CN107451382B - Control method for surface appearance of high-speed cutting workpiece - Google Patents
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- 238000005520 cutting process Methods 0.000 title claims abstract description 157
- 238000000034 method Methods 0.000 title claims abstract description 13
- 238000003801 milling Methods 0.000 claims abstract description 5
- 238000006073 displacement reaction Methods 0.000 claims description 12
- 230000004069 differentiation Effects 0.000 claims description 9
- 239000000463 material Substances 0.000 claims description 9
- 238000003754 machining Methods 0.000 claims description 8
- 238000004519 manufacturing process Methods 0.000 claims description 6
- 239000011159 matrix material Substances 0.000 claims description 6
- 230000009466 transformation Effects 0.000 claims description 6
- 238000013016 damping Methods 0.000 claims description 3
- 238000013507 mapping Methods 0.000 claims description 3
- 238000010008 shearing Methods 0.000 claims description 2
- 238000006243 chemical reaction Methods 0.000 claims 1
- 238000012876 topography Methods 0.000 claims 1
- 238000005516 engineering process Methods 0.000 abstract description 3
- 238000007514 turning Methods 0.000 abstract description 2
- 230000003746 surface roughness Effects 0.000 description 3
- 238000013528 artificial neural network Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 238000000611 regression analysis Methods 0.000 description 1
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Abstract
The patent discloses a control method for high-speed cutting processing workpiece surface appearance, which can be widely applied to mechanical processing technologies such as turning, milling, planing, drawing, inserting and the like, can be used for processing a plane and controlling the surface appearance of a processed curved surface, and realizes the control of the roughness of the preset surface of a processed workpiece.
Description
Technical Field
The invention belongs to the technical field of machining processes, and relates to a control method for the surface appearance of a high-speed cutting workpiece.
Background
With the ever-developing scientific technology, the higher requirements on the surface appearance of the workpiece in the high-speed cutting process are provided, that is, the control method for obtaining the preset roughness of the surface of the machined workpiece is far from enough, and the control on the appearance (wave crest, wave trough, spacing thereof and the like) of different preset positions on the surface of the workpiece needs to be realized. In the traditional machining, the surface roughness of a workpiece machined in a cutting mode is not predicted, and a method for optimizing cutting parameters according to the predicted surface roughness cannot control the surface appearance of the workpiece machined at a high speed.
At present, only a prediction method of the surface roughness of a cutting workpiece exists, and methods such as regression analysis and neural network are adopted, so that the processing control of the preset appearance of the preset surface of the workpiece cannot be realized, and the requirements are difficult to meet. The invention can realize the control of the surface appearance only by carrying out a plurality of groups of cutting processing tests with preset cutting parameters, and has the advantages of low cost, high efficiency and high precision.
Disclosure of Invention
In order to overcome the defects of the prior art, the patent discloses a control method for the surface appearance of a high-speed cutting workpiece, which can be widely applied to mechanical processing technologies such as turning, milling, planing, drawing, inserting and the like, can be used for controlling the surface appearance of a processing plane and a processing curved surface, and realizes the control of the preset roughness of the surface of the processing workpiece.
In order to achieve the purpose, the technical scheme of the invention is as follows:
the invention mainly comprises a three-dimensional surface profiler and a data processing system, the core of the invention is the data processing system, and the concrete steps are as follows: .
A control method for high-speed cutting processing workpiece surface appearance is characterized by comprising the following steps:
determining geometric parameters of a cutter, wherein the geometric parameters comprise a front angle gamma, a rear angle, an installed blade inclination angle and parameters of a manufacturing material, and the parameters of the manufacturing material comprise hardness and density;
step two, obtaining 1 or more groups of tangential, radial and axial cutting force coefficients under different cutting parameters: ktc,Krc,Kac,Kte,Kre,KaeWherein, K istcRepresenting the tangential force coefficient; krcRepresents the radial force coefficient; kacRepresenting the axial force coefficient; kteExpressing the coefficient of tangential edge force, KreRepresenting the radial cutting edge force coefficient; kaeRepresenting the axial edge force coefficient, t the tangential direction, r the radial direction, a the axial direction, c the force coefficient, e the edge force coefficient, then:
β=arcsin(sinη·sini+cosη·cosi·cosα)
gamma is the tool rake angle, η denotes the angle of the chip flow direction to the direction perpendicular to the tool cutting edge, i denotes the angle of the cutting edge to the direction perpendicular to the workpiece motion,is the normal shear angle of the cutting tool shear plane, theta is the position angle of the cutting tool during cutting, β is the effective rake angle, α is the tool relief angle, h is the cutting thickness, dMeans differentiation; z represents the z direction of the workpiece coordinate system x-y-z, dz is an axial cutting depth infinitesimal, d represents differentiation, and h represents cutting thickness; fx represents the x-direction cutting force; fy represents a y-direction cutting force, and Fz represents a z-direction cutting force;
and step three, carrying out a high-speed milling test under the set cutting force coefficient to obtain the surface profile of the machined workpiece, wherein the surface profile of the workpiece is formed by the relative displacement between the cutter and the workpiece in a cutting machining system, namely if no vibration exists, the workpiece is an ideal surface, and the surface profile is equal to the relative displacement X between the cutter and the workpiece1(T);
X, Y and Z represent the relative displacement of the tool tip and the workpiece in the X, Y and Z directions under the workpiece coordinate system X-Y-Z.
Step four, establishing a cutting force model according to the instantaneous rigid force model of the high-speed cutting machining:
Ft=∫Ktc·h·dz+Kte·ds
dFt=Ktc·h·dz+Kte·ds
dFr=Krc·h·dz+Kre·ds
dFa=Kac·h·dz+Kae·ds
wherein, FtDenotes the tangential cutting force, FrDenotes the radial cutting force, FaThe axial cutting force is shown, and h is the cutting thickness; z represents the z-direction of the object coordinate system x-y-z; dFtIs a tangential force infinitesimal, dFrIs a radial force infinitesimal, dFaIs axial force infinitesimal, ds is cutting edge length infinitesimal, dz is axial cutting depth infinitesimalElement, d represents differentiation, h represents cutting thickness;
and step five, establishing a dynamic model of the relative motion of the high-speed cutting workpiece and the cutter according to a mechanical vibration theory, wherein the dynamic model comprises the following steps:
wherein M is1For cutting system equivalent mass, C1(T) is the equivalent damping coefficient of the cutting system, K1(T) is the equivalent stiffness of the cutting system, f1(T) cutting force, x1(T) represents a vibration displacement function, T represents time;
step six, converting the t-r-a coordinate cutting force of the cutting surface of the cutter into an x-y-z coordinate cutting force through coordinates:
wherein, theta1,β1When the t-r-a coordinate of the cutting surface of the cutter is converted to a coordinate system x-y-z, the rotating angle of the coordinate of the cutting surface around the a axis and the rotating angle around the t axis are respectively; a. the3-rRepresenting the rotation theta of the t-r-a coordinate of the cutting surface of the tool about the a-axis1A transformation matrix of angles, r represents the radial direction of the cutting process; a. ther-aRepresenting the rotation theta of the t-r-a coordinate of the cutting surface of the tool about the a-axis1Rotation β of coordinate system around t-axis after angular rotation1A coordinate transformation matrix of the angle; fx represents the x-direction cutting force; fy represents a y-direction cutting force, and Fz represents a z-direction cutting force;
seventhly, obtaining enough three or more groups of surface profile shapes X1(T), i.e. M is obtained1,C1(T),K1(T) establishing a mapping rule of cutting processing and workpiece surface appearance;
step eight, obtaining the geometric parameters and cutting parameters of the cutter material required by the surface profile appearance X (T) of any workpiece under the same high-speed cutting machine tool through the dynamic model in the step five; the control of the surface appearance of the high-speed cutting processing is realized.
In a further improvement, in the third step, the surface profile of the machined workpiece is obtained by a three-dimensional surface profiler.
Detailed Description
Example 1
A control method for high-speed cutting processing workpiece surface appearance comprises the following steps:
determining geometric parameters of a cutter, wherein the geometric parameters comprise a front angle gamma, a rear angle, an installed blade inclination angle and parameters of a manufacturing material, and the parameters of the manufacturing material comprise hardness and density;
step two, obtaining 1 or more groups of tangential, radial and axial cutting force coefficients under different cutting parameters: ktc,Krc,Kac,Kte,Kre,KaeWherein, K istcRepresenting the tangential force coefficient; krcRepresents the radial force coefficient; kacRepresenting the axial force coefficient; kteExpressing the coefficient of tangential edge force, KreRepresenting the radial cutting edge force coefficient; kaeRepresenting the axial edge force coefficient, t the tangential direction, r the radial direction, a the axial direction, c the force coefficient, e the edge force coefficient, then:
β=arcsin(sinη·sini+cosη·cosi·cosα)
gamma is the tool rake angle, η denotes the angle of the chip flow direction to the direction perpendicular to the tool cutting edge, i denotes the angle of the cutting edge to the direction perpendicular to the workpiece motion,the cutting tool cutting depth is a normal cutting angle of a cutting tool shearing surface, theta is a position angle of the cutting tool in the cutting process, β is an effective front angle, α is a cutting tool rear angle, h is a cutting thickness, d is a differentiation value, z is the z direction of a workpiece coordinate system x-y-z, dz is an axial cutting depth infinitesimal, d is a differentiation value, h is a cutting thickness value, Fx is an x-direction cutting force, Fy is a y-direction cutting force, and Fz is a z-direction cutting force;
thirdly, a high-speed milling test is carried out under the set cutting force coefficient, the surface profile of the processed workpiece is obtained through a three-dimensional surface profile instrument, the surface profile of the workpiece is formed by the relative displacement between a cutter and the workpiece in a cutting processing system, namely if no vibration exists and the workpiece is an ideal surface, the surface profile is equal to the relative displacement X between the cutter and the workpiece1(T);
X, Y and Z represent the relative displacement of the tool tip and the workpiece in the X, Y and Z directions under the workpiece coordinate system X-Y-Z.
Step four, establishing a cutting force model according to the instantaneous rigid force model of the high-speed cutting machining:
Ft=∫Ktc·h·dz+Kte·ds
Fr=∫Krc·h·dz+Kre·ds
Fa=∫Kac·h·dz+Kae·ds
dFt=Ktc·h·dz+Kte·ds
dFr=Krc·h·dz+Kre·ds
dFa=Kac·h·dz+Kae·ds
wherein, FtDenotes the tangential cutting force, FrDenotes the radial cutting force, FaThe axial cutting force is shown, and h is the cutting thickness; z represents the z-direction of the object coordinate system x-y-z; dFtIs a tangential force infinitesimal, dFrIs a radial force infinitesimal, dFaThe axial force is a infinitesimal, ds is a cutting edge length infinitesimal, dz is an axial cutting depth infinitesimal, d represents differentiation, and h represents cutting thickness;
and step five, establishing a dynamic model of the relative motion of the high-speed cutting workpiece and the cutter according to a mechanical vibration theory, wherein the dynamic model comprises the following steps:
wherein M is1For cutting system equivalent mass, C1(T) is the equivalent damping coefficient of the cutting system, K1(T) is the equivalent stiffness of the cutting system, f1(T) represents a cutting force, x1(T) represents a vibration displacement function, T represents time;
step six, converting the t-r-a coordinate cutting force of the cutting surface of the cutter into an x-y-z coordinate cutting force through coordinates:
wherein, theta1,β1When the t-r-a coordinate of the cutting surface of the cutter is converted to a coordinate system x-y-z, the rotating angle of the coordinate of the cutting surface around the a axis and the rotating angle around the t axis are respectively; a. the3-rRepresenting the rotation theta of the t-r-a coordinate of the cutting surface of the tool about the a-axis1A transformation matrix of angles, r represents the radial direction of the cutting process; a. ther-aRepresenting the t-r-a coordinate of the cutting face of the toolRotation theta about axis a1Rotation β of coordinate system around t-axis after angular rotation1A coordinate transformation matrix of the angle; fx represents the x-direction cutting force; fy represents a y-direction cutting force, and Fz represents a z-direction cutting force;
seventhly, obtaining enough three or more groups of surface profile shapes X1(T), i.e. M is obtained1,C1(T),K1(T) establishing a mapping rule of cutting processing and workpiece surface appearance;
step eight, obtaining the surface profile shape X of any workpiece under the same high-speed cutting machine tool through the dynamic model in the step five1(T) the required geometrical parameters of the tool material, cutting parameters; the control of the surface appearance of the high-speed cutting processing is realized.
Claims (2)
1. A control method for high-speed cutting processing workpiece surface appearance is characterized by comprising the following steps:
determining geometric parameters of a cutter, wherein the geometric parameters comprise a front angle gamma, a rear angle, an installed blade inclination angle and parameters of a manufacturing material, and the parameters of the manufacturing material comprise hardness and density;
step two, obtaining 1 or more groups of tangential, radial and axial cutting force coefficients under different cutting parameters: ktc,Krc,Kac,Kte,Kre,KaeWherein, K istcRepresenting the tangential force coefficient; krcRepresents the radial force coefficient; kacRepresenting the axial force coefficient; kteExpressing the coefficient of tangential edge force, KreRepresenting the radial cutting edge force coefficient; kaeRepresenting the axial edge force coefficient, t the tangential direction, r the radial direction, a the axial direction, c the force coefficient, e the edge force coefficient, then:
β=arcsin(sinη·sini+cosη·cosi·cosα)
gamma is the tool rake angle, η denotes the angle of the chip flow direction to the direction perpendicular to the tool cutting edge, i denotes the angle of the cutting edge to the direction perpendicular to the workpiece motion,the cutting tool cutting depth is a normal cutting angle of a cutting tool shearing surface, theta is a position angle of the cutting tool in the cutting process, β is an effective front angle, α is a cutting tool rear angle, h is a cutting thickness, d is a differentiation value, z is the z direction of a workpiece coordinate system x-y-z, dz is an axial cutting depth infinitesimal, d is a differentiation value, h is a cutting thickness value, Fx is an x-direction cutting force, Fy is a y-direction cutting force, and Fz is a z-direction cutting force;
and step three, carrying out a high-speed milling test under the set cutting force coefficient to obtain the surface profile of the machined workpiece, wherein the surface profile of the workpiece is formed by the relative displacement between the cutter and the workpiece in a cutting machining system, namely if no vibration exists, the workpiece is an ideal surface, and the surface profile is equal to the relative displacement X between the cutter and the workpiece1(T);
X, Y and Z represent the relative displacement of the tool tip and the workpiece in the X, Y and Z directions under the workpiece coordinate system X-Y-Z.
Step four, establishing a cutting force model according to the instantaneous rigid force model of the high-speed cutting machining:
Ft=∫Ktc·h·dz+Kte·ds
Fr=∫Krc·h·dz+Kre·ds
Fa=∫Kac·h·dz+Kae·ds
dFt=Ktc·h·dz+Kte·ds
dFr=Krc·h·dz+Kre·ds
dFa=Kac·h·dz+Kae·ds
wherein, FtDenotes the tangential cutting force, FrDenotes the radial cutting force, FaThe axial cutting force is shown, and h is the cutting thickness; z represents the z-direction of the object coordinate system x-y-z; dFtIs a tangential force infinitesimal, dFrIs a radial force infinitesimal, dFaThe axial force is a infinitesimal, ds is a cutting edge length infinitesimal, dz is an axial cutting depth infinitesimal, d represents differentiation, and h represents cutting thickness;
and step five, establishing a dynamic model of the relative motion of the high-speed cutting workpiece and the cutter according to a mechanical vibration theory, wherein the dynamic model comprises the following steps:
wherein M is1For cutting system equivalent mass, C1(T) is the equivalent damping coefficient of the cutting system, K1(T) is the equivalent stiffness of the cutting system, f1(T) represents a cutting force, x1(T) represents a vibration displacement function, T represents time;
step six, converting the t-r-a coordinate cutting force of the cutting surface of the cutter into an x-y-z coordinate cutting force through coordinates:
wherein, theta1,β1From the t-r-a coordinate of the cutting surface of the tool to the coordinate system x-During y-z conversion, the rotation angle of the cutting face coordinate around the a axis and the rotation angle around the t axis; a. the3-rRepresenting the rotation theta of the t-r-a coordinate of the cutting surface of the tool about the a-axis1A transformation matrix of angles, r represents the radial direction of the cutting process; a. ther-aRepresenting the rotation theta of the t-r-a coordinate of the cutting surface of the tool about the a-axis1Rotation β of coordinate system around t-axis after angular rotation1A coordinate transformation matrix of the angle; fx represents the x-direction cutting force; fy represents a y-direction cutting force, and Fz represents a z-direction cutting force;
seventhly, obtaining enough three or more groups of surface profiles X1(T), i.e. M is obtained1,C1(T),K1(T) establishing a mapping rule of cutting processing and workpiece surface appearance;
step eight, obtaining the surface profile X of any workpiece under the same high-speed cutting machine tool through the dynamic model in the step five1(T) the required geometrical parameters of the tool material, cutting parameters; the control of the surface appearance of the high-speed cutting processing is realized.
2. The method for controlling the surface topography of a workpiece machined at high speed according to claim 1, wherein in the third step, the surface profile of the workpiece after machining is obtained by a three-dimensional surface profiler.
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