ; 3) Consumable parts such as electrodes in the process of processing, there are continuous costs in the use of equipment; 4) equipment investment costs are relatively large.
  • the Chinese patent discloses a laser texturing method for achieving uniform random distribution of texturing points. Random delay and random deflection of each laser pulse through random signals, processing the sparse texturing distribution on the roll surface, and then passing Multiple laser heads and multiple passes improve efficiency and area occupancy. Although the problem of the ordering of laser texturing is solved, the random delay of laser pulses, random deflection and multi-pass processing methods will cause a large amount of texturing overlap, resulting in poor uniformity of the shape distribution. Directly affect the subsequent coating performance. At the same time, the overlapping areas of the topography are subjected to laser action many times, which is equivalent to tempering the local area of the roll, affecting or even destroying the metallographic structure of the roll surface, greatly reducing the service life of the roll.
  • Chinese patent discloses a roller surface texturing laser processing system and method for irregularly deflecting the texturing point.
  • the pseudo-random deflection device is controlled to the roller-like workpiece every time.
  • the laser light emitted from the surface is randomly deflected to achieve an irregular distribution of texturing points.
  • the problem of uniformity of the distribution still exists, and the appearance will be piled up and overlapped, and the uniformity of the distribution is not good.
  • the Chinese patent discloses a laser texturing device with controllable deflection of the focused light spot.
  • a piezoelectric ceramic deflection system is arranged before the laser focusing, so that the focused light spot swings in two dimensions, thereby processing irregularly distributed texturing points.
  • the patent does not disclose a method for controlling the uniformity of the topography distribution, and the uniformity problem has not been solved.
  • the present invention provides a roll laser texturing processing equipment and processing method.
  • a suitable texture shape and specific output laser parameters are selected.
  • Each laser end output module processes each processing unit synchronously, designing a disorderly and evenly distributed dot matrix scheme that can be connected end to end, detecting the consistency of the instantaneous position signal of the coaxial encoder and the laser light output position signal, when the laser end output module is at a certain position
  • Send out lasers with certain parameters at the same time give different signals to the beam energy adjustment unit of each laser end output module to complete energy attenuation adjustment, and give the same signal to the one-dimensional beam deflection unit of each laser end output module to complete one-dimensional beam deflection
  • the laser focus of each laser end output module can be randomly and evenly distributed dot-matrix scheme according to the design, using different laser energy to process the roughened hard dots in sequence.
  • the present invention achieves the above technical object through the following technical means.
  • Processing area division the surface processing area of the roller is evenly divided into several roller processing units;
  • Determining the output signal According to the disorderly and uniformly distributed hair lattice distribution scheme, machine parameters and laser parameters, the laser light position signal, beam energy adjustment signal and one-dimensional beam deflection unit deflection are obtained through the information processing module signal;
  • roller laser texturing the laser light output position signal is used to control the light source module to emit laser; the beam energy adjustment signal and the one-dimensional beam deflection unit deflection signal are respectively input into the laser end output module to generate a disordered laser dot matrix Each laser end output module is used to process a roll processing unit.
  • processing area is divided into:
  • the roller processing area is evenly divided into m roller processing units, and the length of any roller processing unit is L 1 ,
  • the laser end output module includes a beam folding unit, a beam energy adjustment unit, and a one-dimensional beam deflection unit; the laser light incident by the light source module passes through the beam folding unit, the beam energy adjustment unit, and the one-dimensional beam deflection unit in order to enter the roller Processing unit
  • the beam folding unit is used to split the incident laser light from the light source module into a reflected laser beam perpendicular to the roll axis direction and a transmitted laser beam parallel to the roll axis direction; the reflected laser beam enters the beam energy adjustment unit Inject into the next laser end output module;
  • the beam energy adjustment unit is used to change the energy of the reflected laser
  • the one-dimensional beam deflection unit is used to offset the angle of the reflected laser light.
  • the beam folding unit has different coating properties through the half mirrors, so that the energy ratio of the reflected laser to the transmitted laser is:
  • P m is the reflected laser power split by the beam folding unit in the Line m laser end output module
  • P m- is the transmitted laser power split by the beam return unit in the Line m laser end output module
  • P input is the laser light source power output by the light source module
  • P output is the input laser power of the laser end output module
  • the one-dimensional beam deflection unit deflects the beam one-dimensionally at a fixed angle ⁇ according to the input electrical signal ⁇ , and acts on the area to be processed through the focusing lens, so that the focal point is shifted from the optical axis by a certain distance ⁇ ,
  • ⁇ max f( ⁇ * ⁇ max ,L 2 ,f)
  • the method for designing an end-to-end disordered uniform lattice distribution specifically includes the following steps:
  • a uniform lattice distribution of the roughening point circle set A 0 is established , which is specifically:
  • a 0 is the coordinate position set of the center point of the texture point of the uniform lattice distribution
  • (x 0i , y 0j ) is the coordinate of the center point of the texture point of the uniform lattice distribution of the ith row and jth column
  • i is the row number
  • j is the column number
  • j max is the maximum column number
  • a is the distance between topography distribution points, the distance between two roughened hard points in the x direction
  • b is the topography distribution line distance, the distance between two roughened hard points in the y direction
  • ⁇ X is the set of random displacement vectors for each texturing point in the uniform lattice distribution
  • ( ⁇ x i , ⁇ y j ) is the coordinate of the center of the center of the texturing point in the uniform lattice distribution of row i and column j in the uniform lattice distribution (x 0i , y 0j ) random displacement vector
  • ⁇ a is a column offset constant
  • ⁇ b is a row offset constant
  • A random and uniform distribution of the center point of the texture points
  • (x i , y j ) random and uniform distribution of the center coordinates of the texture points
  • Finding bad points Find the set SP of row sequence and column sequence of disorderly and uniformly distributed bad points according to the tolerance of roughening point overlap, as follows:
  • SP is the set of disorderly uniformly distributed bad point row sequence and column sequence
  • A(i,j) is the coordinate of the ith and jth furry point center coordinates of the disorderly uniformly distributed furry point circle center set
  • (u q , w q ) is the q-th bad point coordinate row sequence and column sequence
  • q is the bad point order number
  • ⁇ is the uniform tolerance of the disordered uniform distribution of the texture point overlap tolerance
  • Axial center line is used as a reference to adjust the left and right of the uniform center of the random point of the center of distribution
  • the center set A of the random and uniformly distributed hairening points is adjusted to the left and right based on the axial center line, so as to overlap the processing areas of multiple laser end output modules:
  • Aex is the random uniform distribution of the center of the roughening point A.
  • the center of the axis is used as the reference to adjust the center of the random uniform distribution of the center of the roughening point;
  • (xex i ,yex j ) is the i , J coordinates of the center of the fur point;
  • SPex is the set of random and uniformly distributed bad point row and column sequences according to the tolerance of the overlap of the softening point for the area near the center line after the left and right swap process
  • (uex qex , wex qex ) is the qex bad point coordinate Row sequence and column sequence
  • qex is the sorting number of dead pixels
  • Aex (i, j) is the coordinate of the i- and j-th texture points in the coordinate center of the disordered and uniformly distributed texture points after the adjustment
  • Aex is the random and uniform distribution of the lattice distribution scheme that can be connected end to end.
  • the adjusting the random displacement vector set ⁇ X according to the disorderly and uniformly distributed bad point set SP is specifically as follows:
  • ⁇ Xre is the adjusted random displacement vector set
  • ( ⁇ xre i , ⁇ yre j ) is the adjusted random displacement vector
  • ⁇ is the adjustment ratio of the random displacement vector of dead pixels
  • the position of the bad point in the area near the center line is adjusted, specifically:
  • Are is the coordinate set of the center of the disordered uniform distribution of the roughening points after the adjustment of the position of the bad spots near the center line; (xre i , yre j ) is the center of the random uniform distribution of the roughening points after the adjustment of the position of the bad points in the center line area
  • n is the roller speed
  • v is the operating speed of the laser end output module
  • K is the focus motion trajectory number set
  • k is the kth focus motion trajectory, which is the kth machining process
  • P is the number of circles of each focus motion trajectory around the metal cylinder
  • p is the focus motion trajectory around the metal cylinder Circle p
  • the focal coverage ⁇ k set ⁇ during the k-th machining process of the laser end output module is specifically:
  • ⁇ is the set of focal coverage of the laser end output module during each processing process
  • ⁇ k is the focal coverage of the laser end output module during the kth processing process
  • ⁇ is the set of coordinate sets of the center of the random uniform texturing points in the focal coverage area of the laser end output module in each processing process;
  • ⁇ k is the focal coverage area ⁇ k in the kth processing of the laser end output module
  • (x rk , y rk ) is the center coordinate of the rk random uniform texturing point included in the kth processing;
  • rk is the statistical order of the random uniform texturing points included in the kth processing;
  • ⁇ k is the center coordinate of the disordered uniform texturing point in the focal coverage ⁇ k during the kth processing, and the center coordinate set formed after sorting according to the processing order of the texturing point;
  • (x ⁇ k ,y ⁇ k ) is The texture point coordinates of the ⁇ k process in the kth process;
  • ⁇ k is the order of the texture point processing order in the kth process;
  • rk max is the disorder included in the focal coverage ⁇ k in the kth process
  • (y rk ) max is the maximum value of the y-axis coordinate of the center coordinates (x rk , y rk ) of the random uniform texturing points in the focal coverage ⁇ k during the k-th processing ;
  • (Y rk ) min is the minimum value of the y-axis coordinate of the center coordinates (x rk , y rk ) of the random
  • ⁇ Line m is the set of signal sets of the laser light output position signal of the mth laser end output module-beam energy adjustment signal-one-dimensional beam deflection unit deflection signal in each processing process;
  • the signal set of the signal; ( ⁇ ⁇ k , ⁇ m ⁇ k , ⁇ ⁇ k ) is the same laser light output position signal sent to the processing system by the ⁇ k texturing point during the k-th processing, and the beam of the m-th laser end output module
  • p ⁇ k is the number of turns where the ⁇ kth texture point is processed during the kth processing; It is the constant constant of the maximum attenuation of the laser energy of the beam energy
  • the center coordinate set ⁇ k of the random uniform texturing points in the focal coverage range ⁇ k in the k-th processing process arranged in the order of processing is adjusted specifically as follows:
  • ⁇ re k is the coordinate set of the center of the random uniform texturing points in the focal coverage ⁇ k in the k-th processing process after adjustment; (xre ⁇ k ,yre ⁇ k ) is the k-th time after adjustment The center coordinate of the texture point of the ⁇ k process during the process of the process; ⁇ ⁇ k is the center coordinate of the center point of the process of the ⁇ k process of the k process during the y-axis coordinate adjustment; ⁇ is the adjustment ratio of the adjustment amount of the y-axis coordinate .
  • the method for determining the topography distribution point distance a and the topography distribution line distance b is as follows:
  • ⁇ 0 is the initial value of the set morphology area occupancy
  • a0 is the initial value of the topography distribution point distance, the initial value of the distance between the two roughened hard points in the x direction
  • b0 is the initial value of the topography distribution line distance The initial value of the distance between two hard points in the y direction
  • D mor is the diameter of the mor kind of morphology
  • ⁇ is the morphology area occupancy rate
  • a is the distance between topography distribution points, the distance between two roughened hard points in the x direction
  • b is the topography distribution line distance, between two roughened hard points in the y direction distance.
  • a roller laser texturing processing equipment includes a computer, a light source module and a laser end output module; the computer includes a design module and a signal processing module that can be connected end-to-end with a random uniform lattice distribution; according to the parameters of the roller processing unit and the morphology, Through the end-to-end disordered uniform lattice distribution design module, the end-to-end disorderly and uniformly distributed texturing lattice distribution scheme is output; according to the end-to-end disorderly and uniformly distributed texturing lattice distribution scheme, machine parameters and laser Parameters, through the information processing module to obtain the laser light position signal, beam energy adjustment signal and one-dimensional beam deflection unit deflection signal;
  • the laser light emitting position signal is used to control the light source module to emit laser light
  • the beam energy adjustment signal and the one-dimensional beam deflection unit deflection signal are respectively input into a laser end output module to generate a disordered laser dot matrix, and each laser end output module is used to process a roll processing unit;
  • the laser texturing method for rolls according to the present invention can ensure the degree of disorder of the texturing points and the uniformity of the morphological distribution through the design method of the uniform dot matrix distribution which can be connected end to end.
  • the board surface has better consistency in the subsequent coating process.
  • the laser texturing method for rolls according to the present invention can accurately and accurately process the designed texturing point disorderly and uniformly distributed scheme, so that what is manufactured is designed.
  • the laser texturing processing method of the roll according to the present invention obtains a random and uniformly distributed texturing lattice distribution scheme which can be connected end-to-end through a design method which can be connected end-to-end with random uniform lattice distribution, which is a plurality of laser end output modules Processing mode provides the possibility.
  • the present invention adopts laser melting processing technology to obtain the textured appearance, the hardness of the appearance is higher than that of the substrate, and the service life of the appearance is longer, which can ensure the surface stability of the same batch of cold-rolled plates produced at the same time;
  • the processing process is equivalent to laser hardening the surface of the roll, which can effectively extend the service life of the roll.
  • the roughening morphology processed by the present invention is a concave-convex composite morphology.
  • the micro-depressions of the morphology can store lubricating oil to improve the lubrication conditions during the cold-rolled plate process, and the micro-protrusion parts can be Pinned into the surface of the cold-rolled sheet, reducing the relative movement between the cold-rolled sheet and the roll, effectively preventing the surface of the cold-rolled sheet from being scratched and the wear of the roll; at the same time, after the shape is copied to the surface of the cold-rolled sheet, the cold-rolled sheet and the coating can be coated A mechanical anchoring group is formed between the layers, which solves the problem of peeling of the coating layer and provides a solution to the problem of inconsistency in the thermal sensitivity of the cold-rolled sheet and the coating layer.
  • the texturing point distribution scheme and laser light emission control signal of the present invention are calculated by a computer, and then the control signal set is sent to the machine tool processing control system, which effectively simplifies the production process and facilitates enterprises to respond to various types of different requirements of cold rolled plate production , Can effectively ensure the calculation efficiency and calculation accuracy, while not affecting the normal production tasks of the machine tool, and can effectively reduce the cost of machine tool manufacturing.
  • FIG. 1 is a diagram of the installation position of the laser end output module according to the present invention.
  • Fig. 2 is a control principle diagram of laser texturing processing equipment for rolls according to the present invention.
  • FIG. 3 is a flowchart of a method for designing a random uniform laser texturing lattice according to the present invention.
  • FIG. 4 is a flowchart of the information processing module according to the present invention.
  • FIG. 5 is a schematic diagram of the division of the processing area according to the present invention.
  • Fig. 6 is a texture map of the present invention.
  • FIG. 7 is a diagram of a uniform dot matrix scheme according to the present invention.
  • FIG. 8 is a diagram of a random displacement scheme of the uniform lattice scheme according to the present invention.
  • FIG. 9 is a diagram of a scheme for processing a defective pixel of a disordered lattice scheme according to the present invention.
  • FIG. 10 is a schematic diagram of the left-right swapping of the lattice distribution of each processing unit according to the present invention with the center line as a division.
  • FIG. 11 is a diagram of focal coverage during the k-th process according to the present invention.
  • FIG. 12 is a sorting rule diagram of the processing points of the furing points in the focal coverage during the kth (odd) processing according to the present invention.
  • FIG. 13 is a sorting rule diagram of the processing points of the texture points in the focal coverage in the k-th (even-number) processing process of the present invention.
  • FIG. 14 is a judgment of processing singularity during the k-th processing according to the present invention.
  • 15 is a processing diagram of processing singular points during the k-th processing process according to the present invention.
  • 1- metal cylinder to be processed 2- coaxial encoder; 3- laser focusing device; 4- one-dimensional beam deflection unit; 5- beam energy adjustment unit; 6- beam folding unit; 7- laser end output module mount .
  • the roll laser texturing equipment of the present invention includes a computer, a light source module, and a laser end output module; the computer includes a design module and a signal processing module that can be connected end-to-end with a uniform dot matrix distribution;
  • the parameters of the roll processing unit and the shape parameters are output by the end-to-end disordered uniform lattice distribution design module, which can output the end-to-end disordered uniform distribution of the lattice distribution scheme; according to the end-to-end disordered uniform distribution of the texture Lattice distribution scheme, machine tool parameters and laser parameters, through the information processing module to obtain the laser beam position signal, beam energy adjustment signal and one-dimensional beam deflection unit deflection signal; the laser beam position signal is used to control the light source module to emit laser;
  • the beam energy adjustment signal and the one-dimensional beam deflection unit deflection signal are respectively input into a laser end output module for generating a disordered laser dot matrix, and each laser end output module is used for processing a roll processing
  • the laser end output module includes a beam folding unit 6, a beam energy adjusting unit 5 and a one-dimensional beam deflecting unit 4; the laser light incident by the light source module sequentially passes through the beam folding unit 6, the beam energy adjusting unit 5, a one-dimensional beam deflecting unit 4 and the laser focusing device 3 enter the roll processing unit; the beam folding unit 6 is used to split the laser light incident from the light source module into a reflected laser perpendicular to the roll axis and a transmitted laser parallel to the roll axis; the reflected laser Into the beam energy adjustment unit 5, the transmitted laser is injected into the next laser end output module; the beam energy adjustment unit 5 is used to change the energy of the reflected laser; the one-dimensional beam deflection unit 4 is used Offset the angle of the reflected laser light.
  • the laser focusing device 3 is used to focus the offset reflected laser light on the metal cylinder 1 to be processed. Since the laser focusing device 3 is an existing device, the structure and principle will not be described here.
  • the laser end output module is installed on the laser end output module mounting base 7, and the laser end output module mounting base 7 can reciprocate along the axial direction of the roll processing unit area.
  • the laser end output module is labeled in order from near to far from the laser light source, the label is:
  • the beam folding unit 6 divides the incident laser into multiple output lasers with equal energy by using multiple half mirrors, and has the following characteristics: the coating properties of the half mirrors in the beam folding unit 6 are different and can split the incident laser energy It is a reflected laser and a transmitted laser of a specific energy; the beam folding unit 6 can split the incident laser parallel to the axis direction of the roll into a reflected laser perpendicular to the axis direction and a transmitted laser parallel to the axis direction, of which Line m laser end output
  • the ratio of the 6-point beam energy of the beam folding unit in the module is: Through this method, the input laser energy in each laser end output module can be made uniform, ie
  • P m is the terminus of Line m laser module output power laser beam reflected folded the spectroscopic unit; P m- Line m for the first end of the output laser light beam transmitted laser power module spectroscopic unit 6 is folded; P input laser Light source power; P output is the input laser power of the laser end output module.
  • the relationship between the focus position offset ⁇ and the electrical signal ⁇ can be obtained as follows:
  • ⁇ max 0.1 ⁇ 1rad; ⁇ ⁇ [0, ⁇ * ⁇ max ]; ⁇ [50%, 80%];
  • the laser texturing method for rolls of the present invention includes the following steps:
  • roller surface processing area division the roller surface processing area is evenly divided into several roller processing units; as shown in Figure 5, specifically:
  • the roller processing area is evenly divided into m roller processing units, and the length of any roller processing unit is L 1 ,
  • the roughened hard point is set as the laser melting processing morphology. According to the morphological cross-section, it can be divided into spherical crowned hairline point, Mexican hat-shaped hairline point, and crater-shaped hairline point.
  • the specific parameters are:
  • the output laser parameters used in the processing of the hardened hard spots include the laser pulse width, laser power, maximum light emitting frequency, and auxiliary gas, as follows:
  • Morphology is the set of morphological parameters
  • B mor is the morphological parameter of the mor morphology
  • D mor is the diameter of the mor morphology
  • Depth mor is the depth of the mor morphology
  • H mor is the mor morphology Morph height
  • Laser is the topography Laser processing parameter set
  • laser mor is the laser processing parameter of the mor type appearance
  • PluseWidth mor is the laser processing pulse width of the mor type appearance
  • It is the laser processing power of the mor type appearance
  • MaxfLas mor is the highest light emitting frequency of the laser processing of the mor type appearance
  • Gas mor is the type of auxiliary gas for laser processing of the mor type appearance.
  • Step 1-1 Establish a Cartesian coordinate system, expand the area of the unit to be processed in the axial direction to form a square surface with a length and width of L 1 and ⁇ d, respectively, with the starting roughening point as the coordinate origin and the axial direction as the x axis ,
  • the circumferential direction is the y-axis, and a uniform lattice distribution of the center of the roughening point A 0 is established according to the shape distribution.
  • steps 1-1-S1 to steps 1-1-S4 are as follows, steps 1-1-S1 to steps 1-1-S4:
  • Step 1-1-S1 Determine the type of laser-textured hard spots and determine the mor value.
  • Step 1-1-S2 According to the initial value ⁇ 0 of the area occupancy rate, calculate the initial values a0 and b0 of the point spacing and line spacing of the topography, as follows:
  • Step 1-1-S3 Modify the point spacing, line spacing and area occupancy of the topography distribution, as follows:
  • ⁇ is the morphology area occupancy rate
  • a is the distance between topography distribution points, the distance between two roughened hard points in the x direction
  • b is the topography distribution line distance, between two roughened hard points in the y direction distance.
  • Steps 1-1-S4 As shown in FIG. 7, a uniform lattice distribution of the set of center points of the roughening points A 0 is established according to the dot pitch and line pitch, specifically:
  • a 0 is the coordinate position set of the center point of the texture point of the uniform lattice distribution
  • (x 0i , y 0j ) is the coordinate of the center point of the texture point of the uniform lattice distribution of the ith row and jth column
  • i is the row number
  • j is the column number
  • j max is the maximum column number
  • a is the distance between topography distribution points, the distance between two roughened hard points in the x direction
  • b is the topography distribution line distance, the distance between two roughened hard points in the y direction
  • Step 1-2 As shown in FIG. 8, a random displacement vector set ⁇ X for each texturing point in a uniform lattice distribution is established, as follows:
  • ⁇ X is the set of random displacement vectors for each texturing point in the uniform lattice distribution
  • ( ⁇ x i , ⁇ y j ) is the coordinate of the center of the center of the texturing point in the uniform lattice distribution of row i and column j in the uniform lattice distribution (x 0i ,y 0j )
  • ⁇ a is a column offset constant, generally ⁇ a ⁇ (0,2a)
  • Steps 1-3 Calculate the set A of random and uniformly distributed texture center points A from the coordinate position set A 0 of the texture center points of the uniform lattice distribution and the random displacement vector set ⁇ X of each texture point in the uniform lattice distribution, as follows :
  • A random and uniform distribution of the center point of the texture points
  • (x i , y j ) random and uniform distribution of the center coordinates of the texture points
  • Step 1-4 Find the set SP of the row sequence and column sequence of disorderly and uniformly distributed bad points according to the tolerance of the overlap of the roughening points, as follows:
  • SP is the set of disorderly uniformly distributed bad point row sequence and column sequence
  • A(i,j) is the coordinate of the ith and jth furry point center coordinates of the disorderly uniformly distributed furry point circle center set
  • (u q , w q ) is the q-th bad point coordinate row sequence and column sequence
  • q is the bad point order number
  • ⁇ is the uniform tolerance of the disordered uniform distribution of the texture point overlap tolerance, generally ⁇ [0.5,1.5].
  • Step 1-5 Determine whether there is a dead spot, and decide the next step, so as to obtain a random and uniform distribution of the center of the set of hair points, as follows:
  • Step 1-5-S1 Adjust the random displacement vector set ⁇ X according to the disorderly and uniformly distributed bad point set SP, as shown in Fig. 9, as follows:
  • ⁇ Xre is the adjusted random displacement vector set
  • ( ⁇ xre i , ⁇ yre j ) is the adjusted random displacement vector
  • ⁇ is the adjustment ratio of the random displacement vector of dead pixels, generally ⁇ (0,1).
  • Step 1-5-S2 Repeat steps 1-3 to 1-4 until
  • Step 1-6 Align the center A of random uniformly distributed hair points with the axial center line as the reference, and adjust left and right to facilitate the overlapping of the processing areas of multiple laser end output modules, as shown in Figure 10, the specific adjustment rules as follows:
  • Aex is the random uniform distribution of the center of the roughening point A.
  • the center of the axis is used as the reference to adjust the center of the random uniform distribution of the center of the roughening point;
  • (xex i ,yex j ) is the i , J coordinates of the center of the fur point;
  • Step 1-7 In the area near the center line after the left-right swapping process, find the set SPex of disordered and uniformly distributed bad point row and column sequences according to the tolerance of the roughening point overlap, as follows:
  • SPex is the set of random and uniformly distributed bad point row and column sequences according to the tolerance of the overlap of the softening point for the area near the center line after the left and right swap process
  • (uex qex , wex qex ) is the qex bad point coordinate Row sequence and column sequence
  • qex is the sorting number of dead pixels
  • Aex (i, j) is the coordinate of the i- and j-th texture points in the coordinate center of the disordered and uniformly distributed texture points after the adjustment
  • Center is after the adjustment process
  • Step 1-8 Determine whether there is a dead spot in the attachment area of the centerline, and decide the next step, so as to finally obtain a random and uniform distribution of the center of the set of hair points, as follows:
  • step 1-8-S1 to step 1-8-S2 If there is a dead point, it is calculated as follows, step 1-8-S1 to step 1-8-S2:
  • Step 1-8-S1 According to the disorderly and evenly distributed SPex set in the area near the center line, adjust the position of the area near the center line, as follows:
  • Are is the coordinate set of the center of the disordered uniform distribution of the roughening points after the adjustment of the position of the bad spots near the center line; (xre i , yre j ) is the center of the random uniform distribution of the roughening points after the adjustment of the position of the bad points in the center line area
  • Step 1-8-S2 Perform steps 1-6 and 1-7 until
  • Aex is a random and uniform distribution of the designed lattice distribution scheme.
  • S03 Determine the output signal: According to the disorderly and uniformly distributed texturing lattice distribution scheme, machine parameters and laser parameters, the laser light position signal, beam energy adjustment signal and one-dimensional beam deflection unit are obtained through the information processing module
  • the deflection signal is as follows, steps 2-1 to 2-8:
  • n is the roller speed
  • v is the operating speed of the laser end output module
  • Step 2-2 Number the reciprocating motion of the laser end output module according to the processing order, that is, the focus motion track number set K, and calculate the number set P of each focus motion track around the metal cylinder, as follows:
  • K is the focus motion trajectory number set
  • k is the kth focus motion trajectory, that is, the kth machining process
  • P is the number of circles of each focus motion trajectory around the metal cylinder
  • p is the focus motion trajectory around the metal cylinder Circle p
  • Step 2-3 As shown in FIG. 11, calculate the set ⁇ of the focal coverage ⁇ k of each processing process of the laser end output module, and the one-dimensional beam deflection unit (4) deflection angle ⁇ [0, ⁇ * ⁇ max ] At the time, the set of focal coverage ⁇ k during the kth machining process of the laser end output module is specifically:
  • ⁇ is the set of focal coverage of the laser end output module during each processing process
  • ⁇ k is the focal coverage of the laser end output module during the kth processing process
  • Step 2-4 Calculate the set ⁇ of the coordinates of the center of the center of the random uniform texturing point in the focal coverage of the laser output module during each processing, as follows:
  • ⁇ is the set of coordinate sets of the center of the random uniform texturing points in the focal coverage area of the laser end output module in each processing process;
  • ⁇ k is the focal coverage area ⁇ k in the kth processing of the laser end output module
  • (x rk , y rk ) is the center coordinate of the rk random uniform texturing point included in the kth processing;
  • rk is the statistical order of the random uniform texturing points included in the kth processing;
  • Step 2-5 As shown in Figure 12 and Figure 13, the center coordinates of the random uniform texturing points in the focal coverage ⁇ k during the statistical k-th processing are sorted according to the processing order of texturing points To get the coordinate set ⁇ k of the center point of the roughened points after sorting.
  • the specific sorting rules are as follows:
  • ⁇ k is the center coordinate of the disordered uniform texturing point in the focal coverage ⁇ k during the kth processing, and the center coordinate set formed after sorting according to the processing order of the texturing point;
  • (x ⁇ k ,y ⁇ k ) is The texture point coordinates of the ⁇ k process in the kth process;
  • ⁇ k is the order of the texture point processing order in the kth process;
  • rk max is the disorder included in the focal coverage ⁇ k in the kth process
  • (y rk ) max is the maximum value of the y-axis coordinate of the center coordinates (x rk , y rk ) of the random uniform texturing points in the focal coverage ⁇ k during the k-th processing ;
  • (Y rk ) min is the minimum value of the y-axis coordinate of the center coordinates (x rk , y rk ) of the random
  • Step 2-6 Based on the response frequency of the processing system, find the processing singularity in the center coordinate set of the random uniform texturing points in the focus coverage range ⁇ k arranged in the order of processing in the kth processing process
  • the set MSP k the specific search method is as follows:
  • MSP k is the set of processing singularities in ⁇ k ; msp mk is the processing sequence number of processing singularities in the kth processing; F is the comprehensive response frequency of the processing system; MaxfLas mor is the maximum output laser for topography processing Light output frequency; MaxfP res is the highest response frequency of the beam energy adjustment unit 5; MaxfEX res is the highest response frequency of the one-dimensional beam deflection unit 4; R encoder is the resolution of the roller rotary coaxial encoder 2;
  • the safety factor of the system response frequency generally
  • Step 2-7 As shown in Figure 14, determine whether there is a processing singularity, if And k ⁇ K, there is a processing singularity, proceed to steps 2-7-S1 ⁇ S2:
  • Step 2-7-S1 As shown in FIG 15, processing according to collection of the MSP k [Omega] k singularities in the k-th focus processing according to the processing sequence coverage ⁇ k arranged in a uniform random texturing
  • the point circle center coordinate set ⁇ k is adjusted as follows:
  • ⁇ re k is the coordinate set of the center of the random uniform texturing points in the focal coverage ⁇ k in the k-th processing process after adjustment; (xre ⁇ k ,yre ⁇ k ) is the k-th time after adjustment The center coordinate of the texture point of the ⁇ k process during the process of the process; ⁇ ⁇ k is the center coordinate of the center point of the process of the ⁇ k process of the k process during the y-axis coordinate adjustment; ⁇ is the adjustment ratio of the adjustment amount of the y-axis coordinate , Generally ⁇ (0,1);
  • Step 2-7-S2 Repeat steps 2-5 and 2-6 until
  • Step 2-8 Calculate the laser beam position signal of each laser end output module during each processing process-beam energy adjustment according to the coordinates of the random uniform texturing points arranged in the processing order in the focal coverage of each processing Signal-the set of signal sets of the deflection signal of the one-dimensional beam deflection unit ⁇ Line m , as follows:
  • ⁇ Line m is the set of signal sets of the laser light output position signal of the mth laser end output module-beam energy adjustment signal-one-dimensional beam deflection unit deflection signal in each processing process;
  • the signal set of the signal; ( ⁇ ⁇ k , ⁇ m ⁇ k , ⁇ ⁇ k ) is the same laser light output position signal sent to the processing system by the ⁇ k texturing point during the k-th processing, and the beam of the m-th laser end output module
  • p ⁇ k is the number of turns where the ⁇ kth texture point is processed during the kth processing; It is the constant of the maximum attenuation ratio of the laser energy of the beam energy
  • the laser light emitting position signal is used to control the light source module to emit laser; the beam energy adjustment signal and the one-dimensional beam deflection unit deflection signal are respectively input into the laser end output module to generate disordered laser spots Array, each laser end output module is used to process a roll processing unit.
  • the precise control method is: the metal cylinder 1 to be processed moves synchronously with the laser end output module, after determining the type of processing morphology, the computer automatically determines the parameters of the processing laser, and the laser light source enters each laser end for output after multiple splits Module, according to the computer-calculated laser light position signal-beam energy adjustment signal-one-dimensional beam deflection signal set, detect the coaxial encoder 2 instantaneous position signal and laser light position signal consistency, the output module at the laser end is determined At the time of position, a certain parameter input laser is sent, and at the same time, a different signal is given to the beam energy adjustment unit of each laser end output module to complete energy attenuation adjustment, and the same signal is given to the one-dimensional beam deflection unit of each laser end output module to complete the beam
  • One-dimensional deflection makes the laser focus of each laser end output module follow the designed disorderly and uniformly distributed dot matrix scheme, and uses different laser energy to process the textured hard spots in sequence.
  • Each laser end output module reciprocates in a straight line at a constant speed along the roll axis while the roll rotates.
  • the waiting time in place is ⁇ t.
  • the coaxial encoder 2 has the following characteristics: it has a fixed coaxial encoder resolution R encoder , which is an inherent property of the coaxial encoder, and has a range of R encoder ⁇ [2 16 , 2 20 ].
  • the laser end output module moves back and forth at a uniform horizontal speed along the axis of the cylinder to be processed, and monitors the real-time displacement of the laser head relative to the starting processing point x circumferential direction by a position sensor or grating ruler ⁇ x t , compared with the coaxial encoder 2
  • Instantaneous rotation angle ⁇ t , ⁇ t ⁇ [0,2 ⁇ ] guarantee Adjust the position of the laser head in time.

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Abstract

一种轧辊激光毛化加工设备及其加工方法，包括如下步骤：加工区域划分；确定分布方案：根据所述轧辊加工单元参数和形貌参数，得出可首尾相连的无序均匀分布毛化点阵分布方案；确定输出信号：通过信息处理模块得出激光出光位置信号、光束能量调节信号和一维光束偏转单元偏转信号；轧辊激光毛化加工：所述激光出光位置信号用于控制光源模块发出激光；所述光束能量调节信号和一维光束偏转单元偏转信号分别输入激光末端输出模块，用于产生无序的激光点阵，每个激光末端输出模块用于加工一个轧辊加工单元，可保证毛化点无序程度的同时也能确保形貌分布的均匀性，生产的冷轧板表面在后续涂装处理中一致性更好。

Description

一种轧辊激光毛化加工设备及其加工方法 技术领域
本发明涉及表面处理领域中的激光毛化加工技术，特别涉及一种轧辊激光毛化加工设备及其加工方法。
背景技术
冷轧板表面的一定形貌参数对钢板的冲压性和表面涂镀性能有重要影响，而冷轧板的表面形貌在很大程度上又取决于冷轧生产过程中轧机工作辊及光整机组工作辊的表面形貌。实质上，冷轧板表面形貌是轧辊表面形貌的衰减性“拷贝”。为使带钢表面达到满足需要的表面形貌，一般采用轧辊表面毛化的办法。不同种类冷轧板，对毛化形貌的种类、形貌微观尺寸存在不同要求；毛化形貌的保持性、一致性、均匀性，对同一批次冷轧板表面质量一致性影响显著；毛化形貌排列的无序程度，与冷轧板后续涂装处理表面质量呈正相关。
目前，用于轧辊毛化的主流方法有喷丸毛化、电火花毛化、激光毛化。喷丸毛化靠硬质微粒冲击轧辊表面，形成凹陷毛化形貌，该技术明显缺陷有：1)形成的毛化形貌单一，且毛化形貌微观尺寸调节困难，不能适应不同类别钢板轧制需求；2)加工过程环境恶劣，并入冷轧板生产线难度大。电火花毛化是在绝缘液中电极与轧辊表面之间产生脉冲性的火花放电，靠局部放电产生的瞬时高温刻蚀轧辊表面，形成毛化形貌，形貌排列具有随机性，该技术的缺陷有：1)通过热效应烧蚀轧辊表面形成的毛化形貌，具有重铸层、重淬层、热影响层和基材四层，其中使得轧辊表面糙化的重铸层易剥落，形貌保持性差、寿命短，严重影响同一批次轧制钢板表面质量一致性；2)毛化加工中电极损耗，虽有电极补偿反馈，但难以保证轧辊表面毛化形貌微观尺寸一致和可控；3)加工过程中电极等损耗件，设备使用中存在持续成本；4)设备投入成本较大。
激光毛化，通过激光热效应在轧辊表面激光烧蚀或激光熔凝加工出毛化形貌，毛化形貌种类较多，形貌微观尺寸通过改变激光参数调节方便，但依然存在以下几个问题：1)通过激光烧蚀加工出的毛化形貌，形貌表层凸起部分为重铸层，冷轧板过程中易剥落，形貌保持性差；2)激光加工过程中激光作用点(焦点)位置固定，加工无序排列的毛化形貌难度大；3)毛化形貌随机分布时，总是会出现毛化形貌出现大批量重叠，分布的均匀性无法得到保证。
中国专利公开了一种实现毛化点均匀随机分布的激光毛化方法，通过随机信号对每个激光脉冲进行随机延时和随机偏转，在轧辊表面加工较疏的毛化形貌分布，再通过多激光头多道次提高效率和面积占有率。虽然解决了激光毛化有序性的问题，但激光脉冲的随机延时、 随机偏转和多道次的加工方法都会导致毛化形貌出现大批量重叠，导致形貌分布的均匀性较差，直接影响后续涂装性能。同时形貌的多次重叠区域多次受到激光作用，相当于对轧辊局部区域进行回火处理，影响甚至破坏轧辊表层金相组织，极大地降低了轧辊使用寿命。
中国专利公开了一种无规则偏转毛化点的辊类表面毛化激光加工系统及方法，通过由正弦波精确控制变化得来的伪随机信号，控制伪随机偏转装置对每次向辊类工件表面发射的激光进行随机偏转，实现毛化点无规则分布。该方案在面积占有率较大的分布中，分布的均匀性问题依然存在，形貌会出现扎堆和重叠，分布的均匀性不佳。
中国专利公开了一种聚焦光点可控偏摆的激光毛化加工装置，在激光聚焦前布置压电陶瓷偏转系统，使得聚焦光点做二维摆动，从而加工无规则分布的毛化点。该专利并未公开控制形貌分布均匀性的方法，均匀性问题并未得到解决。
发明内容
针对现有技术中存在的不足，本发明提供了一种轧辊激光毛化加工设备及其加工方法，在轧辊表面待加工区域，选用合适的织构形貌并配合特定的输出激光参数，通过多个激光末端输出模块同步加工每个加工单元，设计可首尾相连的无序均匀分布点阵方案，检测同轴编码器瞬时位置信号与激光出光位置信号一致性，在激光末端输出模块处于确定位置时发出确定参数激光，同时给每个激光末端输出模块的光束能量调节单元不同的信号，完成能量衰减调节，并给每个激光末端输出模块的一维光束偏转单元同样的信号，完成光束一维偏转，使得各个激光末端输出模块的激光焦点按所设计可首尾相连的无序均匀分布点阵方案，采用不同的激光能量依次加工毛化硬质点。
本发明是通过以下技术手段实现上述技术目的的。
一种轧辊激光毛化加工方法，其特征在于，包括如下步骤：
加工区域划分：将轧辊表面加工区域均匀划分为若干轧辊加工单元；
确定分布方案：根据所述轧辊加工单元参数和形貌参数，通过可首尾相连无序均匀点阵分布设计方法得出可首尾相连的无序均匀分布毛化点阵分布方案；
确定输出信号：根据所述可首尾相连的无序均匀分布毛化点阵分布方案、机床参数和激光参数，通过信息处理模块得出激光出光位置信号、光束能量调节信号和一维光束偏转单元偏转信号；
轧辊激光毛化加工：所述激光出光位置信号用于控制光源模块发出激光；所述光束能量调节信号和一维光束偏转单元偏转信号分别输入激光末端输出模块，用于产生无序的激光点阵，每个激光末端输出模块用于加工一个轧辊加工单元。
进一步，加工区域划分具体为：
确定轧辊表面加工区域；所述轧辊加工区域为长度L 01和宽度πd的方形区域，其中，L 01＝5％～100％L 0，L 0-01为距轧辊端面距离，L 0-01＝0～90％L 0；L 0为轧辊表面展开长度，d为轧辊直径；
将轧辊加工区域均匀划分为m个轧辊加工单元，任一轧辊加工单元长度为L 1，
Figure PCTCN2018124564-appb-000001
任一轧辊加工单元宽度为πd；其中，m∈{1,2,3…m max}，m max＝1～30。
进一步，所述激光末端输出模块包括光束折返单元、光束能量调节单元和一维光束偏转单元；所述光源模块入射的激光依次经过光束折返单元、光束能量调节单元和一维光束偏转单元后入射轧辊加工单元；
所述光束折返单元用于将光源模块入射的激光分光为垂直于轧辊轴线方向的反射激光和平行于轧辊轴线方向的透射激光；所述反射激光射入所述光束能量调节单元，所述透射激光射入下一个激光末端输出模块；
所述光束能量调节单元用于改变所述反射激光的能量；
所述一维光束偏转单元用于偏移所述反射激光的角度。
进一步，所述光束折返单元通过各半反镜片镀膜性质不同，使反射激光和透射激光能量比例为：
Figure PCTCN2018124564-appb-000002
其中，P m为第Line m个激光末端输出模块中光束折返单元分光的反射激光功率；
P m-为第Line m个激光末端输出模块中光束折返单元分光的透射激光功率；
P input为光源模块输出的激光光源功率；
P output为激光末端输出模块输入激光功率；
所述光束能量调节单元根据输入的电信号ψ使光束能量衰减固定值，即P focus＝(1-Damp(ψ))P output，其中，ψ为光束能量调节单元驱动电源输入电信号，ψ∈[ψ min,ψ max]，对应能量衰减比例Damp(ψ)从0～100％变化；ψ min为最小输入电信号；ψ max为最大输入电信号；Damp(ψ)为激光能量衰减比例；P focus为所述光束能量调节单元输出的激光功率；
所述一维光束偏转单元根据输入电信号ξ使光束一维偏转固定角度α，经过聚焦镜片作用在待加工区域，使得焦点相对于光轴偏移确定距离σ，
σ＝f(α,L 2,f)＝f(α(ξ),L 2,f)，
σ min＝f(α min,L 2,f)＝f(0,L 2,f)
σ max＝f(η*α max,L 2,f)
其中，L 2为所述一维光束偏转单元距工件表面距离；f为所述一维光束偏转单元不发生偏 转时的焦距；α为一维光束偏转单元使光束偏转角度，即α＝α(ξ)；α min为所述一维光束偏转单元使光束最小偏转角度；α max为一维光束偏转单元使光束最大偏转角度；η为一维光束偏转单元安全使用系数；σ为焦点位置偏移量；σ min为焦点位置偏移量最小值；σ max为焦点位置偏移量最大值。
进一步，所述可首尾相连无序均匀点阵分布设计方法具体包括如下步骤：
根据形貌参数分布建立均匀点阵分布毛化点圆心集A 0，具体为：
Figure PCTCN2018124564-appb-000003
其中：A 0为均匀点阵分布毛化点圆心坐标位置集；(x 0i,y 0j)为第i行第j列均匀点阵分布毛化点圆心坐标；i为行序号；i max为最大行序号，i max＝πd/b；j为列序号，
Figure PCTCN2018124564-appb-000004
j max为最大列序号；a为形貌分布点距，x方向两个毛化硬质点之间距离；b为形貌分布线距，y方向两个毛化硬质点之间距离；
建立均匀点阵分布中每个毛化点随机位移向量集合ΔX，具体如下：
Figure PCTCN2018124564-appb-000005
其中：ΔX为均匀点阵分布中每个毛化点随机位移向量集合；(δx i,δy j)为均匀点阵分布中第i行、第j列均匀点阵分布毛化点圆心坐标(x 0i,y 0j)的随机位移向量；ε a为列偏移常量；ε b为行偏移常量；
建立无序均匀分布毛化点圆心集A：将均匀点阵分布毛化点圆心坐标位置集A 0和均匀点阵分布中每个毛化点随机位移向量集合ΔX叠加：
Figure PCTCN2018124564-appb-000006
其中：A，无序均匀分布毛化点圆心集；(x i,y j)，无序均匀分布毛化点圆心坐标；
查找坏点：按毛化点重叠容忍度查找无序均匀分布坏点行序列、列序列的集SP，具体如下：
Figure PCTCN2018124564-appb-000007
其中：SP为无序均匀分布坏点行序列、列序列的集；A(i,j)为无序均匀分布毛化点圆心坐标集中第i、j个毛化点圆心坐标；(u q,w q)为第q个坏点坐标行序列、列序列；q为坏点排序号；ζ为无序均匀分布毛化点重叠容忍常量；
判断是否存在坏点：当
Figure PCTCN2018124564-appb-000008
时，则存在坏点，则根据无序均匀分布坏点集SP，调整随机位移向量集合ΔX，重复建立无序均匀分布毛化点圆心集A和查找坏点，直至
Figure PCTCN2018124564-appb-000009
当
Figure PCTCN2018124564-appb-000010
时，则不存在坏点；
建立无序均匀分布毛化点圆心集A以轴向中心线为基准进行左右对调后的无序均匀分布毛化点圆心集Aex：当
Figure PCTCN2018124564-appb-000011
时，对无序均匀分布毛化点圆心集A以轴向中心线为基准进行左右对调，以便多个激光末端输出模块加工区域的搭接：
Figure PCTCN2018124564-appb-000012
其中：Aex为对无序均匀分布毛化点圆心集A以轴向中心线为基准进行左右对调后的无序均匀分布毛化点圆心集；(xex i,yex j)为左右对调后第i、j个毛化点圆心坐标；
查找中心线附近区域坏点：在左右对调过程后的中心线附近区域，按毛化点重叠容忍度查找无序均匀分布坏点行序列、列序列的集SPex，具体为：
Figure PCTCN2018124564-appb-000013
其中：SPex为对左右对调过程后的中心线附近区域按毛化点重叠容忍度查找无序均匀分 布坏点行序列、列序列的集；(uex qex,wex qex)为第qex个坏点坐标行序列、列序列；qex为坏点排序号；Aex(i,j)为对调后的无序均匀分布毛化点圆心坐标集中第i、j个毛化点圆心坐标；Center为左右对调过程后的中心线附近区域：
Figure PCTCN2018124564-appb-000014
Figure PCTCN2018124564-appb-000015
为输入的中心线附近区域比例；
判断中心线附件区域是否存在坏点：当
Figure PCTCN2018124564-appb-000016
则存在坏点，则根据中心线附近区域无序均匀分布坏点集SPex，调整中心线附近区域坏点位置，重复建立无序均匀分布毛化点圆心集A以轴向中心线为基准进行左右对调后的无序均匀分布毛化点圆心集Aex和查找中心线附近区域坏点，直至
Figure PCTCN2018124564-appb-000017
当
Figure PCTCN2018124564-appb-000018
时，则不存在坏点，即Aex为所述可首尾相连的无序均匀分布毛化点阵分布方案。
进一步，所述根据无序均匀分布坏点集SP，调整随机位移向量集合ΔX，具体为：
Figure PCTCN2018124564-appb-000019
式中：
Figure PCTCN2018124564-appb-000020
其中：ΔXre为调整后的随机位移向量集；(δxre i,δyre j)为调整后的随机位移向量；λ为坏点的随机位移向量的调整比例；
所述根据中心线附近区域无序均匀分布坏点集SPex，调整中心线附近区域坏点位置，具体为：
Figure PCTCN2018124564-appb-000021
式中：
Figure PCTCN2018124564-appb-000022
其中：Are为中心线附近区域坏点位置调整后的无序均匀分布毛化点圆心坐标集；(xre i,yre j)为中心线区域坏点位置调整后的无序均匀分布毛化点圆心坐标集中第i、j个毛化点圆心坐标；
Figure PCTCN2018124564-appb-000023
为中心线附近区域坏点坐标调整比例。
进一步，通过信息处理模块得出激光出光位置信号、光束能量调节信号和一维光束偏转单元偏转信号具体为如下步骤：
确定焦点运动轨迹与轧辊轴向夹角：当一维光束偏转单元不工作时即α＝0时，焦点运动轨迹与轧辊轴向夹角θ：
Figure PCTCN2018124564-appb-000024
其中：n为轧辊转速；v为激光末端输出模块的运行速度；
确定焦点运动轨迹序号集K和计算每个焦点运动轨迹绕金属圆柱体圈数集P，
k∈K＝{1,2,3,…k max}，式中：
Figure PCTCN2018124564-appb-000025
p∈P＝{1,2,3…p max}，式中：
Figure PCTCN2018124564-appb-000026
其中：K为焦点运动轨迹序号集；k为第k个焦点运动轨迹，即第k次加工过程；P为每个焦点运动轨迹绕金属圆柱体圈数集；p为焦点运动轨迹绕金属圆柱体第p圈；
确定一维光束偏转单元偏转角度α∈[0,η*α max]时，激光末端输出模块第k次加工过程中焦点覆盖范围Λ k的集合Λ，具体为：
Figure PCTCN2018124564-appb-000027
式中，
Figure PCTCN2018124564-appb-000028
Figure PCTCN2018124564-appb-000029
其中：Λ为激光末端输出模块每次加工过程中焦点覆盖范围的集合；Λ k为激光末端输出模块第k次加工过程中焦点覆盖范围；xk min(y,p)＝xk(y,p,σ＝0)为偏转角度α＝0即偏转量σ＝0时，第k条第p圈焦点运动轨迹方程；xk max(y,p)＝xk(y,p,σ＝σ max)为偏转角度α＝η*α max即偏转量σ＝σ max时，第k条第p圈焦点运动轨迹方程；
统计激光末端输出模块每次加工过程中焦点覆盖范围中的无序均匀毛化点圆心坐标的集合Φ，具体如下：
Φ＝{Φ k|k＝1,2,3…k max}，
式中：
Figure PCTCN2018124564-appb-000030
其中，Φ为激光末端输出模块每次加工过程中焦点覆盖范围中的无序均匀毛化点圆心坐标集的集合；Φ k为激光末端输出模块第k次加工过程中焦点覆盖范围Λ k中的无序均匀毛化点圆心坐标集，即圆心坐标落在xk min＝xk(y,σ＝0)、xk max＝xk(y,σ＝σ max)两条轨迹线之间的毛化点圆心坐标集；(x rk,y rk)为第k次加工过程中包含的第rk个无序均匀毛化点圆心坐标；rk为第k次加工过程中包含的无序均匀毛化点统计次序；
确定第k次加工过程中排序后的毛化点圆心坐标集Ω k：按照毛化点加工先后顺序对(x rk,y rk)进行排序得到排序后的毛化点圆心坐标集Ω k，具体排序规则如下：
Figure PCTCN2018124564-appb-000031
其中：Ω k为第k次加工过程中焦点覆盖范围Λ k中的无序均匀毛化点圆心坐标，按照毛化点加工顺序进行排序后形成的圆心坐标集；(x τk,y τk)为第k次加工过程中第τk个加工的毛化点坐标；τk为第k次加工过程中毛化点加工顺序排序；rk max为第k次加工过程中焦点覆盖范围Λ k中包含的无序均匀毛化点数量统计值最大值；(y rk) max为第k次加工过程中焦点覆盖范围Λ k中的无序均匀毛化点圆心坐标(x rk,y rk)的y轴坐标最大值；(y rk) min为第k次加工过程中焦点覆盖范围Λ k中的无序均匀毛化点圆心坐标(x rk,y rk)的y轴坐标最小值；
查找Ω k中的加工奇点的集合MSP k：根据加工系统响应频率查找Ω k中的加工奇点的集合MSP k，具体查找方式如下：
Figure PCTCN2018124564-appb-000032
式中：
Figure PCTCN2018124564-appb-000033
其中：MSP k为Ω k中的加工奇点的集合；msp mk为第k次加工过程中加工奇点的加工顺序序号；F为加工系统综合响应频率；MaxfLas mor为加工第mor种形貌的输出激光最大出光频率；MaxfP res为光束能量调节单元最高响应频率；MaxfEX res为一维光束偏转单元最高响应频率；R encoder为轧辊旋转同轴安装的编码器分辨率；
Figure PCTCN2018124564-appb-000034
为系统响应频率安全系数；
判断是否存在加工奇点：当
Figure PCTCN2018124564-appb-000035
且k∈K，则存在加工奇点，根据Ω k中的加工奇点的集合MSP k对第k次加工过程中焦点覆盖范围Λ k中的按加工先后顺序排列的无序均匀毛化点圆心坐标集Ω k进行调整，重复确定第k次加工过程中排序后的毛化点圆心坐标集Ω k和查找Ω k中的加工奇点的集合MSP k，直至
Figure PCTCN2018124564-appb-000036
当
Figure PCTCN2018124564-appb-000037
时，则不存在坏点；
当
Figure PCTCN2018124564-appb-000038
且k∈K，计算激光末端输出模块的激光出光位置信号-光束能量调节信号- 一维光束偏转单元偏转信号的信号集的集合ΓLine m：
Figure PCTCN2018124564-appb-000039
式中：
Figure PCTCN2018124564-appb-000040
其中：ΓLine m为每次加工过程中第m个激光末端输出模块的激光出光位置信号-光束能量调节信号-一维光束偏转单元偏转信号的信号集的集合；
Figure PCTCN2018124564-appb-000041
为加工第k次加工过程中焦点覆盖范围中的按加工顺序排列的无序均匀毛化点第m个激光末端输出模块所需的激光出光位置信号-光束能量调节信号-一维光束偏转单元偏转信号的信号集；(β τk,ψm τk,ξ τk)为第k次加工过程中加工第τk个毛化点给加工系统发出的同样的激光出光位置信号、第m个激光末端输出模块的光束能量调节信号和同样的一维光束偏转单元偏转信号；p τk为第k次加工过程中加工第τk个毛化点所在圈数；
Figure PCTCN2018124564-appb-000042
为光束能量调节单元激光能量最大衰减比例常量。
进一步，根据Ω k中的加工奇点的集合MSP k对第k次加工过程中焦点覆盖范围Λ k中的按加工先后顺序排列的无序均匀毛化点圆心坐标集Ω k进行调整具体为：
Figure PCTCN2018124564-appb-000043
式中，
Figure PCTCN2018124564-appb-000044
其中：Ωre k为调整后第k次加工过程中焦点覆盖范围Λ k中的按加工先后顺序排列的无序 均匀毛化点圆心坐标集；(xre τk,yre τk)为调整后的第k次加工过程中第τk个加工的毛化点圆心坐标；Δ τk为第k次加工过程中第τk个加工的毛化点的圆心坐标y轴坐标调整量；γ为y轴坐标调整量的调整比例。
进一步，所述形貌分布点距a和形貌分布线距b的确定方法如下：
确定激光毛化硬质点形貌种类；
根据面积占有率初始值ρ0，计算形貌点距a0的初始值和线距的初始值b0，具体如下：
Figure PCTCN2018124564-appb-000045
其中：ρ0为设定的形貌面积占有率初始值；a0为形貌分布点距初始值，x方向两个毛化硬质点之间距离初始值；b0为形貌分布线距初始值，y方向两个硬质点之间距离初始值；D mor为第mor种形貌的直径；
修正形貌分布点距、线距和面积占有率，具体如下：
Figure PCTCN2018124564-appb-000046
其中：ρ为形貌面积占有率；a为形貌分布点距，x方向两个毛化硬质点之间距离；b为形貌分布线距，y方向两个毛化硬质点之间距离。
一种轧辊激光毛化加工设备，包括计算机、光源模块和激光末端输出模块；所述计算机包括可首尾相连无序均匀点阵分布设计模块和信号处理模块；根据轧辊加工单元参数和形貌参数，通过可首尾相连无序均匀点阵分布设计模块输出可首尾相连的无序均匀分布毛化点阵分布方案；根据所述可首尾相连的无序均匀分布毛化点阵分布方案、机床参数和激光参数，通过信息处理模块得出激光出光位置信号、光束能量调节信号和一维光束偏转单元偏转信号；
所述激光出光位置信号用于控制光源模块发出激光；
所述光束能量调节信号和一维光束偏转单元偏转信号分别输入激光末端输出模块，用于产生无序的激光点阵，每个激光末端输出模块用于加工一个轧辊加工单元；
每个所述激光末端输出模块在对应的轧辊加工单元区域轴向往复移动，所述往复运动起始线为
Figure PCTCN2018124564-appb-000047
终止线为x＝L 1。
本发明的有益效果在于：
1.本发明所述的轧辊激光毛化加工方法，通过可首尾相连无序均匀点阵分布设计方法，保证毛化点无序程度的同时也能确保形貌分布的均匀性，生产的冷轧板表面在后续涂装处理中一致性更好。
2.本发明所述的轧辊激光毛化加工方法，能够精确准确加工所设计的毛化点无序均匀分布方案，实现所制造即所设计。
3.本发明所述的轧辊激光毛化加工方法，通过可首尾相连无序均匀点阵分布设计方法得出可首尾相连的无序均匀分布毛化点阵分布方案，为多个激光末端输出模块加工模式提供了可能。
4.本发明采用激光熔凝加工技术获得毛化形貌，形貌硬度高于基材，形貌使用寿命更长，能够保证生产的同批次冷轧板表面稳定性更好；同时毛化加工过程相当于对轧辊表面进行激光淬火，能够有效延长轧辊使用寿命。
5.本发明所提供的毛化形貌种类多，且形貌的微观尺寸可通过改变激光参数精确调控，能够满足各种类别不同要求冷轧板生产。
6.本发明所加工的毛化形貌为凹凸复合形貌，形貌的微凹陷部分在冷轧板过程中，能够储存润滑油改善润滑条件，微凸起部分在冷轧板过程中，能够钉扎入冷轧板表面，减小冷轧板与轧辊间相对运动，有效防止冷轧板表面划伤和轧辊磨损；同时形貌复印至冷轧板表面后，能够在冷轧板与涂覆层之间形成机械锚固群，解决了涂覆层剥落问题，为冷轧板和涂覆层热敏感度不一致问题提供了解决方案。
7.本发明的毛化点分布方案和激光出光控制信号通过计算机计算，再将控制信号集发送给机床加工控制系统，有效地简化了生产过程，方便企业应对各种类别不同要求冷轧板生产，能有效保证计算效率、计算精度，同时不影响机床正常生产任务，还能有效降低机床制造成本。
附图说明
图1为本发明所述的激光末端输出模块安装位置图。
图2为本发明所述的轧辊激光毛化加工设备控制原理图。
图3为本发明所述的无序均匀激光毛化点阵方案设计方法流程图。
图4为本发明所述的信息处理模块流程图。
图5为本发明所述的加工区域划分示意图。
图6为本发明所述的毛化形貌图。
图7为本发明所述的均匀点阵方案图
图8为本发明所述的均匀点阵方案随机位移方案图。
图9为本发明所述的无序点阵方案坏点处理方案图。
图10为本发明所述的每个加工单元点阵分布以中心线为分割左右对调示意图。
图11为本发明所述的第k次加工过程中焦点覆盖范围图。
图12为本发明所述的第k(奇数)次加工过程中焦点覆盖范围中毛化点加工先后排序规则图。
图13为本发明所述的第k(偶数)次加工过程中焦点覆盖范围中毛化点加工先后排序规则图。
图14为本发明所述的第k次加工过程中加工奇点判断。
图15为本发明所述的第k次加工过程中加工奇点处理图。
图中：
1-待加工金属圆柱体；2-同轴编码器；3-激光聚焦装置；4-一维光束偏转单元；5-光束能量调节单元；6-光束折返单元；7-激光末端输出模块安装座。
具体实施方式
下面结合附图以及具体实施例对本发明作进一步的说明，但本发明的保护范围并不限于此。
如图1所示，本发明所述的轧辊激光毛化加工设备，包括计算机、光源模块和激光末端输出模块；所述计算机包括可首尾相连无序均匀点阵分布设计模块和信号处理模块；根据轧辊加工单元参数和形貌参数，通过可首尾相连无序均匀点阵分布设计模块输出可首尾相连的无序均匀分布毛化点阵分布方案；根据所述可首尾相连的无序均匀分布毛化点阵分布方案、机床参数和激光参数，通过信息处理模块得出激光出光位置信号、光束能量调节信号和一维光束偏转单元偏转信号；所述激光出光位置信号用于控制光源模块发出激光；所述光束能量调节信号和一维光束偏转单元偏转信号分别输入激光末端输出模块，用于产生无序的激光点阵，每个激光末端输出模块用于加工一个轧辊加工单元；每个所述激光末端输出模块在对应的轧辊加工单元区域轴向往复移动。
所述激光末端输出模块包括光束折返单元6、光束能量调节单元5和一维光束偏转单元4；所述光源模块入射的激光依次经过光束折返单元6、光束能量调节单元5、一维光束偏转单元4和激光聚焦装置3后入射轧辊加工单元；所述光束折返单元6用于将光源模块入射的激光分光为垂直于轧辊轴线方向的反射激光和平行于轧辊轴线方向的透射激光；所述反射激光射入所述光束能量调节单元5，所述透射激光射入下一个激光末端输出模块；所述光束能量调节单元5用于改变所述反射激光的能量；所述一维光束偏转单元4用于偏移所述反射激光的角度。所述激光聚焦装置3用于将偏移后的反射激光聚焦到待加工金属圆柱体1上，由于激光聚焦装置3为现有的装置在此不再介绍结构和原理。所述激光末端输出模块安装在激光末端输出模块安装座7上，所述激光末端输出模块安装座7可以沿轧辊加工单元区域轴向往复移动。
所述激光末端输出模块按与激光光源由近及远的顺序标号，标号为：
Figure PCTCN2018124564-appb-000048
分别加工第1个、第2个…第m个…第m max个单元：
所述光束折返单元6，利用多个半反镜片将入射激光均分为多个能量相等的输出激光，具有以下特征：光束折返单元6中各半反镜片镀膜性质不同，可将入射激光能量分光为特定能量的反射激光和透射激光；光束折返单元6可将平行于轧辊轴线方向的入射激光分光为垂直于轴线方向的反射激光和平行于轴线方向的透射激光，其中第Line m个激光末端输出模块中光束折返单元6分光能量比例为：
Figure PCTCN2018124564-appb-000049
通过此方法，能够使得每个激光末端输出模块中的输入激光能量一致，即
Figure PCTCN2018124564-appb-000050
其中：P m为第Line m个激光末端输出模块中光束折返单元分光的反射激光功率；P m-为第Line m个激光末端输出模块中光束折返单元6分光的透射激光功率；P input为激光光源功率；P output为激光末端输出模块输入激光功率。
所述光束能量调节单元5可通过对光束能量调节单元驱动电源输入电信号无极改变通过激光的能量，具有以下特征：可根据电信号ψ使光束能量衰减固定值，即P focus＝(1-DampψPoutput；电信号ψ可连续变化，具有固定范围，即ψ∈ψmin,ψmax，对应能量衰减比例Damp(ψ)从0～100％变化；
其中：ψ为光束能量调节单元5驱动电源输入电信号；ψ min为最小输入电信号；ψ max为最大输入电信号；Damp(ψ)为激光能量衰减比例；P focus为激光末端输出模块聚焦激光输出功率。
所述一维光束偏转单元4，具有以下特性：可根据电信号ξ使光束一维偏转固定角度α，即α＝α(ξ)；使光束一维偏转角度α具有固定范围，且α max为一维光束偏转单元4固有属性；具有固定的最高响应频率Maxf res，Maxf res≥10Khz；使光束一维偏转固定角度α，经过聚焦镜片作用在待加工区域，使得焦点相对于光轴偏移确定距离σ，即σ∝α，σ∝L 2，σ∝f，即σ＝f(α,L 2,f)＝f(α(ξ),L 2,f)；故当加工系统中L 2、f固定时，可得到焦点位置偏移量σ与电信号ξ的关系如下：
σ＝f(α)＝f(α(ξ))
σ min＝f(α＝α min＝0)＝0
σ max＝f(α＝η*α max)
式中：α max＝0.1～1rad；α∈[0,η*α max]；η∈[50％，80％]；
其中，L 2为所述一维光束偏转单元4距工件表面距离；f为所述一维光束偏转单元4不发生偏转时的焦距；α为一维光束偏转单元4使光束偏转角度，即α＝α(ξ)；α min为所述一维光束偏转单元4使光束最小偏转角度；α max为一维光束偏转单元4使光束最大偏转角度；η为一维光束偏转单元4安全使用系数；σ为焦点位置偏移量；σ min为焦点位置偏移量最小值；σ max为焦点位置偏移量最大值；Maxf res为一维光束偏转单元最高响应频率。
如图2、图3和图4所示，本发明所述的轧辊激光毛化加工方法，包括如下步骤：
S01加工区域划分：将轧辊表面加工区域均匀划分为若干轧辊加工单元；如图5所示，具体为：
确定轧辊表面加工区域；所述轧辊加工区域为长度L 01和宽度πd的方形区域，其中，L 01＝5％～100％L 0，L 0-01为距轧辊端面距离，L 0-01＝0～90％L 0；L 0为轧辊表面展开长度，d为轧辊直接；
将轧辊加工区域均匀划分为m个轧辊加工单元，任一轧辊加工单元长度为L 1，
Figure PCTCN2018124564-appb-000051
任一轧辊加工单元宽度为πd；其中，m∈{1,2,3…m max}，m max＝1～30。
S02确定分布方案：根据所述轧辊加工单元参数和形貌参数，通过可首尾相连无序均匀点阵分布设计方法得出可首尾相连的无序均匀分布毛化点阵分布方案；具体为：
如图6所示，设定毛化硬质点为激光熔凝加工形貌，根据形貌截面可分为球冠状毛化点、墨西哥帽状毛化点、火山口状毛化点，形貌具体参数为：
Figure PCTCN2018124564-appb-000052
式中：
B 1＝(30～200,0～5,3～30)μm
B 2＝(30～300,1～15,3～30)μm
B 3＝(30～300,1～30,1～10)μm
其中所述毛化硬质点加工所采用的输出激光参数，有激光脉冲宽度、激光功率、最高出光频率、辅助气体，具体如下：
Figure PCTCN2018124564-appb-000053
Figure PCTCN2018124564-appb-000054
Figure PCTCN2018124564-appb-000055
Figure PCTCN2018124564-appb-000056
其中：Morphology为形貌参数集合；B mor为第mor种形貌的形貌参数；D mor为第mor种形貌的直径；Depth mor为第mor种形貌的深度；H mor为第mor种形貌的高度；mor为形貌次序，mor＝1,2,3分别表示激光熔凝形貌的火山口状毛化点、球冠状毛化点、墨西哥帽状毛化点；Laser为形貌的激光加工参数集合；laser mor为第mor种形貌的激光加工参数；PluseWidth mor为第mor种形貌的激光加工脉宽；
Figure PCTCN2018124564-appb-000057
为第mor种形貌的激光加工功率；MaxfLas mor为第mor种形貌的激光加工最高出光频率；Gas mor为第mor种形貌的激光加工辅助气体种类。
步骤1-1：建立笛卡尔坐标系，将待加工单元区域沿轴向展开，形成长、宽分别为L 1、πd的方形表面，以起始毛化点为坐标原点，轴向为x轴，圆周方向为y轴，根据形貌分布建立均匀点阵分布毛化点圆心集A 0，详细步骤如下，步骤1-1-S1至步骤1-1-S4：
步骤1-1-S1：确定激光毛化硬质点形貌种类，确定mor值。
步骤1-1-S2：根据面积占有率初始值ρ0，计算形貌点距和线距的初始值a0、b0，具体如下：
Figure PCTCN2018124564-appb-000058
其中：ρ0为设定的形貌面积占有率初始值，一般ρ0＝50％；a0为形貌分布点距初始值，x方向两个毛化硬质点之间距离初始值；b0为形貌分布线距初始值，y方向两个硬质点之间距离初始值；D mor为第mor种形貌的直径；
步骤1-1-S3：修正形貌分布点距、线距和面积占有率，具体如下：
Figure PCTCN2018124564-appb-000059
其中：ρ为形貌面积占有率；a为形貌分布点距，x方向两个毛化硬质点之间距离；b为形貌分布线距，y方向两个毛化硬质点之间距离。
步骤1-1-S4：如图7所示，根据点距、线距建立均匀点阵分布毛化点圆心集A 0，具体为：
Figure PCTCN2018124564-appb-000060
其中：A 0为均匀点阵分布毛化点圆心坐标位置集；(x 0i,y 0j)为第i行第j列均匀点阵分布毛化点圆心坐标；i为行序号；i max为最大行序号，i max＝πd/b；j为列序号，
Figure PCTCN2018124564-appb-000061
j max为最大列序号；a为形貌分布点距，x方向两个毛化硬质点之间距离；b为形貌分布线距， y方向两个毛化硬质点之间距离；
步骤1-2：如图8所示，建立均匀点阵分布中每个毛化点随机位移向量集合ΔX，具体如下：
Figure PCTCN2018124564-appb-000062
其中：ΔX为均匀点阵分布中每个毛化点随机位移向量集合；(δx i,δy j)为均匀点阵分布中第i行、第j列均匀点阵分布毛化点圆心坐标(x 0i,y 0j)的随机位移向量；ε a为列偏移常量，一般ε a∈(0,2a]；ε b为行偏移常量，一般ε b∈(0,2b]，ε a＝ε b。
步骤1-3：由均匀点阵分布毛化点圆心坐标位置集A 0和均匀点阵分布中每个毛化点随机位移向量集合ΔX，计算无序均匀分布毛化点圆心集A，具体如下：
Figure PCTCN2018124564-appb-000063
其中：A，无序均匀分布毛化点圆心集；(x i,y j)，无序均匀分布毛化点圆心坐标；
步骤1-4：按毛化点重叠容忍度查找无序均匀分布坏点行序列、列序列的集SP，具体如下：
Figure PCTCN2018124564-appb-000064
其中：SP为无序均匀分布坏点行序列、列序列的集；A(i,j)为无序均匀分布毛化点圆心坐标集中第i、j个毛化点圆心坐标；(u q,w q)为第q个坏点坐标行序列、列序列；q为坏点排序号；ζ为无序均匀分布毛化点重叠容忍常量，一般ζ∈[0.5,1.5]。
步骤1-5：判断是否存在坏点，决定下一步，从而获得无序均匀分布毛化点圆心集，具体如下：
若
Figure PCTCN2018124564-appb-000065
存在坏点，则按以下进行计算，步骤1-5-S1至步骤1-5-S2：
步骤1-5-S1：根据无序均匀分布坏点集SP，调整随机位移向量集合ΔX，如图9所示，具体如下：
Figure PCTCN2018124564-appb-000066
式中：
Figure PCTCN2018124564-appb-000067
其中：ΔXre为调整后的随机位移向量集；(δxre i,δyre j)为调整后的随机位移向量；λ为坏点的随机位移向量的调整比例，一般λ∈(0,1)。
步骤1-5-S2：重复步骤1-3到步骤1-4，直至
Figure PCTCN2018124564-appb-000068
若
Figure PCTCN2018124564-appb-000069
不存在坏点，则进行步骤1-6。
步骤1-6：对无序均匀分布毛化点圆心集A以轴向中心线为基准，进行左右对调，以便多个激光末端输出模块加工区域的搭接，如图10所示，具体对调规则如下：
Figure PCTCN2018124564-appb-000070
其中：Aex为对无序均匀分布毛化点圆心集A以轴向中心线为基准进行左右对调后的无序均匀分布毛化点圆心集；(xex i,yex j)为左右对调后第i、j个毛化点圆心坐标；
步骤1-7：在左右对调过程后的中心线附近区域，按毛化点重叠容忍度查找无序均匀分布坏点行序列、列序列的集SPex，具体如下：
Figure PCTCN2018124564-appb-000071
其中：SPex为对左右对调过程后的中心线附近区域按毛化点重叠容忍度查找无序均匀分布坏点行序列、列序列的集；(uex qex,wex qex)为第qex个坏点坐标行序列、列序列；qex为 坏点排序号；Aex(i,j)为对调后的无序均匀分布毛化点圆心坐标集中第i、j个毛化点圆心坐标；Center为左右对调过程后的中心线附近区域：
Figure PCTCN2018124564-appb-000072
Figure PCTCN2018124564-appb-000073
为输入的中心线附近区域比例，一般
Figure PCTCN2018124564-appb-000074
步骤1-8：判断中心线附件区域是否存在坏点，决定下一步，从而最终获得无序均匀分布毛化点圆心集，具体如下：
若
Figure PCTCN2018124564-appb-000075
存在坏点，则按以下进行计算，步骤1-8-S1至步骤1-8-S2：
步骤1-8-S1：根据中心线附近区域无序均匀分布坏点集SPex，调整中心线附近区域坏点位置，具体如下：
Figure PCTCN2018124564-appb-000076
式中：
Figure PCTCN2018124564-appb-000077
其中：Are为中心线附近区域坏点位置调整后的无序均匀分布毛化点圆心坐标集；(xre i,yre j)为中心线区域坏点位置调整后的无序均匀分布毛化点圆心坐标集中第i、j个毛化点圆心坐标；
Figure PCTCN2018124564-appb-000078
为中心线附近区域坏点坐标调整比例，一般
Figure PCTCN2018124564-appb-000079
步骤1-8-S2：执行步骤1-6和1-7，直至
Figure PCTCN2018124564-appb-000080
若
Figure PCTCN2018124564-appb-000081
不存在坏点，则Aex为所设计的无序均匀分布毛化点阵分布方案。
S03确定输出信号：根据所述可首尾相连的无序均匀分布毛化点阵分布方案、机床参数和激光参数，通过信息处理模块得出激光出光位置信号、光束能量调节信号和一维光束偏转单元偏转信号，具体如下，步骤2-1至步骤2-8：
步骤2-1：计算激光末端输出模块相对于金属圆柱体表面的运动方向与圆柱体轴线方向的夹角，当一维光束偏转单元(4)不工作时即α＝0时也就是偏转量σ＝0时，焦点运动轨迹与x轴夹角θ，具体如下：
Figure PCTCN2018124564-appb-000082
其中：n为轧辊转速；v为激光末端输出模块的运行速度；
步骤2-2：对激光末端输出模块往复运动按加工顺序进行编号，即焦点运动轨迹序号集K，计算每个焦点运动轨迹绕金属圆柱体圈数集P，具体如下：
k∈K＝{1,2,3,…k max}，式中：
Figure PCTCN2018124564-appb-000083
p∈P＝{1,2,3…p max}，式中：
Figure PCTCN2018124564-appb-000084
其中：K为焦点运动轨迹序号集；k为第k个焦点运动轨迹，即第k次加工过程；P为每个焦点运动轨迹绕金属圆柱体圈数集；p为焦点运动轨迹绕金属圆柱体第p圈；
步骤2-3：如图11所示，计算激光末端输出模块每次加工过程中焦点覆盖范围Λ k的集合Λ，一维光束偏转单元(4)偏转角度α∈[0,η*α max]时，激光末端输出模块第k次加工过程中焦点覆盖范围Λ k的集合Λ，具体为：
Figure PCTCN2018124564-appb-000085
式中，
Figure PCTCN2018124564-appb-000086
Figure PCTCN2018124564-appb-000087
其中：Λ为激光末端输出模块每次加工过程中焦点覆盖范围的集合；Λ k为激光末端输出模块第k次加工过程中焦点覆盖范围；xk min(y,p)＝xk(y,p,σ＝0)为偏转角度α＝0即偏转 量σ＝0时，第k条第p圈焦点运动轨迹方程；xk max(y,p)＝xk(y,p,σ＝σ max)为偏转角度α＝η*α max即偏转量σ＝σ max时，第k条第p圈焦点运动轨迹方程；
步骤2-4：统计激光末端输出模块每次加工过程中焦点覆盖范围中的无序均匀毛化点圆心坐标的集合Φ，具体如下：
Φ＝{Φ k|k＝1,2,3…k max}，
式中：
Figure PCTCN2018124564-appb-000088
其中，Φ为激光末端输出模块每次加工过程中焦点覆盖范围中的无序均匀毛化点圆心坐标集的集合；Φ k为激光末端输出模块第k次加工过程中焦点覆盖范围Λ k中的无序均匀毛化点圆心坐标集，即圆心坐标落在xk min＝xk(y,σ＝0)、xk max＝xk(y,σ＝σ max)两条轨迹线之间的毛化点圆心坐标集；(x rk,y rk)为第k次加工过程中包含的第rk个无序均匀毛化点圆心坐标；rk为第k次加工过程中包含的无序均匀毛化点统计次序；
步骤2-5：如图12和图13所示，对统计来的第k次加工过程中的焦点覆盖范围Λ k中的无序均匀毛化点圆心坐标，按照毛化点加工先后顺序进行排序，得到排序后的毛化点圆心坐标集Ω k，具体排序规则如下：
Figure PCTCN2018124564-appb-000089
其中：Ω k为第k次加工过程中焦点覆盖范围Λ k中的无序均匀毛化点圆心坐标，按照毛化点加工顺序进行排序后形成的圆心坐标集；(x τk,y τk)为第k次加工过程中第τk个加工的毛化点坐标；τk为第k次加工过程中毛化点加工顺序排序；rk max为第k次加工过程中焦点覆盖范围Λ k中包含的无序均匀毛化点数量统计值最大值；(y rk) max为第k次加工过程中焦点覆盖范围Λ k中的无序均匀毛化点圆心坐标(x rk,y rk)的y轴坐标最大值；(y rk) min为第k次加工过程中焦点覆盖范围Λ k中的无序均匀毛化点圆心坐标(x rk,y rk)的y轴坐标最小值；
步骤2-6：以加工系统响应频率为依据，查找在第k次加工过程中焦点覆盖范围Λ k中的按加工先后顺序排列的无序均匀毛化点圆心坐标集Ω k中的加工奇点的集合MSP k，具体查找方式 如下：
Figure PCTCN2018124564-appb-000090
式中：
Figure PCTCN2018124564-appb-000091
其中：MSP k为Ω k中的加工奇点的集合；msp mk为第k次加工过程中加工奇点的加工顺序序号；F为加工系统综合响应频率；MaxfLas mor为形貌加工的最大输出激光出光频率；MaxfP res为光束能量调节单元5最高响应频率；MaxfEX res为一维光束偏转单元4最高响应频率；R encoder为轧辊旋转同轴编码器2分辨率；
Figure PCTCN2018124564-appb-000092
为系统响应频率安全系数，一般
Figure PCTCN2018124564-appb-000093
步骤2-7：如图14所示，判断是否存在加工奇点，若
Figure PCTCN2018124564-appb-000094
且k∈K，则存在加工奇点，进行步骤2-7-S1～S2：
步骤2-7-S1：如图15所示，根据Ω k中的加工奇点的集合MSP k对第k次加工过程中焦点覆盖范围Λ k中的按加工先后顺序排列的无序均匀毛化点圆心坐标集Ω k进行调整，具体如下：
Figure PCTCN2018124564-appb-000095
式中，
Figure PCTCN2018124564-appb-000096
其中：Ωre k为调整后第k次加工过程中焦点覆盖范围Λ k中的按加工先后顺序排列的无序均匀毛化点圆心坐标集；(xre τk,yre τk)为调整后的第k次加工过程中第τk个加工的毛化点圆心坐标；Δ τk为第k次加工过程中第τk个加工的毛化点的圆心坐标y轴坐标调整量；γ为y轴坐标调整量的调整比例，一般γ∈(0,1)；
步骤2-7-S2：重复步骤2-5和步骤2-6，直至
Figure PCTCN2018124564-appb-000097
若
Figure PCTCN2018124564-appb-000098
不存在加工奇点，则进行步骤2-8。
步骤2-8：根据每次加工过程中焦点覆盖范围中的按加工先后顺序排列的无序均匀毛化点 坐标，计算每次加工过程中各个激光末端输出模块的激光出光位置信号-光束能量调节信号-一维光束偏转单元偏转信号的信号集的集合ΓLine m，具体如下：
Figure PCTCN2018124564-appb-000099
式中：
Figure PCTCN2018124564-appb-000100
其中：ΓLine m为每次加工过程中第m个激光末端输出模块的激光出光位置信号-光束能量调节信号-一维光束偏转单元偏转信号的信号集的集合；
Figure PCTCN2018124564-appb-000101
为加工第k次加工过程中焦点覆盖范围中的按加工顺序排列的无序均匀毛化点第m个激光末端输出模块所需的激光出光位置信号-光束能量调节信号-一维光束偏转单元偏转信号的信号集；(β τk,ψm τk,ξ τk)为第k次加工过程中加工第τk个毛化点给加工系统发出的同样的激光出光位置信号、第m个激光末端输出模块的光束能量调节信号和同样的一维光束偏转单元偏转信号；p τk为第k次加工过程中加工第τk个毛化点所在圈数；
Figure PCTCN2018124564-appb-000102
为光束能量调节单元5激光能量最大衰减比例常量，一般
Figure PCTCN2018124564-appb-000103
S04轧辊激光毛化加工：所述激光出光位置信号用于控制光源模块发出激光；所述光束能量调节信号和一维光束偏转单元偏转信号分别输入激光末端输出模块，用于产生无序的激光点阵，每个激光末端输出模块用于加工一个轧辊加工单元。
所述精确控制方法为：待加工金属圆柱体1与激光末端输出模块同步运动，确定了加工形貌种类后，计算机自动的确定加工激光的参数，激光光源多次分光后分别进入各激光末端输出模块，根据计算机计算得到的激光出光位置信号-光束能量调节信号-一维光束偏转信号的信号集，检测同轴编码器2瞬时位置信号与激光出光位置信号一致性，在激光末端输出模块处于确定位置时发出确定参数输入激光，同时给每个激光末端输出模块的光束能量调节单元不同的信号，完成能量衰减调节，并给每个激光末端输出模块的一维光束偏转单元同样的信号，完成光束一维偏转，使得各个激光末端输出模块的激光焦点按所设计无序均匀分布点 阵方案，采用不同的激光能量依次加工毛化硬质点。
其中所述轧辊与激光末端输出模块的同步运动为轧辊即待加工金属圆柱体1沿轴线方向匀速旋转，同轴编码器2与轧辊同轴同步旋转，转速为n，参数范围为n＝200rpm，各激光末端输出模块在轧辊自转的同时沿轧辊轴线方向匀速直线往复运动，往复运动范围为
Figure PCTCN2018124564-appb-000104
所述往复运动起始线为
Figure PCTCN2018124564-appb-000105
终止线为x＝L 1，运动速度υ，范围为υ＝200mm/s，激光末端输出模块匀速往返运动过程中，每次运动速度方向改变时，在原地等待时间Δt。
其中所述同轴编码器2，具有如下特性：具有固定的同轴编码器分辨率R encoder，是同轴编码器固有属性，范围为R encoder∈[2 16,2 20]。
上述方案中，所述激光末端输出模块匀速往返运动过程中，每次运动速度方向改变时，在原地等待时间Δt，
Figure PCTCN2018124564-appb-000106
上述方案中，所述激光末端输出模块沿待加工圆柱体轴线匀速水平往返运动，通过位置传感器或光栅尺，实时监控激光头相对于起始加工点x周方向位移Δx t，对照同轴编码器2瞬时旋转角度β t，β t∈[0,2π]，保证
Figure PCTCN2018124564-appb-000107
适时调整激光头位置。
所述实施例为本发明的优选的实施方式，但本发明并不限于上述实施方式，在不背离本发明的实质内容的情况下，本领域技术人员能够做出的任何显而易见的改进、替换或变型均属于本发明的保护范围。

Claims (10)

  1. 一种轧辊激光毛化加工方法，其特征在于，包括如下步骤：
    加工区域划分：将轧辊表面加工区域均匀划分为若干轧辊加工单元；
    确定分布方案：根据所述轧辊加工单元参数和形貌参数，通过可首尾相连无序均匀点阵分布设计方法得出可首尾相连的无序均匀分布毛化点阵分布方案；
    确定输出信号：根据所述可首尾相连的无序均匀分布毛化点阵分布方案、机床参数和激光参数，通过信息处理模块得出激光出光位置信号、光束能量调节信号和一维光束偏转单元偏转信号；
    轧辊激光毛化加工：所述激光出光位置信号用于控制光源模块发出激光；所述光束能量调节信号和一维光束偏转单元偏转信号分别输入激光末端输出模块，用于产生无序的激光点阵，每个激光末端输出模块用于加工一个轧辊加工单元。
  2. 根据权利要求1所述的轧辊激光毛化加工方法，其特征在于，加工区域划分具体为：
    确定轧辊表面加工区域；所述轧辊加工区域为长度L 01和宽度πd的方形区域，其中，L 01＝5％～100％L 0，L 0-01为距轧辊端面距离，L 0-01＝0～90％L 0；L 0为轧辊表面展开长度，d为轧辊直接；
    将轧辊加工区域均匀划分为m个轧辊加工单元，任一轧辊加工单元长度为L 1，
    Figure PCTCN2018124564-appb-100001
    任一轧辊加工单元宽度为πd；其中，m∈{1,2,3…m max}，m max＝1～30。
  3. 根据权利要求1所述的轧辊激光毛化加工方法，其特征在于，所述激光末端输出模块包括光束折返单元(6)、光束能量调节单元(5)和一维光束偏转单元(4)；所述光源模块入射的激光依次经过光束折返单元(6)、光束能量调节单元(5)和一维光束偏转单元(4)后入射轧辊加工单元；
    所述光束折返单元(6)用于将光源模块入射的激光分光为垂直于轧辊轴线方向的反射激光和平行于轧辊轴线方向的透射激光；所述反射激光射入所述光束能量调节单元(5)，所述透射激光射入下一个激光末端输出模块；
    所述光束能量调节单元(5)用于改变所述反射激光的能量；
    所述一维光束偏转单元(4)用于偏移所述反射激光的角度。
  4. 根据权利要求3所述的轧辊激光毛化加工方法，其特征在于，所述光束折返单元(6)通过各半反镜片镀膜性质不同，使反射激光和透射激光能量比例为：
    Figure PCTCN2018124564-appb-100002
    Figure PCTCN2018124564-appb-100003
    其中，P m为第Line m个激光末端输出模块中光束折返单元(6)分光的反射激光功率；
    P m-为第Line m个激光末端输出模块中光束折返单元(6)分光的透射激光功率；
    P input为光源模块输出的激光光源功率；
    P output为激光末端输出模块输入激光功率；
    所述光束能量调节单元(5)根据输入的电信号ψ使光束能量衰减固定值，即P focus＝(1-Damp(ψ))P output，其中，ψ为光束能量调节单元(5)驱动电源输入电信号，ψ∈[ψ min,ψ max]，对应能量衰减比例Damp(ψ)从0～100％变化；ψ min为最小输入电信号；ψ max为最大输入电信号；Damp(ψ)为激光能量衰减比例；P focus为所述光束能量调节单元(5)输出的激光功率；
    所述一维光束偏转单元(4)根据输入电信号ξ使光束一维偏转固定角度α，经过聚焦镜片作用在待加工区域，使得焦点相对于光轴偏移确定距离σ，
    σ＝f(α,L 2,f)＝f(α(ξ),L 2,f)，
    σ min＝f(α min,L 2,f)＝f(0,L 2,f)
    σ max＝f(η*α max,L 2,f)
    其中，L 2为所述一维光束偏转单元(4)距工件表面距离；f为所述一维光束偏转单元(4)不发生偏转时的焦距；α为一维光束偏转单元(4)使光束偏转角度，即α＝α(ξ)；α min为所述一维光束偏转单元(4)使光束最小偏转角度；α max为一维光束偏转单元(4)使光束最大偏转角度；η为一维光束偏转单元(4)安全使用系数；σ为焦点位置偏移量；σ min为焦点位置偏移量最小值；σ max为焦点位置偏移量最大值。
  5. 根据权利要求1所述的轧辊激光毛化加工方法，其特征在于，所述可首尾相连无序均匀点阵分布设计方法具体包括如下步骤：
    根据形貌参数分布建立均匀点阵分布毛化点圆心集A 0，具体为：
    Figure PCTCN2018124564-appb-100004
    其中：A 0为均匀点阵分布毛化点圆心坐标位置集；(x 0i,y 0j)为第i行第j列均匀点阵分布毛化点圆心坐标；i为行序号；i max为最大行序号，i max＝πd/b；j为列序号，
    Figure PCTCN2018124564-appb-100005
    j max为最大列序号；a为形貌分布点距，x方向两个毛化硬质点之间距离；b为形貌分布线距，y方向两个毛化硬质点之间距离；
    建立均匀点阵分布中每个毛化点随机位移向量集合ΔX，具体如下：
    Figure PCTCN2018124564-appb-100006
    其中：ΔX为均匀点阵分布中每个毛化点随机位移向量集合；(δx i,δy j)为均匀点阵分布中第i行、第j列均匀点阵分布毛化点圆心坐标(x 0i,y 0j)的随机位移向量；ε a为列偏移常量；ε b为行偏移常量；
    建立无序均匀分布毛化点圆心集A：将均匀点阵分布毛化点圆心坐标位置集A 0和均匀点阵分布中每个毛化点随机位移向量集合ΔX叠加：
    Figure PCTCN2018124564-appb-100007
    其中：A，无序均匀分布毛化点圆心集；(x i,y j)，无序均匀分布毛化点圆心坐标；
    查找坏点：按毛化点重叠容忍度查找无序均匀分布坏点行序列、列序列的集SP，具体如下：
    Figure PCTCN2018124564-appb-100008
    其中：SP为无序均匀分布坏点行序列、列序列的集；A(i,j)为无序均匀分布毛化点圆心坐标集中第i、j个毛化点圆心坐标；(u q,w q)为第q个坏点坐标行序列、列序列；q为坏点排序号；
    Figure PCTCN2018124564-appb-100009
    为无序均匀分布毛化点重叠容忍常量；
    判断是否存在坏点：当
    Figure PCTCN2018124564-appb-100010
    时，则存在坏点，则根据无序均匀分布坏点集SP，调整随机位移向量集合ΔX，重复建立无序均匀分布毛化点圆心集A和查找坏点，直至
    Figure PCTCN2018124564-appb-100011
    当
    Figure PCTCN2018124564-appb-100012
    时，则不存在坏点；
    建立无序均匀分布毛化点圆心集A以轴向中心线为基准进行左右对调后的无序均匀分布毛化点圆心集Aex：当
    Figure PCTCN2018124564-appb-100013
    时，对无序均匀分布毛化点圆心集A以轴向中心线为基准进行左右对调，以便多个激光末端输出模块加工区域的搭接：
    Figure PCTCN2018124564-appb-100014
    其中：Aex为对无序均匀分布毛化点圆心集A以轴向中心线为基准进行左右对调后的无序均匀分布毛化点圆心集；(xex i,yex j)为左右对调后第i、j个毛化点圆心坐标；
    查找中心线附近区域坏点：在左右对调过程后的中心线附近区域，按毛化点重叠容忍度查找无序均匀分布坏点行序列、列序列的集SPex，具体为：
    Figure PCTCN2018124564-appb-100015
    其中：SPex为对左右对调过程后的中心线附近区域按毛化点重叠容忍度查找无序均匀分布坏点行序列、列序列的集；(uex qex,wex qex)为第qex个坏点坐标行序列、列序列；qex为坏点排序号；Aex(i,j)为对调后的无序均匀分布毛化点圆心坐标集中第i、j个毛化点圆心坐标；Center为左右对调过程后的中心线附近区域：
    Figure PCTCN2018124564-appb-100016
    为输入的中心线附近区域比例；
    判断中心线附件区域是否存在坏点：当
    Figure PCTCN2018124564-appb-100017
    则存在坏点，则根据中心线附近区域无序均匀分布坏点集SPex，调整中心线附近区域坏点位置，重复建立无序均匀分布毛化点圆心集A以轴向中心线为基准进行左右对调后的无序均匀分布毛化点圆心集Aex和查找中心线附近区域坏点，直至
    Figure PCTCN2018124564-appb-100018
    当
    Figure PCTCN2018124564-appb-100019
    时，则不存在坏点，即Aex为所述可首尾相连的无序均匀分布毛化点阵分布方案。
  6. 根据权利要求5所述的轧辊激光毛化加工方法，其特征在于，所述根据无序均匀分布 坏点集SP，调整随机位移向量集合ΔX，具体为：
    Figure PCTCN2018124564-appb-100020
    式中：
    Figure PCTCN2018124564-appb-100021
    其中：ΔXre为调整后的随机位移向量集；(δxre i,δyre j)为调整后的随机位移向量；λ为坏点的随机位移向量的调整比例；
    所述根据中心线附近区域无序均匀分布坏点集SPex，调整中心线附近区域坏点位置，具体为：
    Figure PCTCN2018124564-appb-100022
    式中：
    Figure PCTCN2018124564-appb-100023
    其中：Are为中心线附近区域坏点位置调整后的无序均匀分布毛化点圆心坐标集；(xre i,yre j)为中心线区域坏点位置调整后的无序均匀分布毛化点圆心坐标集中第i、j个毛化点圆心坐标；
    Figure PCTCN2018124564-appb-100024
    为中心线附近区域坏点坐标调整比例。
  7. 根据权利要求4所述的轧辊激光毛化加工方法，其特征在于，通过信息处理模块得出激光出光位置信号、光束能量调节信号和一维光束偏转单元偏转信号具体为如下步骤：
    确定焦点运动轨迹与轧辊轴向夹角：当一维光束偏转单元(4)不工作时即α＝0时，焦点运动轨迹与轧辊轴向夹角θ：
    Figure PCTCN2018124564-appb-100025
    其中：n为轧辊转速；v为激光末端输出模块的运行速度；
    确定焦点运动轨迹序号集K和计算每个焦点运动轨迹绕金属圆柱体圈数集P，
    k∈K＝{1,2,3,…k max}，式中：
    Figure PCTCN2018124564-appb-100026
    p∈P＝{1,2,3…p max}，式中：
    Figure PCTCN2018124564-appb-100027
    其中：K为焦点运动轨迹序号集；k为第k个焦点运动轨迹，即第k次加工过程；P为每个焦点运动轨迹绕金属圆柱体圈数集；p为焦点运动轨迹绕金属圆柱体第p圈；
    确定一维光束偏转单元(4)偏转角度α∈[0,η*α max]时，激光末端输出模块第k次加工过程中焦点覆盖范围Λ k的集合Λ，具体为：
    Figure PCTCN2018124564-appb-100028
    式中，
    Figure PCTCN2018124564-appb-100029
    Figure PCTCN2018124564-appb-100030
    其中：Λ为激光末端输出模块每次加工过程中焦点覆盖范围的集合；Λ k为激光末端输出模块第k次加工过程中焦点覆盖范围；xk min(y,p)＝xk(y,p,σ＝0)为偏转角度α＝0即偏转量σ＝0时，第k条第p圈焦点运动轨迹方程；xk max(y,p)＝xk(y,p,σ＝σ max)为偏转角 度α＝η*α max即偏转量σ＝σ max时，第k条第p圈焦点运动轨迹方程；
    统计激光末端输出模块每次加工过程中焦点覆盖范围中的无序均匀毛化点圆心坐标的集合Φ，具体如下：
    Φ＝{Φ k|k＝1,2,3…k max}，
    式中：
    Figure PCTCN2018124564-appb-100031
    其中，Φ为激光末端输出模块每次加工过程中焦点覆盖范围中的无序均匀毛化点圆心坐标集的集合；Φ k为激光末端输出模块第k次加工过程中焦点覆盖范围Λ k中的无序均匀毛化点圆心坐标集，即圆心坐标落在xk min＝xk(y,σ＝0)、xk max＝xk(y,σ＝σ max)两条轨迹线之间的毛化点圆心坐标集；(x rk,y rk)为第k次加工过程中包含的第rk个无序均匀毛化点圆心坐标；rk为第k次加工过程中包含的无序均匀毛化点统计次序；
    确定第k次加工过程中排序后的毛化点圆心坐标集Ω k：按照毛化点加工先后顺序对(x rk,y rk)进行排序得到排序后的毛化点圆心坐标集Ω k，具体排序规则如下：
    Figure PCTCN2018124564-appb-100032
    其中：Ω k为第k次加工过程中焦点覆盖范围Λ k中的无序均匀毛化点圆心坐标，按照毛化点加工顺序进行排序后形成的圆心坐标集；(x τk,y τk)为第k次加工过程中第τk个加工的毛化点坐标；τk为第k次加工过程中毛化点加工顺序排序；rk max为第k次加工过程中焦点覆盖范围Λ k中包含的无序均匀毛化点数量统计值最大值；(y rk) max为第k次加工过程中焦点覆盖范围Λ k中的无序均匀毛化点圆心坐标(x rk,y rk)的y轴坐标最大值；(y rk) min为第k次加工过程中焦点覆盖范围Λ k中的无序均匀毛化点圆心坐标(x rk,y rk)的y轴坐标最小值；
    查找Ω k中的加工奇点的集合MSP k：根据加工系统响应频率查找Ω k中的加工奇点的集合MSP k，具体查找方式如下：
    Figure PCTCN2018124564-appb-100033
    式中：
    Figure PCTCN2018124564-appb-100034
    其中：MSP k为Ω k中的加工奇点的集合；msp mk为第k次加工过程中加工奇点的加工顺序序号；F为加工系统综合响应频率；Maxf Las mor为加工第mor种形貌的输出激光最大出光频率；Maxf P res为光束能量调节单元(5)最高响应频率；Maxf EX res为一维光束偏转单元(4)最高响应频率；R encod为轧辊旋转同轴编码器(2)分辨率；
    Figure PCTCN2018124564-appb-100035
    为系统响应频率安全系数；
    判断是否存在加工奇点：当
    Figure PCTCN2018124564-appb-100036
    且k∈K，则存在加工奇点，根据Ω k中的加工奇点的集合MSP k对第k次加工过程中焦点覆盖范围Λ k中的按加工先后顺序排列的无序均匀毛化点圆心坐标集Ω k进行调整，重复确定第k次加工过程中排序后的毛化点圆心坐标集Ω k和查找Ω k中的加工奇点的集合MSP k，直至
    Figure PCTCN2018124564-appb-100037
    当
    Figure PCTCN2018124564-appb-100038
    时，则不存在坏点；
    当
    Figure PCTCN2018124564-appb-100039
    且k∈K，计算激光末端输出模块的激光出光位置信号-光束能量调节信号-一维光束偏转单元偏转信号的信号集的集合ΓLine m：
    Figure PCTCN2018124564-appb-100040
    式中：
    Figure PCTCN2018124564-appb-100041
    m∈{1,2,3…m max}，
    其中：ΓLine m为每次加工过程中第m个激光末端输出模块的激光出光位置信号-光束能量调节信号-一维光束偏转单元偏转信号的信号集的集合；
    Figure PCTCN2018124564-appb-100042
    为加工第k次加工过程中焦点覆盖范围中的按加工顺序排列的无序均匀毛化点第m个激光末端输出模块所需的激 光出光位置信号-光束能量调节信号-一维光束偏转单元偏转信号的信号集；(β τk,ψm τk,ξ τk)为第k次加工过程中加工第τk个毛化点给加工系统发出的同样的激光出光位置信号、第m个激光末端输出模块的光束能量调节信号和同样的一维光束偏转单元偏转信号；p τk为第k次加工过程中加工第τk个毛化点所在圈数；
    Figure PCTCN2018124564-appb-100043
    为光束能量调节单元(5)激光能量最大衰减比例常量。
  8. 根据权利要求7所述的轧辊激光毛化加工方法，其特征在于，根据Ω k中的加工奇点的集合MSP k对第k次加工过程中焦点覆盖范围Λ k中的按加工先后顺序排列的无序均匀毛化点圆心坐标集Ω k进行调整具体为：
    Figure PCTCN2018124564-appb-100044
    式中，
    Figure PCTCN2018124564-appb-100045
    其中：Ωre k为调整后第k次加工过程中焦点覆盖范围Λ k中的按加工先后顺序排列的无序均匀毛化点圆心坐标集；(xre τk,yre τk)为调整后的第k次加工过程中第τk个加工的毛化点圆心坐标；Δ τk为第k次加工过程中第τk个加工的毛化点的圆心坐标y轴坐标调整量；γ为y轴坐标调整量的调整比例。
  9. 根据权利要求5所述的轧辊激光毛化加工方法，其特征在于，所述形貌分布点距a和形貌分布线距b的确定方法如下：
    确定激光毛化硬质点形貌种类；
    根据面积占有率初始值ρ0，计算形貌点距a0的初始值和线距的初始值b0，具体如下：
    Figure PCTCN2018124564-appb-100046
    其中：ρ0为设定的形貌面积占有率初始值；a0为形貌分布点距初始值，x方向两个毛化硬质点之间距离初始值；b0为形貌分布线距初始值，y方向两个硬质点之间距离初始值；D mor为第mor种形貌的直径；
    修正形貌分布点距、线距和面积占有率，具体如下：
    Figure PCTCN2018124564-appb-100047
    其中：ρ为形貌面积占有率；a为形貌分布点距，x方向两个毛化硬质点之间距离；b为形貌分布线距，y方向两个毛化硬质点之间距离。
  10. 一种根据权利要求1所述的轧辊激光毛化加工方法的加工设备，其特征在于，包括计算机、光源模块和激光末端输出模块；所述计算机包括可首尾相连无序均匀点阵分布设计模块和信号处理模块；根据轧辊加工单元参数和形貌参数，通过可首尾相连无序均匀点阵分布设计模块输出可首尾相连的无序均匀分布毛化点阵分布方案；根据所述可首尾相连的无序均匀分布毛化点阵分布方案、机床参数和激光参数，通过信息处理模块得出激光出光位置信号、光束能量调节信号和一维光束偏转单元偏转信号；
    所述激光出光位置信号用于控制光源模块发出激光；
    所述光束能量调节信号和一维光束偏转单元偏转信号分别输入激光末端输出模块，用于产生无序的激光点阵，每个激光末端输出模块用于加工一个轧辊加工单元；
    每个所述激光末端输出模块在对应的轧辊加工单元区域轴向往复移动，所述往复运动起始线为
    Figure PCTCN2018124564-appb-100048
    终止线为x＝L 1。
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