Multi-dimensional detection method applied to hot melt filling drilling processing of laminated material

Abstract

A kind of multi-dimension detection method applied to the processing of laminated material hot melt filling drilling, the surface morphology of hot melt drill and the original element composition of hot melt drill are recorded by microscopic measurement of hot melt drill, index analysis is carried out according to the material characteristics of hot melt drill in the processing stage to detect the health condition of hot melt drill, monitor the processing temperature of filling material, index analysis is carried out according to the characteristics of filling material to detect the health condition of workpiece, by section measurement, the filling cavity is respectively cut in the plane perpendicular to the axis and the plane where the axis is, the filling gap of filling material and cavity in radial and axial direction is measured to detect the filling effect of laminated material, the filling effect of laminated material, processing health condition, filling hole wall processing quality factor are comprehensively considered in the application, the filling gap in axial and radial direction of filling hole, processing axial force and circumferential torque of hot melt drill, processing temperature of filling material, hot melt drill wear and chip adhesion condition, surface roughness of filling hole wall and burr height of drilling entrance and exit are measured, and the filling effect of laminated material hot melt filling drilling is detected.

Description

Technical Field

[0001] This invention relates to a technology in the field of machining, specifically a multi-dimensional inspection method applied to the hot-melt filling drilling process of laminated materials. Background Technology

[0002] The high-speed rotation of the thermoforming drill plastically shapes the material, accompanied by intense extrusion pressure and frictional heat, which in turn produces adverse effects such as filling voids, rough surface finish, and drill wear. To objectively and accurately reflect the processing effect of thermoforming filling holes in laminated materials, a multi-dimensional detection method is needed. Summary of the Invention

[0003] To address the aforementioned shortcomings of existing technologies, this invention proposes a multi-dimensional detection method for drilling in the hot-melt filling process of laminated materials. This method comprehensively considers factors such as the filling effect of the laminated material, the processing health status, and the processing quality of the filling hole wall. It measures the axial and radial filling gap of the filling hole, the axial force and circumferential torque of the hot-melt drill, the processing temperature of the filling material, the wear and chip adhesion of the hot-melt drill, the surface roughness of the filling hole wall, and the burr height at the drill inlet and outlet to detect the processing effect of the hot-melt filling drilling of laminated materials.

[0004] This invention is achieved through the following technical solution:

[0005] This invention relates to a multi-dimensional inspection method for hot-melt filling drilling of laminated materials, comprising:

[0006] ① During the processing preparation stage, microscopic measurements are performed on the hot melt drill to record the surface morphology and original elemental composition of the hot melt drill;

[0007] ② Monitoring each stage of processing: The hot melt drill is subjected to axial force and circumferential torque. Based on the material characteristics of the hot melt drill, index analysis is performed to detect the health status of the hot melt drill. The processing temperature of the filler material is monitored. Based on the characteristics of the filler material, index analysis is performed to detect the health status of the workpiece.

[0008] ③ In the processing completion stage, the filling cavity is cut in the plane perpendicular to the axis and the plane where the axis is located by sectional measurement. The filling gap between the filling material and the cavity in the radial and axial directions is measured to detect the filling effect of the laminated material.

[0009] ④ Evaluation and analysis stage: After the hole machining is completed, the hot melt drill is subjected to microscopic measurement and compared with the initial surface morphology and original elemental composition of the hot melt drill to detect the wear of the hot melt drill and the adhesion of chips on the surface of the hot melt drill; the surface roughness and the height of the burrs at the inlet and outlet of the machined filling hole are measured to detect the surface quality of the filling hole wall.

[0010] This invention relates to a system for implementing the above-mentioned method, comprising: a thermoplastic drill wear detection unit, a chip adhesion detection unit, a thermoplastic drill health status detection unit, a filler material health status detection unit, a filler quality detection unit, and a filler hole wall surface quality detection unit. The thermoplastic drill wear detection unit calculates the axial wear amount by comparing the thermoplastic drill length based on the geometric changes of the thermoplastic drill before and after processing, and then normalizes the wear amount to obtain a wear coefficient. The chip adhesion detection unit analyzes the increase in characteristic elements of the filler material on the thermoplastic drill surface based on the elemental composition ratio before and after processing, and then normalizes the chip adhesion amount to obtain a chip adhesion coefficient. The thermoplastic drill health status detection unit detects the axial force and circumferential rotation of the thermoplastic drill during processing. The torque data is compared with the allowable axial force and circumferential torque of the thermal fusion drill to obtain the load health status of the thermal fusion drill; the filler material health status detection unit compares the filler material temperature information during processing with the filler material's thermal softening temperature and melting point to obtain the filler material health status; the filler quality detection unit measures 10 gap values ​​each in the radial and axial directions based on the section measurement results, calculates the average gap value as the filler material filling void, performs maximum and minimum normalization on the filling void to obtain the filling void coefficient, and evaluates the filling quality of the laminated material; the filler hole wall surface quality detection unit evaluates the filler hole wall surface quality by dividing the filler hole wall surface roughness by 20μm to obtain the roughness coefficient and dividing the average inlet and outlet burr height by 1mm to obtain the burr coefficient. Technical effect

[0011] This invention provides a comprehensive inspection of the entire process for drilling holes in laminated materials using thermal fusion filling. It assesses three key aspects: the filling effect, processing health, and hole wall quality. These aspects are monitored by measuring the axial and radial filling gaps, axial force and circumferential torque during thermal fusion drilling, the processing temperature of the filling material, thermal fusion drill wear and chip adhesion, and the surface roughness of the hole wall and the burr height at the drill inlet and outlet. Compared to existing technologies, this invention provides a direct visual representation of the filling effect, processing health, and hole wall quality during thermal fusion filling drilling, facilitating parameter optimization, improving filling quality, and extending the lifespan of the thermal fusion drill. Attached Figure Description

[0012] Figure 1 This is a schematic diagram of the process of the present invention;

[0013] Figure 2 A schematic diagram of hot-melt drilling and filling processing for laminated materials;

[0014] Figure 3 The results of the morphology inspection of the thermal fusion drill;

[0015] Figure 4 The results of the transverse section filling radial void detection;

[0016] Figure 5 The results of longitudinal sectioning and filling of axial voids are presented.

[0017] Figure 6 Data on cutting force and cutting torque during the hot-melt drilling process of laminated materials;

[0018] Figure 7 Data on the inlet temperature of titanium alloy drill holes during the hot-melt drilling process of laminated materials;

[0019] Figure 8 The results of optical microscope inspection of wear on thermal fusion drills;

[0020] Figure 9 The results are from EDS elemental energy dispersive spectroscopy analysis of the surface of a thermal fusion drill. Detailed Implementation

[0021] This embodiment is for the following: Figure 2 The multi-dimensional detection method shown in the diagram for the hot-melt drilling and filling process of titanium alloy-aluminum alloy laminated materials comprehensively considers factors such as the filling effect of the laminated materials, the processing health status, and the processing quality of the filled hole walls. Figure 1 Specifically, it includes:

[0022] Step 1: For the TC4 titanium alloy-aluminum alloy laminate material requiring infill processing, where the infill material is TC4 titanium alloy and the cavity material is aluminum alloy, perform microscopic inspection on the hot melt drill used for processing to obtain the surface morphology and original elemental composition of the hot melt drill. Record the surface morphology, axial length, and original elemental composition ratio of the hot melt drill, such as... Figure 3 As shown, processing parameters were formulated to ensure that the temperature of the contact area between the hot melt drill and the filler material is higher than the thermal softening temperature of the filler material and lower than the thermal melting point of the filler material.

[0023] Step 2: Perform hot-melt drilling and filling of the TC4 titanium alloy-aluminum alloy laminate. During the process, measure the axial force and circumferential torque of the hot-melt drill, and measure the processing temperature of the filler material. A rotary force gauge is used to measure the axial force and circumferential torque on the hot-melt drill during the processing, and an infrared thermometer is used to measure the processing temperature of the filler material. The temperature measurement area is at the entrance of the machined hole.

[0024] Step 3: After processing, use a sectioning measurement method to section the aluminum alloy filling cavity on a plane perpendicular to the axis and on the plane containing the axis, respectively, and measure the radial and axial filling gaps between the TC4 titanium alloy filling material and the aluminum alloy cavity; for the surface quality of the filling hole wall, check the surface roughness of the filling hole wall and the burr height at the drill inlet and outlet. Specifically, this includes:

[0025] 3.1) Perform a transverse section along a plane perpendicular to the axis on the machined aluminum alloy filling cavity using end milling, milling to the measurement surface position, such as... Figure 4 As shown. After sectioning, the filling condition of TC4 titanium alloy was inspected using a microscope. The radial voids between the filling material and the filling cavity were measured at 10 different locations. The radial voids were normalized to their maximum and minimum values ​​to obtain the radial void coefficient.

[0026] 3.2) Perform a longitudinal section along the plane containing the axis on the machined aluminum alloy filling cavity. Use side milling for the longitudinal section, milling to the plane where the diameter of the filling hole is measured. Figure 5 As shown. After sectioning, the filling material was inspected using a microscope, and the axial clearance between the filling material and the filling cavity was measured at 10 different locations. The axial clearance was normalized to its maximum and minimum values ​​to obtain the axial clearance coefficient.

[0027] 3.3) Measure the surface roughness of three regions of the filled hole wall on the longitudinally cut laminated material, and divide the average roughness by 20 μm to obtain the roughness coefficient.

[0028] 3.4) Measure the burr height at the borehole inlet and outlet on the filled laminated material. Use laser to measure the burr height at ten locations at both the inlet and outlet. Calculate the average burr value and divide it by 1 mm to obtain the burr coefficient.

[0029] Step 4: Evaluate and analyze the axial force, circumferential torque, and processing temperature of the filler material during the machining process, specifically including:

[0030] 4.1) Based on the geometry and material properties of the thermo-melt drill, calculate the allowable axial force and circumferential torque during the thermo-melt drill machining process, and determine the appropriate range of axial force and circumferential torque. In this example, the allowable axial force of the thermo-melt drill is 1200N, and the allowable circumferential torque is 0.9N·m.

[0031] 4.2) Analysis of the axial force of the thermoforming drill during the drilling process. Based on the trend of cutting force variation, the cutting stage is divided using the method of calculating the average of sample point data. The entire drilling process is divided into three parts: the feed stage, the filling stage, and the retraction stage. Figure 6 As shown, the average axial force during the feed and filling stages is calculated, and the ratio of the average axial force to the allowable axial force is used as the axial load coefficient.

[0032] 4.3) Analysis of the circumferential torque during the drilling process of the thermoelectric drill. Based on the trend of cutting torque variation, the cutting stage is divided using the method of calculating the average value of sample point data. The entire drilling process is divided into three parts: the feed stage, the filling stage, and the retraction stage. Figure 6As shown, the average circumferential torque of the thermal fusion drill in all three stages is calculated, and the ratio of the average circumferential torque to the allowable circumferential torque is used as the circumferential load coefficient.

[0033] 4.4) Analysis was performed on the temperature of the filler material during drilling. The measurement area was the borehole inlet of TC4 titanium alloy filler material. The measured temperature was as follows: Figure 7 As shown. The temperature load coefficient is obtained by dividing the difference between the highest inlet temperature of the filler material surface and the thermal softening temperature of the filler material by the difference between the melting point and the thermal softening temperature of the filler material.

[0034] Step 5: Perform thermal drill inspection on the processed drill, checking for wear and chip adhesion. Specifically, this includes:

[0035] 5.1) Anhydrous ethanol was used to ultrasonically clean the processed thermoplastic drill. After cleaning, the remaining axial length of the thermoplastic drill was measured. Figure 8 As shown, the difference in axial length of the hot melt drill before and after processing is the wear amount of the hot melt drill. The wear amount is normalized to the maximum and minimum to obtain the wear coefficient.

[0036] 5.2) Elemental energy dispersive spectroscopy (EDS) was performed on the surface of the thermal fusion drill. The results were... Figure 9 As shown, titanium was selected as the characteristic element of the filler material. The titanium content on the surface of the hot melt drill before and after processing was analyzed as the chip adhesion amount. The chip adhesion amount was normalized to the maximum and minimum to obtain the chip adhesion coefficient.

[0037] Step 6: Calculate the average values ​​of axial load coefficient, circumferential load coefficient, temperature load coefficient, radial clearance coefficient, axial clearance coefficient, wear coefficient, chip adhesion coefficient, roughness coefficient, and burr coefficient to determine the comprehensive evaluation of machining quality. The machining parameters with the smallest average coefficient have the best machining quality.

[0038] Through specific practical experiments, under the specific environmental settings of using a FANUC ROBODRILL small machining center for hot melt filling drilling of TC4-aluminum alloy laminated material, and running the above method with the parameters in Table 1, the experimental data shown in Table 2 can be obtained. The detection coefficients shown in Table 3 are calculated according to the above steps. It can be found that the optimal machining effect can be obtained with a feed speed of 2000 rpm, a feed rate of 30 mm / min, a retraction speed of 500 rpm, and a retraction feed rate of 50 mm / min.

[0039] Experimental data

[0040] Table 1 Processing Experiment Parameters

[0041] Table 2 Experimental Data

[0042] Table 3 Test Coefficients

[0043] Compared with the prior art, the present invention uses radial void coefficient and axial void coefficient to reflect the filling effect of the laminated material, axial load coefficient, circumferential load coefficient, temperature load coefficient, wear coefficient and chip adhesion coefficient to reflect the processing health status, and roughness coefficient and burr coefficient to reflect the processing quality of the filled hole wall. By combining the above three aspects, the quality of the laminated filling hole can be determined, and a multi-dimensional detection of the hot melt filling drilling process of titanium alloy-aluminum alloy laminated material can be completed.

[0044] The above-described specific implementations can be partially adjusted by those skilled in the art in different ways without departing from the principles and purpose of the present invention. The scope of protection of the present invention is defined by the claims and is not limited to the above-described specific implementations. All implementation schemes within the scope of the claims are bound by the present invention.

Claims

1. A multi-dimensional inspection method for hot-melt filling drilling of laminated materials, characterized in that, This includes multi-dimensional detection systems that implement multi-dimensional detection methods; The multi-dimensional detection system includes: a thermoplastic drill wear detection unit, a chip adhesion detection unit, a thermoplastic drill health status detection unit, a filler material health status detection unit, a filler quality detection unit, and a filler hole wall surface quality detection unit. Specifically: before detecting thermoplastic drill wear and chip adhesion, the thermoplastic drill is ultrasonically cleaned with anhydrous ethanol after processing; the thermoplastic drill wear detection unit calculates the axial wear amount by comparing the length of the thermoplastic drill before and after processing based on the geometric changes of the thermoplastic drill, and determines the wear coefficient based on this wear amount; the chip adhesion detection unit analyzes the increase in characteristic elements of the filler material on the surface of the thermoplastic drill based on the elemental composition ratio of the surface before and after processing, obtains the chip adhesion amount, and determines the chip adhesion coefficient based on this chip adhesion amount; the thermoplastic drill health status detection unit compares the axial force and circumferential torque data of the thermoplastic drill during processing with the allowable axial force and circumferential torque of the thermoplastic drill to obtain the load health status of the thermoplastic drill and determines the axial load coefficient and circumferential load coefficient; the filler material health status detection unit... Based on the temperature information of the filler material during processing, and compared with the thermal softening temperature and melting point of the filler material, the health status of the filler material is obtained. Specifically, the temperature load coefficient is determined by dividing the difference between the highest temperature at the inlet of the filler material surface and the thermal softening temperature of the filler material by the difference between the melting point and the thermal softening temperature of the filler material. The filler quality inspection unit measures 10 gap values ​​in both the radial and axial directions based on the cutting measurement results, calculates the average value of the gap values ​​as the filler material filling void, obtains the filler material filling quality, and determines the radial void coefficient and axial void coefficient. The filler hole wall surface quality inspection unit obtains the roughness coefficient by dividing the surface roughness of the filler hole wall by 20μm and the burr coefficient by dividing the average value of the inlet and outlet burr height by 1mm based on the filler hole wall surface roughness and inlet and outlet burr height information. The average values ​​of the axial load coefficient, circumferential load coefficient, temperature load coefficient, radial void coefficient, axial void coefficient, wear coefficient, chip adhesion coefficient, roughness coefficient, and burr coefficient are calculated to determine the comprehensive evaluation of the processing quality. The aforementioned multi-dimensional detection method includes: ① During the processing preparation stage, microscopic measurements are performed on the hot melt drill to record the surface morphology and original elemental composition of the hot melt drill; ② Monitoring each stage of processing: The hot melt drill is subjected to axial force and circumferential torque. Based on the material characteristics of the hot melt drill, index analysis is performed to detect the health status of the hot melt drill. The processing temperature of the filler material is monitored. Based on the characteristics of the filler material, index analysis is performed to detect the health status of the workpiece. ③ In the processing completion stage, the filling cavity is cut in the plane perpendicular to the axis and the plane where the axis is located by sectional measurement. The filling gap between the filling material and the cavity in the radial and axial directions is measured to detect the filling effect of the laminated material. ④ Evaluation and analysis stage: After the hole machining is completed, the hot melt drill is subjected to microscopic measurement and compared with the initial surface morphology and original elemental composition of the hot melt drill to detect the wear of the hot melt drill and the chip adhesion on the surface of the hot melt drill; the surface roughness and the height of the burrs at the inlet and outlet of the machined filling hole are measured to detect the surface quality of the filling hole wall. The aforementioned processing preparation stage specifically involves: for the TC4 titanium alloy-aluminum alloy laminate material that requires filling processing, wherein the filling material is TC4 titanium alloy and the cavity material is aluminum alloy, microscopic inspection is performed on the hot melt drill used for processing to obtain the surface and original elements of the hot melt drill, the surface morphology, axial length and original element composition ratio of the hot melt drill are recorded, and processing parameters are formulated so that the temperature of the contact area between the hot melt drill and the filling material is higher than the thermal softening temperature of the filling material and lower than the thermal melting point of the filling material; The aforementioned processing stage specifically involves: performing hot-melt drilling and filling of TC4 titanium alloy-aluminum alloy laminated material. During the processing, the axial force and circumferential torque data of the hot-melt drill are measured, the processing temperature of the filling material is measured, the axial force and circumferential torque on the hot-melt drill during the processing are measured using a rotary force gauge, and the processing temperature of the filling material is measured using an infrared thermometer. The temperature measurement area is the entry position of the processing hole. The aforementioned processing completion stage specifically includes: 3.1) A transverse section is made on the aluminum alloy filling cavity after processing along a plane perpendicular to the axis. The transverse section is made by end milling until the measurement surface is reached. After the section is completed, the filling condition of TC4 titanium alloy is inspected using a microscope, and the radial clearance between the filling material and the filling cavity at 10 different positions is measured. 3.2) Perform longitudinal sectioning along the plane of the axis on the processed aluminum alloy filling cavity. Use side milling to perform longitudinal sectioning. Mill to the plane where the diameter of the filling hole is measured. After sectioning, use a microscope to inspect the filling material and measure the axial clearance between the filling material and the filling cavity at 10 different positions. 3.3) Measure the surface roughness of three regions of the filled hole wall on the longitudinally cut laminated material, and divide the average roughness by 20 μm to obtain the roughness coefficient; 3.4) Measure the burr height at the borehole inlet and outlet on the filled laminated material. Use laser to measure the burr height at ten locations at both the inlet and outlet. Calculate the average burr value and divide it by 1 mm to obtain the burr coefficient. The aforementioned evaluation and analysis phase specifically includes: a) Based on the geometry and material properties of the thermal fusion drill, calculate the allowable axial force and circumferential torque during the thermal fusion drill machining process, and determine the appropriate range of axial force and circumferential torque. b) Analyze the axial force of the hot melt drill during the drilling process. Based on the trend of cutting force change, the cutting stage is divided by calculating the average value of sample point data. The entire drilling process is divided into three parts: the infeed stage, the filling stage, and the retraction stage. Calculate the average axial force in the infeed stage and the filling stage. Use the ratio of the average axial force to the allowable axial force as the axial load coefficient. c) Analyze the circumferential torque of the thermoelectric drill during the drilling process. Based on the trend of cutting torque change, the cutting stage is divided by calculating the average value of sample point data. The entire drilling process is divided into three parts: the infeed stage, the filling stage, and the retraction stage. Calculate the average circumferential torque of the thermoelectric drill in all three stages. Use the ratio of the average circumferential torque to the allowable circumferential torque as the circumferential load coefficient. d) Analyze the temperature of the filler material during the drilling process. The measurement area is the drilling entrance of the TC4 titanium alloy filler material. Measure the temperature and divide the difference between the highest temperature at the inlet of the filler material surface and the thermal softening temperature of the filler material by the difference between the melting point and the thermal softening temperature of the filler material as the temperature load coefficient. e) Use anhydrous ethanol to perform ultrasonic cleaning on the processed hot melt drill. After cleaning, measure the remaining axial length of the hot melt drill after processing. The difference in axial length of the hot melt drill before and after processing is the wear amount of the hot melt drill. f) Perform elemental energy dispersive spectroscopy on the surface of the hot melt drill, select titanium as the characteristic element of the filler material, and analyze the titanium content on the surface of the hot melt drill before and after processing as the amount of chip adhesion.

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