Parameter setting method and system for speeding up processing of robot component alloy material

Abstract

The application provides a processing speed-up parameter setting method and system for robot part alloy materials, which is suitable for ordinary numerical control machine tools. The method obtains the material properties of the workpiece to be processed and the speed-up target of each process, calibrates the critical effective flow rate of each type of process under the target feed speed, that is, the minimum nozzle flow rate that can penetrate the air barrier and achieve effective cooling, and then calculates the matched liquid supply pressure and flow rate based on the critical flow rate and in combination with the nozzle structure parameters, and configures the feed speed. Compared with the traditional scheme relying on an ultrahigh pressure system, the application can meet the processing cooling demand after speed-up through medium and low pressure, greatly reducing the equipment modification cost; at the same time, the application breaks through the one-size-fits-all cooling mode, realizes accurate matching of cooling parameters according to the process, and ensures the stability of the surface quality and tool life after speed-up. The overall scheme does not require experience trial and error, has strong adaptability, and significantly improves the processing efficiency and process reliability of light alloy parts.

Description

Technical Field

[0001] This application relates to the field of parts processing technology, specifically to a parameter setting method and system for accelerating the processing of alloy materials for robot parts. Background Technology

[0002] In CNC machining of lightweight alloys (such as aluminum and magnesium alloys), the cutting fluid system has long been considered an auxiliary component. Its parameter settings generally rely on operator experience or equipment manufacturer recommendations, lacking scientific basis. Current mainstream practices typically employ fixed pressure (e.g., 3–5 bar) and universal nozzle configurations, a "one-size-fits-all" cooling strategy that fails to consider the significant differences in cooling requirements based on different materials, machining stages (roughing / finishing), feed rates, and geometric features. Especially with the promotion of high-speed machining technology and continuously increasing feed rates, the high-speed spindle rotation and high feed motion together create a strong dynamic air barrier in the tool tip area, severely hindering the effective delivery of traditional low-pressure coolant to the cutting zone.

[0003] Against this backdrop, existing technologies reveal the following core shortcomings: There is no quantitative benchmark for critical cooling efficiency—the industry has not yet established a clear criterion for "what flow rate can truly penetrate the air barrier and achieve effective cooling," leading to a coexistence of insufficient cooling (tool sticking, thermal deformation) or excessive cooling (energy waste, impact on thin-walled parts); parameter settings are highly dependent on trial and error—there is a strong coupling relationship between parameters such as pressure, flow rate, and nozzle diameter, but existing methods lack physical model support, often requiring repeated adjustments, resulting in long debugging cycles, poor stability, and difficulty in reproducing in mass production; high speed and high precision are difficult to balance—to avoid tool sticking, operators are often forced to reduce feed rate, sacrificing efficiency; while forcibly increasing speed can lead to abnormal tool wear or surface quality deterioration due to improper cooling, resulting in a dilemma where increased efficiency inevitably leads to decreased quality.

[0004] Therefore, there is an urgent need for a low-cost, high-efficiency cooling control method based on scientific calibration, applicable to ordinary CNC machine tools, and capable of synergistically optimizing cutting fluid parameters and feed rate, in order to overcome the current technical bottleneck in high-speed machining of light alloys. This method should be able to ensure efficient cooling under high-speed machining conditions through precise calculation and real-time adjustment without increasing hardware modification costs, thereby improving machining efficiency and product quality, reducing tool wear and scrap rate, and ultimately achieving a dual improvement in economic benefits and technical performance. Summary of the Invention

[0005] In view of this, this application provides a parameter setting method and system for accelerating the processing of alloy materials for robot parts. It can configure multiple control parameters suitable for ordinary CNC machine tools based on scientific calibration, and can also optimize the cutting fluid parameters and feed rate in a coordinated manner for production processing.

[0006] In a first aspect, this application provides a parameter setting method for accelerating the processing of alloy materials for robot parts, comprising: step S1, obtaining the target feed rate corresponding to the acceleration target of each processing step, and calling the corresponding spindle speed range; step S2, performing a single calibration process on the workpiece to be processed: controlling the cutting tool spindle to run at the maximum value of the spindle speed range, controlling the cutting tool to advance at the target feed rate, and controlling the cooling nozzle to spray coolant into the cutting area at a test flow rate; step S3, collecting processing result parameters after the single calibration process, and determining whether the processing result parameters meet the qualification conditions; step S4, if the processing result parameters do not meet the qualification conditions, increasing the flow rate of the cooling nozzle in the previous single calibration process by a preset step size to obtain the test flow rate in the next single calibration process; step S5, repeating steps S2, S3, and S4. 4. Until the processing result parameters meet the qualification conditions, set the current test flow rate as the critical flow rate corresponding to the current processing step; Step S6. Sequentially switch each processing step and execute steps S2, S3, S4 and S5 accordingly to obtain the critical flow rate corresponding to each processing step; Step S7. Configure the production processing parameters of each processing step: the target feed rate and the set coolant flow rate; wherein, the set coolant flow rate is greater than or equal to the critical flow rate; Step S8. Calculate the corresponding set supply pressure and set single nozzle flow rate according to the set coolant flow rate and the structural parameters of the cooling nozzle; Step S9. When the machine tool performs production processing, configure the corresponding target feed rate, set coolant flow rate, set supply pressure and set single nozzle flow rate according to the currently executed processing step.

[0007] In conjunction with the first aspect, one possible implementation further includes: step S10, at the end of the current machining process, controlling the cutting tool to disengage from the workpiece; step S11, controlling the cutting tool spindle to switch to the spindle speed corresponding to the next machining process with a preset acceleration; step S12, configuring the target feed rate, the set coolant flow rate, the set supply pressure, and the set single nozzle flow rate corresponding to the next machining process; step S13, controlling the cutting tool to perform the next machining process on the workpiece.

[0008] In conjunction with the first aspect, in one possible implementation, step S3, "determining whether the processing result parameters meet the qualification conditions," includes: step S301, identifying whether there are adhesive substances larger than a preset size on the cutting surface of the cutting tool; step S302, detecting whether the roughness of the cutting area meets the process requirements corresponding to the current processing step; step S303, detecting whether the cutting tool's blade temperature is within the safe blade temperature range; and step S304, detecting whether the cutting area temperature of the cutting area is within the safe cutting area temperature range.

[0009] In conjunction with the first aspect, in one possible implementation, a chip flushing nozzle is further provided on the side of the cooling nozzle; the method further includes: step S14, controlling the chip flushing nozzle to start during a first redundant time period before production processing; step S15, configuring the chip flushing nozzle to spray chip flushing fluid onto the workpiece at a chip flushing flow rate; step S16, controlling the chip flushing nozzle to stop during a second redundant time period after production processing is completed.

[0010] In conjunction with the first aspect, in one possible implementation, step S15 includes: step S1501, configuring the chip flushing velocity corresponding to each of the processing steps: setting a preset multiple of the critical velocity corresponding to the processing step as the chip flushing velocity; wherein the preset multiple is greater than 0 and less than 1.

[0011] In conjunction with the first aspect, in one possible implementation, step S8 includes: step S801, obtaining the nozzle efficiency, nozzle diameter, first empirical correction coefficient, and second empirical correction coefficient of the cooling nozzle based on the structural parameters; step S802, calculating the set supply pressure based on the set coolant flow rate, the nozzle efficiency, and the first empirical correction coefficient, according to a preset correction orifice outflow formula; and step S803, calculating the set single nozzle flow rate based on the set coolant flow rate, the nozzle diameter, and the second empirical correction coefficient, according to a preset single nozzle flow rate matching formula.

[0012] In conjunction with the first aspect, one possible implementation further includes: step S211, before the first execution of step S2, calling the flow rate of the cooling nozzle in the historical production process as a reference flow rate; step S212, based on the preset test correction coefficient and the reference flow rate, obtaining the test flow rate in the first execution of step S2.

[0013] In conjunction with the first aspect, one possible implementation also includes: step S17, after the machine tool finishes its production processing, controlling the cooling nozzle to continue operating for a third redundant duration.

[0014] In conjunction with the first aspect, one possible implementation further includes: step S18, obtaining the material properties of the workpiece to be processed; step S19, configuring the corresponding spindle speed range, the target feed rate, and the set coolant flow rate according to the material properties in each of the processing steps.

[0015] Secondly, this application provides a parameter setting system for accelerating the processing of alloy materials for robot parts, comprising: a data acquisition module configured to execute: step S1, acquiring the target feed rate corresponding to the acceleration target of each processing step, and calling the corresponding spindle speed range; the types of processing steps include: roughing, finishing, and corner machining; a calibration module, communicatively connected to the data acquisition module, the calibration module configured to execute: step S2, performing a single calibration process on the workpiece to be processed: controlling the cutting tool spindle to run at the maximum value of the spindle speed range, controlling the cutting tool to advance at the target feed rate, and controlling the cooling nozzle to spray coolant onto the cutting area at a test flow rate; step S3, collecting processing result parameters after the single calibration process, and determining whether the processing result parameters meet the qualification conditions; the processing result parameters include: blade surface image, workpiece surface image, and cutting area temperature data; step S4, if the processing result parameters do not meet the qualification conditions, increasing the flow rate of the cooling nozzle in the previous single calibration process by a preset step size to obtain the test flow rate of the next single calibration process. Test flow rate; Step S5: Repeat steps S2, S3, and S4 until the processing result parameters meet the qualification conditions, and set the current test flow rate as the critical flow rate corresponding to the current processing step; Step S6: Sequentially switch each processing step and execute steps S2, S3, S4, and S5 accordingly to obtain the critical flow rate corresponding to each processing step; The parameter configuration module is communicatively connected to the data acquisition module and the calibration module, and the parameter configuration module is configured to execute: Step S7: Configure the production processing parameters for each processing step: the target feed rate and the set coolant flow rate; wherein, the set coolant flow rate is greater than or equal to the critical flow rate; Step S8: Calculate the corresponding set liquid supply pressure and set single nozzle flow rate according to the set coolant flow rate and the structural parameters of the cooling nozzle; Step S9: When the machine tool performs production processing, configure the corresponding target feed rate, set coolant flow rate, set liquid supply pressure, and set single nozzle flow rate according to the currently executed processing step.

[0016] In this embodiment, separate calibrations are performed for different machining processes to ensure that while increasing the feed rate, the coolant can completely penetrate the air barrier layer formed by the high-speed rotation of the spindle, effectively covering the cutting area of ​​the tool tip. This achieves effective cooling and ensures no residue on the tool surface, acceptable workpiece surface finish, and acceptable temperature in the cutting area. This embodiment abandons the traditional one-cut ultra-high pressure cooling solution. Instead, it determines the critical flow rate required for each type of process based on actual working conditions through incremental flow rate calibration, and then configures appropriate supply pressure and flow rate. This satisfies the cooling requirements of high-speed machining without requiring large-scale modifications to the machine tool or the use of expensive ultra-high pressure systems, greatly reducing hardware upgrade costs and enabling efficient cooling even for ordinary economical CNC machine tools. Each machining process has its specific critical flow rate, ensuring optimal cooling effect without wasting resources. In formal production, after configuring a coolant flow rate greater than or equal to the critical flow rate, the specific set supply pressure and set single-nozzle flow rate are calculated based on the set coolant flow rate. Once the target feed rate, set coolant flow rate, set supply pressure, and set single-nozzle flow rate are configured, production can begin. The target feed rate effectively improves processing efficiency, and calibrating the critical flow rate significantly reduces equipment modification costs, providing a practical and feasible technical path for the efficient manufacturing of robot parts. Attached Figure Description

[0017] Figure 1 The diagram shows the steps of a parameter setting method for accelerating the processing of alloy materials for robot parts according to an embodiment of this application.

[0018] Figure 2 The diagram shows the steps involved in switching processing steps.

[0019] Figure 3 The diagram shows the steps for determining whether the calibration process results are qualified.

[0020] Figure 4 The diagram shows the steps involved in redundancy control before and after production and processing.

[0021] Figure 5 The diagram shows the steps for configuring the chip flushing velocity.

[0022] Figure 6 The diagram shows the steps involved in calculating the various parameters.

[0023] Figure 7 The diagram shows the steps involved in calculating the initial test flow rate.

[0024] Figure 8 The diagram shows the steps involved in the continued cooling process after production.

[0025] Figure 9 The diagram shows the steps for configuring parameters based on the material properties of the workpiece.

[0026] Figure 10 The figure shown is a schematic diagram of the parameter setting system for accelerating the processing of alloy materials for robot parts according to an embodiment of this application. Detailed Implementation

[0027] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of this application.

[0028] Figure 1 The diagram shows the steps of a method for setting parameters to accelerate the machining of alloy materials for robot parts, according to an embodiment of this application. This application provides a method for setting parameters to accelerate the machining of alloy materials for robot parts. In one embodiment, as shown... Figure 1 As shown, the method includes: Step S1: Obtain the target feed rate corresponding to the speed-up target of each machining process, and call the corresponding spindle speed range. The types of machining processes include: roughing, finishing, and corner machining.

[0029] In this step, the speed-up targets and matching spindle speed ranges for each machining process are preset, and the mapping between the machining process and the target feed rate is established, which can provide clear high-speed machining condition boundaries for subsequent cooling parameter calibration.

[0030] Step S2: Perform a single calibration operation on the workpiece to be machined: control the cutting tool spindle to run at the maximum value of the spindle speed range, control the cutting tool to advance at the target feed rate, and control the cooling nozzle to spray coolant into the cutting area at the test flow rate.

[0031] Step S3: After a single calibration process is completed, collect the machining result parameters and determine whether the machining result parameters meet the qualification conditions. The machining result parameters include: the image of the cutting tool surface, the image of the machined workpiece surface, and the temperature data of the cutting area.

[0032] Step S4: If the processing result parameters do not meet the qualification conditions, the flow rate of the previous single calibration process on the cooling nozzle is increased by a preset step size to obtain the test flow rate of the next single calibration process.

[0033] In this step, the flow rate is gradually increased by a preset step size, which can avoid the flow rate from increasing too quickly during the calibration test, causing the actual critical point to be skipped, resulting in parameter redundancy (overcooling) or misjudgment of the critical point, leading to inaccurate critical flow rate test.

[0034] Step S5: Repeat steps S2, S3 and S4 until the processing result parameters meet the qualification conditions, and set the current test flow rate as the critical flow rate corresponding to the current processing step.

[0035] In steps S2-S5, a single calibration test is conducted by incrementally increasing the coolant flow rate at the limit spindle speed and target feed rate. The minimum effective flow rate that meets the requirements is automatically searched, using actual machining quality (tool condition, surface morphology, temperature) as the criterion. This scientifically determines the critical flow rate required for each type of process, avoiding trial and error and ensuring the effectiveness of cooling after speed increases.

[0036] Step S6: Sequentially switch each processing step and execute steps S2, S3, S4 and S5 accordingly to obtain the critical flow rate corresponding to each processing step.

[0037] In step S6, all typical processing steps are traversed, and the critical flow rate of each processing step is calibrated to build a critical flow rate database covering the entire processing flow, supporting segmented collaborative control.

[0038] Step S7: Configure the production parameters for each processing step: target feed rate and set coolant flow rate; wherein, the set coolant flow rate is greater than or equal to the critical flow rate.

[0039] Step S8: Calculate the corresponding set liquid supply pressure and set single nozzle flow rate based on the set coolant flow rate and the structural parameters of the cooling nozzle.

[0040] In step S8, based on fluid dynamics, the corresponding supply pressure and single-nozzle flow rate are obtained from the set coolant flow rate and structural parameters. This transforms the abstract set coolant flow rate into hydraulic system parameters executable by the machine tool, ensuring that the parameters are practically applicable.

[0041] Step S9: When the machine tool is performing production processing, configure the corresponding target feed rate, set the coolant flow rate, set the supply pressure, and set the single nozzle flow rate according to the currently executing processing procedure.

[0042] In this embodiment, separate calibrations are performed for different machining processes (roughing, finishing, and cornering) (steps S2-S6) to ensure that while increasing the feed rate, the coolant can completely penetrate the air barrier layer formed by the high-speed rotation of the spindle, effectively covering the cutting area of ​​the tool tip, thereby achieving effective cooling and ensuring no residue on the tool surface, acceptable workpiece surface finish, and acceptable temperature in the cutting area. This embodiment abandons the traditional one-cut ultra-high pressure cooling scheme. Instead, based on actual working conditions, the critical flow rate required for each type of process is determined through incremental flow rate calibration (steps S2-S5), and then appropriate supply pressure and flow rate are configured (steps S7-S8). This satisfies the cooling requirements of high-speed machining without requiring large-scale modifications to the machine tool or the use of expensive ultra-high pressure systems, greatly reducing hardware upgrade costs and enabling efficient cooling even for ordinary economical CNC machine tools. Each machining process has its specific critical flow rate, ensuring optimal cooling effect without wasting resources. In formal production, after configuring a coolant flow rate greater than or equal to the critical flow rate, the specific set supply pressure and set single-nozzle flow rate are calculated based on the set coolant flow rate. Once the target feed rate, set coolant flow rate, set supply pressure, and set single-nozzle flow rate are configured, production can begin. The target feed rate effectively improves processing efficiency, and calibrating the critical flow rate significantly reduces equipment modification costs, providing a practical and feasible technical path for the efficient manufacturing of robot parts.

[0043] This application provides a method and system for setting machining speed-up parameters for alloy materials used in robot parts, applicable to ordinary CNC machine tools. The method obtains the material properties of the workpiece and the speed-up targets for each process, calibrating the critical effective flow rate for each type of process at the target feed rate: the minimum nozzle flow rate required to penetrate air barriers and achieve effective cooling. Based on this critical flow rate and combined with nozzle structural parameters, the matching liquid supply pressure and flow rate are calculated and configured in conjunction with the feed rate. Compared to traditional solutions relying on ultra-high pressure systems (≥70 bar), this application only requires 12–20 bar of medium-low pressure to meet the cooling needs of high-speed machining, significantly reducing equipment modification costs. Simultaneously, it breaks through the "one-size-fits-all" cooling mode, achieving precise matching of cooling parameters according to the process, ensuring stable surface quality and tool life after speed increase. The overall solution requires no trial and error and has strong adaptability, capable of increasing machining feed rate by more than 50% and significantly improving process reliability.

[0044] In some embodiments, in steps S2 - S5, taking the conventional spindle speed as an example of 8,000–20,000 rpm, the preset step size is set to a certain value within 1.0–1.5 m / s. After testing, for rough machining: the critical effective flow velocity V = 8 m / s (mainly for efficient chip flushing, with a weak air barrier); for finish machining: the critical effective flow velocity V = 15 m / s (required to penetrate a strong air barrier and suppress thermal deformation); for corner machining: the cutting direction of the tool changes suddenly, and chips are prone to retention, and the critical effective flow velocity V = 18 m / s.

[0045] Figure 2 The figure shows a schematic diagram of the method steps for executing when switching machining processes. In one embodiment, as Figure 2 shown, the method for setting parameters to increase the machining speed of the alloy material of the robot parts further includes: Step S10: At the end of the current machining process, control the cutting tool to disengage from the workpiece to be machined.

[0046] In this step, after the current machining process ends, since the spindle speeds of adjacent machining processes are different, the control system automatically commands the cutting tool to disengage from the workpiece surface and then switches the spindle speed of the cutting tool, which can avoid unnecessary contact and wear, thereby avoiding machining defects caused by speed mismatch.

[0047] Step S11: Control the spindle of the cutting tool to switch to the spindle speed corresponding to the next machining process at a preset acceleration.

[0048] In this step, according to the requirements of the next machining process, the spindle speed is gradually adjusted at a preset acceleration to achieve a smooth transition. It can reduce mechanical shock and extend the service life of the machine tool.

[0049] Step S12: Configure the target feed rate corresponding to the next machining process, set the coolant flow rate, set the supply pressure, and set the single nozzle flow rate.

[0050] Step S13: Control the cutting tool to perform the next machining process on the workpiece to be machined.

[0051] When applied in this embodiment, precise parameter control in high-speed machining is achieved, significantly improving the coherence and automation degree of the machining process. First, control the cutting tool to disengage from the workpiece to be machined, and then switch the spindle speed, which can avoid machining defects caused by speed mismatch. Through an orderly process switching mechanism, human errors and equipment losses are effectively avoided. The non-production time is reduced, enabling each process to complete its task quickly and accurately.

[0052] Figure 3 The figure shows a schematic diagram of the method steps for judging whether the machining result of the calibration process is qualified. In one embodiment, as Figure 3As shown, step S3, "determining whether the processing result parameters meet the qualification conditions," includes: Step S301: Identify whether there are any adhesive materials larger than a preset size on the cutting surface of the cutting tool.

[0053] In this step, a high-resolution industrial camera is used to automatically photograph the cutting tool surface after a single calibration process. Pre-trained image processing algorithms (such as edge detection, morphological analysis, or deep learning models) are used to identify the presence of adhering material (such as built-up edge) on the tool surface and calculate its area or maximum size. If the size of the adhering material exceeds a preset threshold (e.g., 0.2 mm² or 0.5 mm maximum diameter), it is deemed unqualified.

[0054] Step S302: Check whether the surface roughness of the cutting area meets the process requirements corresponding to the current machining process.

[0055] In this step, a surface roughness meter is used to sample and measure the surface Ra value of the workpiece in the machining area. The measured value is compared with the process requirements corresponding to the current process (e.g., Ra≤0.8μm for finishing, Ra≤3.2μm for roughing, and Ra≤0.8μm for corner machining) to determine whether it meets the requirements.

[0056] Step S303: Check whether the cutting tool's blade temperature is within the safe blade temperature range.

[0057] In this step, a non-contact temperature measurement is performed on the blade area using an infrared thermal imager. The temperature data of the blade is collected within a certain period of time (e.g., within 3 minutes) after the cutting is completed, and compared with the safe blade temperature range allowed by the material (e.g., carbide blades typically need to be ≤600°C). Exceeding this range is considered an overheating risk.

[0058] Step S304: Detect whether the temperature of the cutting zone is within the safe cutting zone temperature range.

[0059] In this step, within a certain time period after cutting (e.g., within 3 minutes), an infrared thermal imager is used to detect the temperature of the cutting area of ​​the workpiece, and the highest or average temperature is obtained as the cutting area temperature. This cutting area temperature is compared with a preset safe cutting temperature threshold (e.g., for aluminum alloy machining, it is generally controlled at ≤200°C to avoid thermal deformation) to determine whether the cooling is sufficient.

[0060] In this embodiment, all processing result parameters are collected after a single calibration process. This scheme achieves objective, quantifiable, and automated evaluation of cooling effectiveness and processing quality, replacing the traditional subjective judgment that relies on operational experience. By incorporating key indicators such as tool sticking, surface quality, and temperature into the critical flow rate calibration criteria, it ensures that the determined "critical flow rate" truly reflects the actual cooling requirements under high-speed processing, thereby providing a reliable guarantee for subsequent speed-up processing and significantly improving process stability and yield.

[0061] Figure 4 The diagram illustrates the steps of a redundancy control method before and after production and processing. In one embodiment, as shown... Figure 4 As shown, a chip-removing nozzle is also provided on the side of the cooling nozzle. Existing machine tools typically have multiple nozzles, therefore no modification to the existing machine tool is required; only the flow rate of each nozzle needs to be controlled. The parameter setting method for accelerating the processing of alloy materials for robot parts also includes: Step S14: During the first redundant time before production and processing, control the chip ejector to start.

[0062] Step S15: Configure the chip flushing nozzle to spray chip flushing fluid onto the workpiece at a chip flushing flow rate.

[0063] Step S16: During the second redundant time period after the production and processing is completed, control the chip ejector to stop.

[0064] In this embodiment, the chip-removing nozzle located on the side is used to clean up the chips that have been dispersed by the cooled nozzle over a large area, preventing chip accumulation or re-adhesion to the machined surface. A first redundant duration is activated before processing begins to pre-wet or clean the initial area; a second redundant duration is delayed after processing ends to thoroughly rinse away any remaining chips.

[0065] Figure 5 The diagram illustrates the steps of configuring the chip flushing velocity. In one embodiment, as shown... Figure 5 As shown, step S15 includes: Step S1501: Configure the chip flushing velocity corresponding to each processing step: Set the preset multiple of the critical velocity corresponding to the processing step as the chip flushing velocity. The preset multiple is greater than 0 and less than 1.

[0066] In this embodiment, a strong correlation is achieved between the chip removal flow rate and the target feed rate. By setting the chip removal flow rate to a preset multiple (e.g., 0.3–0.6 times) less than 1 of the critical flow rate for the corresponding machining process, a dynamic correlation between the chip removal parameters and the main cooling requirements is realized. Since the critical flow rate itself is strongly coupled with the target feed rate (the faster the feed, the higher the critical flow rate), this design implicitly enables the chip removal flow rate to be dynamically adjusted with the feed rate: in the roughing stage, the feed is high and the critical flow rate is low (≥8 m / s), and the chip removal flow rate is automatically set to a lower value (e.g., 3–5 m / s) through the preset multiple; in the finishing or corner stages, although the feed may decrease slightly, the critical flow rate is high (≥15 m / s), and the chip removal flow rate is correspondingly increased (e.g., 6–9 m / s) through the preset multiple to cope with finer and more easily adhered chips. This avoids a "one-size-fits-all" approach to chip removal flow rate, significantly reducing the total liquid consumption while ensuring chip removal effect; the chip removal and main cooling share the same critical flow rate system, simplifying the control logic. The chip flushing velocity is always lower than the cooling velocity, which can significantly reduce pump power consumption and waste liquid treatment burden. Moreover, there is no need to calibrate the chip flushing parameters separately, as they are automatically matched with the main process, thus improving the level of automation.

[0067] Figure 6 The diagram illustrates the steps involved in calculating various parameters. In one embodiment, as shown... Figure 6 As shown, step S8 includes: Step S801: Obtain the nozzle efficiency, nozzle diameter, first empirical correction coefficient, and second empirical correction coefficient of the cooling nozzle based on the structural parameters.

[0068] Step S802: Based on the preset modified orifice outflow formula, the set supply pressure is calculated according to the set coolant flow rate, nozzle efficiency and first empirical correction coefficient.

[0069] Step S803: Based on the preset single nozzle flow matching formula, the set single nozzle flow rate is calculated according to the set coolant flow rate, nozzle diameter and second empirical correction coefficient.

[0070] In this embodiment, the preset modified orifice outflow formula is: ; in, V Nozzle outlet velocity (m / s); P Liquid supply pressure (bar); η Nozzle efficiency (0.85 for direct-fire nozzles, verified by calibration).

[0071] Among them, 4.47 is the first empirical correction factor, used to match the measured data. In engineering practice, due to: the cutting fluid is not pure water (containing additives, with slightly different density / viscosity); the internal flow channel of the nozzle is not ideally contracted; the pressure gauge reading is the system pressure rather than the actual static pressure in front of the nozzle; through a large number of flow-pressure calibration tests, an empirical correction factor is derived to make the calculated value closer to the measured flow rate.

[0072] If measured in practice, when P =10 bar, η When =0.85, V ≈13m / s, then the first empirical correction factor k satisfy: In engineering, it is often taken k =4.47 is used as the standard calculation coefficient.

[0073] The preset single-nozzle flow rate matching formula is: ; 0.0471 is the second empirical correction factor derived from unit conversions and fundamental fluid mechanics relationships. Q Single nozzle flow rate (L / min); d Nozzle outlet diameter (mm); V Nozzle outlet velocity (m / s).

[0074] The basic formula for volumetric flow rate is: ;in: A The nozzle outlet cross-sectional area (m²) is the total area of ​​the nozzle outlet. V Flow velocity (m / s). For a circular nozzle: ; d In meters; but: ; Will Q Unit conversion to L / min: 1m 3 =1000L, then ; therefore: ; Will d If the unit is converted from (mm) to (m), then: ; Substitute into the above formula: ; Calculate the constant term: ; Final result: .

[0075] Figure 7 The diagram illustrates the steps of a method for calculating the initial test flow rate. In one embodiment, as shown... Figure 7 As shown, the parameter setting method for accelerating the processing of alloy materials for robot parts also includes: Step S211: Before executing step S2 for the first time, call the flow rate of the cooling nozzle in the historical production process as the reference flow rate.

[0076] Step S212: Based on the preset test correction coefficient and reference flow rate, obtain the test flow rate in the first execution of step S2.

[0077] In this embodiment, in the historical production process where the feed rate and coolant flow rate are not increased, the coolant flow rate of the historical production process is used as the reference flow rate, that is, as the initial flow rate for the first execution of step S2. Starting from this reference flow rate, the flow rate of the previous single calibration process on the cooling nozzle is gradually increased by a preset step size to obtain the test flow rate of the next single calibration process, thereby having a reasonable initial test flow rate and avoiding the calibration process of steps S2-S5 being too lengthy.

[0078] Figure 8 The diagram illustrates the steps of a method for continued cooling after production and processing. In one embodiment, as shown... Figure 8 As shown, the parameter setting method for accelerating the processing of alloy materials for robot parts also includes: Step S17: After the machine tool finishes its production process, control the cooling nozzle to continue running for the third redundant time.

[0079] In this embodiment, the method controls the cooling nozzle to continue running for a third redundant time after the machine tool finishes production processing, so as to ensure that the tool and workpiece are sufficiently cooled before stopping the machine. This effectively prevents thermal deformation, micro-cracks or solidification of material adhering to the tool tip caused by residual heat accumulation. At the same time, it avoids high-temperature chips adhering to the machined surface and causing scratches or corrosion, thereby further improving the dimensional stability and surface quality of the parts and extending the tool life. It is especially suitable for high-speed machining scenarios of lightweight alloys such as aluminum alloys and magnesium alloys that have fast thermal conductivity but are easy to oxidize and stick to the tool.

[0080] Figure 9 The diagram illustrates the steps of configuring parameters based on the material properties of the workpiece. In one embodiment, as shown... Figure 9 As shown, the parameter setting method for accelerating the processing of alloy materials for robot parts also includes: Step S18: Obtain the material properties of the workpiece to be processed.

[0081] Step S19: In each machining process, configure the corresponding spindle speed range, target feed rate and set coolant flow rate according to the material properties.

[0082] This embodiment is executed before step S1. Before step S1, the material properties of the workpiece to be processed (such as aluminum alloy 7075, magnesium alloy AZ31, etc.) are obtained, and the spindle speed range and target feed rate of each processing step are dynamically configured accordingly. Then, the critical flow rate of each processing step for the current material properties is calibrated. After the critical flow rate is calibrated, the coolant flow rate is configured based on the material properties for the machine tool during production processing. This achieves precise matching of material-process-cooling parameters, avoids a uniform processing strategy, and significantly improves the adaptability, stability, and efficiency of different alloy materials in high-speed processing. Specific embodiments are as follows: Example 1 (Roughing of 7075-T6 Aluminum Alloy): After identifying the material as high-strength aluminum alloy 7075-T6, the system automatically configures the spindle speed for the roughing process to be 12,000 rpm, the target feed rate to be 3,600 mm / min, and sets the coolant flow rate to 9 m / s (≥8 m / s critical value) to ensure efficient removal of large allowances and no built-up edge.

[0083] Example 2 (Fine Machining of AZ31B Magnesium Alloy): After identifying the material as flammable and sticky magnesium alloy AZ31B, the system is configured for the fine machining process with a spindle speed of 18,000 rpm, a target feed rate of 1,800 mm / min, and a coolant flow rate of 18 m / s (≥15 m / s critical value), which effectively suppresses tool sticking and thermal deformation, and achieves a surface roughness of Ra 0.75 μm.

[0084] Example 3 (6061-T6 aluminum alloy corner machining): After identifying the material as 6061-T6, the high cooling standard is automatically called in the corner process, and the spindle speed is configured to 15,000 rpm, feed rate to 1,000 mm / min, and coolant flow rate to 18.4 m / s, to ensure that there is no adhesion or overcutting in the transition area and to meet the high assembly accuracy requirements.

[0085] In summary, this embodiment uses material properties to drive parameter adaptation, enabling the same process framework to be flexibly adapted to various light alloys, greatly improving versatility and intelligence.

[0086] Figure 10 The diagram shown is a schematic representation of a parameter setting system for accelerating the processing of alloy materials for robot parts, according to an embodiment of this application. This application also provides a parameter setting system for accelerating the processing of alloy materials for robot parts. In one embodiment, as shown... Figure 10 As shown, the system includes: a data acquisition module 1001, a calibration module 1002, and a parameter configuration module 1003.

[0087] The data acquisition module 1001 is configured to execute: Step S1, acquire the target feed rate corresponding to the speed-up target of each machining process, and call the corresponding spindle speed range; the types of machining processes include: roughing, finishing, and corner machining.

[0088] The calibration module 1002 is communicatively connected to the data acquisition module 1001. The calibration module 1002 is configured to execute: Step S2, perform a single calibration operation on the workpiece: control the cutting tool spindle to run at the maximum value of the spindle speed range, control the cutting tool to advance at the target feed rate, and control the cooling nozzle to spray coolant onto the cutting area at a test flow rate; Step S3, after the single calibration operation is completed, collect the machining result parameters and determine whether the machining result parameters meet the qualification conditions; the machining result parameters include: the image of the cutting tool surface, the image of the workpiece surface, and the temperature of the cutting area. Step S4: If the processing result parameters do not meet the qualification conditions, increase the flow rate of the previous single calibration process on the cooling nozzle by a preset step size to obtain the test flow rate of the next single calibration process; Step S5: Repeat steps S2, S3 and S4 until the processing result parameters meet the qualification conditions, and set the current corresponding test flow rate as the critical flow rate corresponding to the current processing process; Step S6: Switch each processing process in sequence and execute steps S2, S3, S4 and S5 accordingly to obtain the critical flow rate corresponding to each processing process.

[0089] The parameter configuration module 1003 is communicatively connected to the data acquisition module 1001 and the calibration module 1002, respectively. The parameter configuration module 1003 is configured to execute the following steps: Step S7: Configure the production processing parameters for each processing step: target feed rate and set coolant flow rate; wherein, the set coolant flow rate is greater than or equal to the critical flow rate; Step S8: Calculate the corresponding set supply pressure and set single nozzle flow rate based on the set coolant flow rate and the structural parameters of the cooling nozzle; Step S9: When the machine tool is performing production processing, configure the corresponding target feed rate, set coolant flow rate, set supply pressure and set single nozzle flow rate according to the currently executing processing step.

[0090] In this embodiment, separate calibrations are performed for different machining processes (roughing, finishing, and cornering) (steps S2-S6) to ensure that while increasing the feed rate, the coolant can completely penetrate the air barrier layer formed by the high-speed rotation of the spindle, effectively covering the cutting area of ​​the tool tip, thereby achieving effective cooling and ensuring no residue on the tool surface, acceptable workpiece surface finish, and acceptable temperature in the cutting area. This embodiment abandons the traditional one-cut ultra-high pressure cooling scheme. Instead, based on actual working conditions, the critical flow rate required for each type of process is determined through incremental flow rate calibration (steps S2-S5), and then appropriate supply pressure and flow rate are configured (steps S7-S8). This satisfies the cooling requirements of high-speed machining without requiring large-scale modifications to the machine tool or the use of expensive ultra-high pressure systems, greatly reducing hardware upgrade costs and enabling efficient cooling even for ordinary economical CNC machine tools. Each machining process has its specific critical flow rate, ensuring optimal cooling effect without wasting resources. In formal production, after configuring a coolant flow rate greater than or equal to the critical flow rate, the specific set supply pressure and set single-nozzle flow rate are calculated based on the set coolant flow rate. Once the target feed rate, set coolant flow rate, set supply pressure, and set single-nozzle flow rate are configured, production can begin. The target feed rate effectively improves processing efficiency, and calibrating the critical flow rate significantly reduces equipment modification costs, providing a practical and feasible technical path for the efficient manufacturing of robot parts.

[0091] This application provides a method and system for setting machining speed-up parameters for alloy materials used in robot parts, applicable to ordinary CNC machine tools. The method obtains the material properties of the workpiece and the speed-up targets for each process, calibrating the critical effective flow rate for each type of process at the target feed rate: the minimum nozzle flow rate required to penetrate air barriers and achieve effective cooling. Based on this critical flow rate and combined with nozzle structural parameters, the matching liquid supply pressure and flow rate are calculated and configured in conjunction with the feed rate. Compared to traditional solutions relying on ultra-high pressure systems (≥70 bar), this application only requires 12–20 bar of medium-low pressure to meet the cooling needs of high-speed machining, significantly reducing equipment modification costs. Simultaneously, it breaks through the "one-size-fits-all" cooling mode, achieving precise matching of cooling parameters according to the process, ensuring stable surface quality and tool life after speed increase. The overall solution requires no trial and error and has strong adaptability, capable of increasing machining feed rate by more than 50% and significantly improving process reliability.

[0092] The basic principles of this application have been described above with reference to specific embodiments. However, it should be noted that the advantages, benefits, and effects mentioned in this application are merely examples and not limitations, and should not be considered as essential features of each embodiment of this application. Furthermore, the specific details disclosed above are for illustrative and facilitative purposes only, and are not limitations. These details do not limit the application to the necessity of employing the aforementioned specific details for implementation.

[0093] The block diagrams of devices, apparatuses, devices, and systems involved in this application are merely illustrative examples and are not intended to require or imply that they must be connected, arranged, or configured in the manner shown in the block diagrams. As those skilled in the art will recognize, these devices, apparatuses, devices, and systems can be connected, arranged, and configured in any manner. Words such as “comprising,” “including,” “having,” etc., are open-ended terms meaning “including but not limited to,” and are used interchangeably with them. The terms “or” and “and” as used herein refer to the terms “and / or,” and are used interchangeably with them unless the context clearly indicates otherwise. The term “such as” as used herein refers to the phrase “such as but not limited to,” and is used interchangeably with it.

[0094] It should also be noted that in the apparatus, equipment, and methods of this application, the components or steps can be disassembled and / or recombined. These disassemblies and / or recombinations should be considered as equivalent solutions of this application.

[0095] The above description of the disclosed aspects is provided to enable any person skilled in the art to make or use this application. Various modifications to these aspects will be readily apparent to those skilled in the art, and the general principles defined herein can be applied to other aspects without departing from the scope of this application. Therefore, this application is not intended to be limited to the aspects shown herein, but rather to be carried out within the widest scope consistent with the principles and novel features of the invention herein.

[0096] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Any modifications or equivalent substitutions made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A method for setting parameters to accelerate the processing of alloy materials for robot parts, characterized in that, include: Step S1: Obtain the target feed rate corresponding to the speed-up target of each machining process, and call the corresponding spindle speed range; Step S2: Perform a single calibration process on the workpiece to be machined: control the cutting tool spindle to run at the maximum value of the spindle speed range, control the cutting tool to advance at the target feed rate, and control the cooling nozzle to spray coolant into the cutting area at a test flow rate; Step S3: After the single calibration process is completed, collect the processing result parameters and determine whether the processing result parameters meet the qualification conditions; Step S4: If the processing result parameters do not meet the qualification conditions, the flow rate of the cooling nozzle in the previous single calibration process is increased by a preset step size to obtain the test flow rate of the next single calibration process. Step S5: Repeat steps S2, S3 and S4 until the processing result parameters meet the qualification conditions, and set the current test flow rate as the critical flow rate corresponding to the current processing step. Step S6: Sequentially switch each of the processing steps and execute steps S2, S3, S4 and S5 accordingly to obtain the critical flow rate corresponding to each of the processing steps; Step S7: Configure the production processing parameters for each of the processing steps: the target feed rate and the set coolant flow rate; wherein the set coolant flow rate is greater than or equal to the critical flow rate; Step S8: Calculate the corresponding set liquid supply pressure and set single nozzle flow rate based on the set coolant flow rate and the structural parameters of the cooling nozzle; Step S9: When the machine tool is performing production processing, configure the corresponding target feed rate, the set coolant flow rate, the set supply pressure, and the set single nozzle flow rate according to the currently executing processing procedure.

2. The parameter setting method for accelerating the processing of alloy materials for robot parts according to claim 1, characterized in that, Also includes: Step S10: When the current machining process ends, control the cutting tool to disengage from the workpiece; Step S11: Control the cutting tool spindle to switch to the spindle speed corresponding to the next machining process with a preset acceleration; Step S12: Configure the target feed rate, the set coolant flow rate, the set supply pressure, and the set single nozzle flow rate corresponding to the next processing step; Step S13: Control the cutting tool to perform the next machining operation on the workpiece.

3. The parameter setting method for accelerating the processing of alloy materials for robot parts according to claim 1, characterized in that, The step S3, "determining whether the processing result parameters meet the qualification conditions," includes: Step S301: Identify whether there are any adhesive materials larger than a preset size on the cutting surface of the cutting tool; Step S302: Detect whether the surface roughness of the cutting area meets the process requirements corresponding to the current machining process; Step S303: Detect whether the cutting tool's blade temperature is within the safe blade temperature range; Step S304: Detect whether the temperature of the cutting area is within the safe cutting area temperature range.

4. The parameter setting method for accelerating the processing of alloy materials for robot parts according to claim 1, characterized in that, The cooling nozzle is further provided with a chip-removing nozzle on its side; the method also includes: Step S14: During the first redundant time before production and processing, control the chip ejector to start; Step S15: Configure the chip flushing nozzle to spray chip flushing fluid onto the workpiece at a chip flushing flow rate; Step S16: During the second redundant time period after the production and processing is completed, control the chip ejector to stop.

5. The parameter setting method for accelerating the processing of alloy materials for robot parts according to claim 4, characterized in that, Step S15 includes: Step S1501: Configure the chip flushing flow rate corresponding to each of the processing steps: Set a preset multiple of the critical flow rate corresponding to the processing step as the chip flushing flow rate; wherein, the preset multiple is greater than 0 and less than 1.

6. The parameter setting method for accelerating the processing of alloy materials for robot parts according to claim 1, characterized in that, Step S8 includes: Step S801: Obtain the nozzle efficiency, nozzle diameter, first empirical correction coefficient, and second empirical correction coefficient of the cooling nozzle based on the structural parameters. Step S802: Based on the preset modified orifice outflow formula, the set coolant supply pressure is calculated according to the set coolant flow rate, the nozzle efficiency, and the first empirical correction coefficient. Step S803: Based on the preset single nozzle flow matching formula, the set single nozzle flow rate is calculated according to the set coolant flow rate, the nozzle diameter and the second empirical correction coefficient.

7. The parameter setting method for accelerating the processing of alloy materials for robot parts according to claim 1, characterized in that, Also includes: Step S211: Before executing step S2 for the first time, the flow rate of the cooling nozzle in the historical production process is used as the reference flow rate; Step S212: Based on the preset test correction coefficient and the reference flow rate, obtain the test flow rate in step S2 for the first execution.

8. The parameter setting method for accelerating the processing of alloy materials for robot parts according to claim 1, characterized in that, Also includes: Step S17: After the machine tool finishes its production process, control the cooling nozzle to continue running for the third redundant time.

9. The parameter setting method for accelerating the processing of alloy materials for robot parts according to claim 1, characterized in that, Also includes: Step S18: Obtain the material properties of the workpiece to be processed; Step S19: In each of the processing steps, configure the corresponding spindle speed range, target feed rate and set coolant flow rate according to the material properties.

10. A parameter setting system for accelerating the processing of alloy materials for robot parts, characterized in that, include: The data acquisition module is configured to execute: Step S1, acquire the target feed rate corresponding to the speed-up target of each machining process, and call the corresponding spindle speed range; the types of machining processes include: roughing, finishing, and corner machining; The calibration module is communicatively connected to the data acquisition module. The calibration module is configured to execute: Step S2, performing a single calibration operation on the workpiece: controlling the cutting spindle to run at the maximum value of the spindle speed range, controlling the cutting tool to advance at the target feed rate, and controlling the cooling nozzle to spray coolant into the cutting area at a test flow rate; Step S3, collecting machining result parameters after the single calibration operation and determining whether the machining result parameters meet the qualification conditions; the machining result parameters include: blade surface image, workpiece surface image, and cutting area temperature data; Step S4, if the machining... If the result parameters do not meet the qualification conditions, the flow rate of the cooling nozzle in the previous single calibration process is increased by a preset step size to obtain the test flow rate of the next single calibration process; Step S5: Repeat steps S2, S3 and S4 until the processing result parameters meet the qualification conditions, and set the current test flow rate as the critical flow rate corresponding to the current processing process; Step S6: Sequentially switch each processing process and execute steps S2, S3, S4 and S5 accordingly to obtain the critical flow rate corresponding to each processing process; The parameter configuration module is communicatively connected to the data acquisition module and the calibration module, respectively. The parameter configuration module is configured to execute: Step S7, configuring the production processing parameters for each of the processing steps: the target feed rate and the set coolant flow rate; wherein, the set coolant flow rate is greater than or equal to the critical flow rate; Step S8, calculating the corresponding set supply pressure and set single nozzle flow rate based on the set coolant flow rate and the structural parameters of the cooling nozzle; Step S9, configuring the corresponding target feed rate, set coolant flow rate, set supply pressure, and set single nozzle flow rate based on the currently executing processing step when the machine tool is performing production processing.

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