A method and apparatus for testing the wear of an end mill

Abstract

The application discloses a kind of end mill tool wear test method and test device, it is related to tool wear detection technical field, comprising the following steps: step S10: single-edge end mill model is established in three-dimensional modeling software, and end mill model is imported into finite element software;Step S20: the maximum temperature that can be generated when milling in end mill is analyzed, maximum temperature is determined;Step S30: point heat source device is heated to end mill's nose;Step S40: end mill tool wear experiment is carried out;Step S50: constantly repeat, and record end mill tool wear state, simultaneously replace test condition and carry out end mill tool test, and record end mill tool wear state;Step S60: compare the end mill tool wear state obtained from multiple conditions, establish acceleration model.The application is based on heat source method model, equivalent and simplified to get the temperature mode of end mill nose, and combined with actual test, obtain the maximum temperature suitable for not changing tool wear failure condition.

Description

Technical Field

[0001] This invention relates to the field of tool wear detection technology, and in particular to a method and apparatus for testing end mill tool wear. Background Technology

[0002] End mills, as essential machining tools for metal milling, are widely used in modern mechanical manufacturing. During milling operations, end mills often need to operate continuously for several hours under harsh high-temperature conditions, leading to accelerated tool wear, failure to meet accuracy requirements, and ultimately, tool failure. To address this issue, studying the tool wear of end mills and obtaining tool wear life curves allows for more accurate prediction of tool wear time, effectively reducing economic losses caused by tool wear.

[0003] In existing technologies, tool wear testing methods often involve intermittently milling the workpiece with an end mill to collect the tool wear width, requiring hundreds or even thousands of measurements, consuming a significant amount of time, resulting in a long testing cycle and low efficiency. To address these issues, it is necessary to design a new end mill tool wear testing scheme and acceleration device to quickly obtain the tool wear life curve and improve the efficiency of end mill tool wear testing. Summary of the Invention

[0004] The purpose of this invention is to overcome the problems of long testing cycles and low efficiency in end mill wear tests, which cannot meet the requirements of rapid testing, and to provide a testing method and apparatus for accelerating end mill wear at high temperatures. This invention obtains the maximum temperature through finite element simulation using a point heat source, and heats the end mill tip to the highest temperature using a heating device, thereby improving the accuracy of end mill life testing and accelerating the automation of end mill wear testing.

[0005] To achieve the above objectives, the present invention is implemented through the following technical solution:

[0006] A method for testing the wear of end mills includes the following steps:

[0007] Step S10: Create a single-flute end mill model in the 3D modeling software and import the end mill model into the finite element software;

[0008] Step S20: Analyze the maximum temperature that can be generated during end milling and determine the maximum temperature;

[0009] Step S30: The heat source device heats the tip of the end mill;

[0010] Step S40: Conduct a wear test on the end mill tool;

[0011] Step S50: Repeat continuously and record the wear condition of the end mill. At the same time, change the test conditions to conduct end mill test and record the wear condition of the end mill.

[0012] Step S60: Compare the wear status of the end mill obtained under various conditions and establish an acceleration model.

[0013] Preferably, in step S10, the single-edge end mill model simplifies the end mill's cutting edge from multiple cutting edges to a single cutting edge for milling the workpiece, the tool milling cycle is simplified to the milling cycle of one cutting edge, and the end mill tool wear is simplified to the wear of one cutting edge.

[0014] Preferably, in step S20, the formula is used. The maximum temperature a1 that can be generated during end milling is analyzed.

[0015] in, The temperature rise at any point in the medium is expressed in °C. Let J be the heat emitted by the instantaneous heat source, c be the specific heat of the heat-conducting medium (J / kg·C), p be the density of the heat-conducting medium (kg / m3), a be the thermal diffusivity (m2 / s), and t be any time (s) after the heat source generates heat instantaneously. The coordinates of the heat source point are the origin of the selected rectangular coordinate system.

[0016] Preferably, in step S30, during the experiment, the point heat source device on the robotic arm heats the blade tip, and under the detection of the infrared temperature sensor, the temperature rises to a1. The robotic arm then rotates, and the point heat source device stops heating.

[0017] Preferably, in step S40, after a milling process begins, the motor controls the lead screw to rotate, and the high-speed camera on the lead screw moves to take pictures of the surface of the milled end mill and record image data. After the recording is completed, the motor controls the lead screw to rotate, and the high-speed camera on the lead screw moves away.

[0018] When the high-speed camera moves to its original position, the robotic arm rotates, and the point heat source device heats the blade tip under the detection of the infrared thermal imager until it reaches the highest temperature a1. Then, the robotic arm rotates, and the point heat source device moves away.

[0019] Preferably, in step S50, the end mill wear step is repeated until the tool wears out, data a1 is recorded, and the end mill wear curve is plotted; the end mill test is performed without using high temperature conditions, data a2 is recorded, and the end mill wear curve is plotted.

[0020] Preferably, in step S60, the wear state of the end milling tool obtained by comparing data a1 and data a2 is used to establish an acceleration model.

[0021] A milling cutter wear testing device includes an infrared temperature sensor, a lead screw, a robotic arm, and a point heat source device mounted on the robotic arm. The milling cutter has a cutting tip, the point heat source device is used to heat the cutting tip, the infrared temperature sensor is used to detect the temperature of the cutting tip, and a high-speed camera is mounted on the lead screw. The high-speed camera is used to photograph and record image data of the surface of the milling cutter after grinding.

[0022] Preferably, the system also includes a motor for controlling the rotation of the lead screw.

[0023] Preferably, the system also includes a test bench, with the robotic arm and lead screw both positioned above the test bench.

[0024] Compared with the prior art, the advantages of the present invention are:

[0025] Based on the heat source method model, this invention equivalences and simplifies the method of obtaining the temperature of the end mill tip. Combined with actual experiments, it obtains the maximum temperature suitable for tool wear failure without changing the tool wear failure condition, and builds a high-temperature accelerated experimental platform. By heating the tip at high temperature to accelerate tool wear, the tool wear life curve can be obtained efficiently.

[0026] This invention obtains the maximum temperature through finite element simulation of a point heat source, and heats the end mill tip to the highest temperature through a heating device, thereby improving the accuracy of end mill life testing and accelerating the automation of end mill wear. Attached Figure Description

[0027] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0028] Figure 1 This is a schematic diagram of a structure according to an embodiment of the present invention;

[0029] Figure 2 This is a schematic diagram of a PCD end mill according to an embodiment of the present invention;

[0030] Figure 3 This is a diagram of a point heat source device according to an embodiment of the present invention;

[0031] Figure 4 This is a diagram showing the heating of the blade tip according to an embodiment of the present invention.

[0032] Figure 5 This is a flowchart illustrating an embodiment of the present invention.

[0033] In the diagram: 1. Infrared temperature sensor, 2. Robotic arm, 3. High-speed camera, 4. Lead screw, 5. Blade tip, 6. Point heat source device. Detailed Implementation

[0034] Embodiments of the present invention are described in detail below, examples of which are illustrated in the accompanying drawings. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, and should not be construed as limiting the present invention.

[0035] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0036] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0037] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a connection that allows communication between them; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0038] See Figure 1-5 This is an embodiment of a method for testing the wear of end mills according to the present invention, which includes the following steps: Step S10: Create a single-flute end mill model in a three-dimensional modeling software and import the end mill model into a finite element software;

[0039] Step S20: Analyze the maximum temperature that can be generated during end milling and determine the maximum temperature;

[0040] Step S30: The heat source device heats the tip of the end mill;

[0041] Step S40: Conduct a wear test on the end mill tool;

[0042] Step S50: Repeat continuously and record the wear condition of the end mill. At the same time, change the test conditions to conduct end mill test and record the wear condition of the end mill.

[0043] Step S60: Compare the wear status of the end mill obtained under various conditions and establish an acceleration model.

[0044] In this embodiment, in step S10, the cutting edge of the end mill in the single-edge end mill model is simplified from multiple cutting edges to a single cutting edge to mill the workpiece, the tool milling cycle is simplified to the milling cycle of one cutting edge, and the end mill tool wear is simplified to the wear of one cutting edge.

[0045] In this embodiment, in step S20, the formula is used. The maximum temperature a1 that can be generated during end milling is analyzed.

[0046] in, The temperature rise at any point in the medium is expressed in °C. Let J be the heat emitted by the instantaneous heat source, c be the specific heat of the heat-conducting medium (J / kg·C), p be the density of the heat-conducting medium (kg / m3), a be the thermal diffusivity (m2 / s), and t be any time (s) after the heat source generates heat instantaneously. The coordinates of the heat source point are the origin of the selected rectangular coordinate system.

[0047] In this embodiment, in step S30, during the experiment, the point heat source device on the robotic arm heats the blade tip. Under the detection of the infrared temperature sensor, the temperature rises to a1, the robotic arm rotates, and the point heat source device stops heating.

[0048] In this embodiment, in step S40, after a milling process begins, the motor controls the lead screw to rotate, and the high-speed camera on the lead screw moves to take pictures of the surface of the milled end mill and record image data. After the recording is completed, the motor controls the lead screw to rotate, and the high-speed camera on the lead screw moves away.

[0049] When the high-speed camera moves to its original position, the robotic arm rotates, and the point heat source device heats the blade tip under the detection of the infrared thermal imager until it reaches the highest temperature a1. Then, the robotic arm rotates, and the point heat source device moves away.

[0050] In this embodiment, in step S50, the end mill wear step is repeated until the tool wears out, data a1 is recorded, and the end mill wear curve is plotted; the end mill test is performed without using high temperature conditions, data a2 is recorded, and the end mill wear curve is plotted.

[0051] In this embodiment, in step S60, the wear state of the end mill obtained by comparing data a1 and data a2 is used to establish an acceleration model.

[0052] The present invention also provides a test device for end mill wear, including an infrared temperature sensor 1, a lead screw 4, a robotic arm 2, and a point heat source device 6 mounted on the robotic arm 2. The end mill is provided with a cutting tip 5, the point heat source device 6 is used to heat the cutting tip 5, the infrared temperature sensor 1 is used to detect the temperature of the cutting tip 5, and a high-speed camera 3 is mounted on the lead screw 4. The high-speed camera 3 is used to photograph and record image data of the surface of the end mill after grinding.

[0053] In this embodiment, a motor is also included, which is used to control the rotation of the lead screw 4.

[0054] This embodiment also includes a test bench, with the robotic arm 2 and the lead screw 4 both positioned above the test bench. In this embodiment, the PCD end mill spindle speed is 800 r / min, the feed rate is 80 mm / min, the cutting width is 2 mm, the cutting depth is 3 mm, and the workpiece material is 100×100×180 mm structural steel. Specific implementation steps:

[0055] The end mill cutting edge is simplified from multiple cutting edges to a single cutting edge for milling the workpiece, and the tool milling cycle is simplified to the milling cycle of one cutting edge, that is, the end mill tool wear is simplified to the wear of one cutting edge; a single-flute end mill model is created in 3D modeling software and imported into finite element software to analyze the maximum temperature a1 that can be generated during end mill milling;

[0056] During the experiment, the point heat source device 6 on the robotic arm 2 heats the cutting tip 5. Under the detection of the infrared temperature sensor 1, the temperature is raised to a1. The robotic arm 2 rotates, and the point heat source device 6 stops heating. At this time, milling begins.

[0057] After a 100mm milling cycle, the motor controls the lead screw 4 to rotate, and the high-speed camera 3 on the lead screw moves to photograph the ground end mill surface and record the image data. After recording is complete, the motor controls the lead screw 4 to rotate, and the high-speed camera 3 on the lead screw moves away.

[0058] When the high-speed camera moves to its original position, the robotic arm 2 rotates, and the point heat source device heats the blade tip 5 under the detection of the infrared thermal imager until it reaches the highest temperature a1. Then, the robotic arm 2 rotates and the point heat source device moves away.

[0059] Repeat the above steps until the tool wears out, record the data a1, and plot the end mill tool wear curve.

[0060] End mill tests were conducted without using high-temperature conditions, data a2 was recorded, and the end mill tool wear curve was plotted.

[0061] By comparing a1 and a2, a tool wear acceleration model is established.

[0062] Based on the heat source method model, this invention equivalences and simplifies the method of obtaining the temperature of the end mill tip. Combined with actual experiments, it obtains the maximum temperature suitable for tool wear failure without changing the tool wear failure condition, and builds a high-temperature accelerated experimental platform. By heating the tip at high temperature to accelerate tool wear, the tool wear life curve can be obtained efficiently.

[0063] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0064] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.

Claims

1. A method for testing the wear of end mills, characterized in that, Includes the following steps: Step S10: Create a single-flute end mill model in the 3D modeling software and import the end mill model into the finite element software; Step S20: Analyze the maximum temperature that can be generated during end milling and determine the maximum temperature a1; Step S30: The heat source device heats the tip of the end mill to its maximum temperature; Step S40: Conduct a wear test on the end mill tool; Step S50: Repeat continuously and record the wear condition of the end mill. At the same time, change the test conditions to conduct end mill test and record the wear condition of the end mill. Step S60: Compare the wear status of end mills obtained under various conditions and establish an acceleration model; In step S40, after a milling process begins, the motor controls the lead screw to rotate, and the high-speed camera on the lead screw moves to take pictures of the surface of the milled end mill and record image data. After the recording is completed, the motor controls the lead screw to rotate, and the high-speed camera on the lead screw moves away. When the high-speed camera moves to its original position, the robotic arm rotates, and the point heat source device heats the blade tip under the detection of the infrared thermal imager until it reaches the maximum temperature a1. Then, the robotic arm rotates and the point heat source device moves away. In step S50, the end mill wear process is repeated until the tool fails due to wear. Data a1 is recorded and the end mill wear curve is plotted. An end mill test is conducted without using high temperature conditions, and data a2 is recorded and the end mill wear curve is plotted. In step S60, the wear state of the end mill is compared with that obtained from data a1 and data a2 to establish an acceleration model.

2. The end mill wear test method according to claim 1, characterized in that, In step S10, the single-edge end mill model simplifies the end mill's cutting edge from multiple cutting edges to a single cutting edge for milling the workpiece, simplifies the tool milling cycle to the milling cycle of one cutting edge, and simplifies the end mill tool wear to the wear of one cutting edge.

3. The end mill wear test method according to claim 1, characterized in that, In step S20, the formula is used. The maximum temperature a1 that can be generated during end milling is analyzed. in, Let be the temperature rise at any point in the medium, in °C. The heat emitted by the instantaneous point heat source is J, and c is the specific heat of the heat-conducting medium, J / kg·℃. Density of the thermally conductive medium, kg / m³ 3 , m is the thermal diffusivity. 2 / s, where τ is any time after the heat source generates heat instantaneously, and the coordinates of the heat source point are the origin of the selected rectangular coordinate system.

4. The end mill wear test method according to claim 1, characterized in that, In step S30, during the experiment, the point heat source device on the robotic arm heats the blade tip. Under the detection of the infrared temperature sensor, the temperature rises to a1, the robotic arm rotates, and the point heat source device stops heating.

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