Machining method for complex thin-wall part

Abstract

The invention provides a machining method for a complex thin-wall part, and relates to the technical field of mechanical manufacturing, in theory, MASTERCAME software is used for simulating and analyzing a cutting path of a cutting tool on the thin-wall part, a numerical control program is programmed, a high-precision mold mandrel is adopted, the mold mandrel is consistent with an inner cavity of a product in shape, a gap is reserved, small deformation and vibration in the machining process are ensured, and the machining precision is improved. Meanwhile, the clamping fixture mandrel can absorb part of cutting heat, thermal deformation of a cutter and a product is kept small, the long one-time feeding time of a thin-wall workpiece is very long, so that the cutter is greatly abraded due to vibration in the cutting process, and the dimensional accuracy of the workpiece is affected; geometric parameters and abrasion resistance of the tool are reasonably selected, the influence caused by tool abrasion is minimized, small deformation and vibration in the machining process are guaranteed, meanwhile, the clamping fixture mandrel can absorb part of cutting heat, and thermal deformation of the tool and a product is kept small.

Description

Technical Field

[0001] The invention belongs to the technical field of mechanical manufacturing, and more specifically, particularly relates to a processing method for complex thin-walled parts. Background Art

[0002] The air intake casing is a single-wing helicopter engine part. It is a thin-walled part made of 2A12 aluminum. It has flared inner and outer arcs on both sides. The thinnest wall thickness is 1mm. The product has many sizes and poor processing technology. It is prone to processing deformation and cutting vibration. Thin-walled parts are currently generally processed by CNC turning. For this purpose, the clamping of the workpiece, the geometric parameters of the tool, and the compilation of the program must be tested and verified to effectively overcome the deformation of thin-walled parts during processing and ensure processing accuracy.

[0003] The purpose of the present invention is to overcome the shortcomings of the background technology, optimize and improve the clamping of the workpiece, the geometric parameters of the tool, the compilation of the program, etc., overcome the deformation occurring during the machining of thin-walled parts, and ensure the machining accuracy. Summary of the invention

[0004] In order to solve the above technical problems, the present invention provides a method for processing complex thin-walled parts to solve the above problems.

[0005] A method for processing a complex thin-walled part comprises the following steps:

[0006] S1: theoretical simulation tool path;

[0007] S2: Use high-precision mold mandrel to make the mold mandrel consistent with the shape of the product cavity, leaving a gap;

[0008] S3: Cutting process;

[0009] S4: After the inner hole of the workpiece is completed by deep hole, the outer circle is precision turned to improve the manufacturing accuracy of the mandrel and the self-turning soft claws to improve the positioning accuracy;

[0010] S5: Through trial processing and comparison of tools made of various materials, reasonable tool geometry parameters and wear resistance are selected to minimize the impact of tool wear.

[0011] Preferably, the S1 theoretical simulation tool path includes the following contents:

[0012] S11: Model thin-walled parts: Use computer-aided design (CAD) software to create a three-dimensional model of the thin-walled parts to accurately represent their shape, size, and features;

[0013] S12: Determine the processing technology; according to the material, shape and requirements of the thin-walled parts, determine the appropriate processing technology, such as cutting method, tool type, feed speed, etc.;

[0014] S13: Tool path planning: Use CAM (computer-aided manufacturing) software to plan the tool path according to the machining process. This includes determining the tool entry point, cutting direction, cutting depth, etc.

[0015] S14: Simulate the cutting process: Use CAM software to simulate the cutting process to predict possible problems that may occur during the processing, such as tool interference, vibration, deformation, etc.

[0016] S15: Optimize toolpath: According to the simulation results, optimize the toolpath to avoid potential problems and improve machining efficiency and quality;

[0017] S16: Consider machining allowance: Determine the distribution of machining allowance of thin-walled parts to ensure that the final size and shape meet the requirements;

[0018] S17: Analyze cutting forces and temperatures: Evaluate the cutting forces and temperature distribution generated during the cutting process to ensure that no damage or deformation is caused to thin-walled parts;

[0019] S18: Verify processing feasibility: Check whether the simulation results meet the processing requirements, such as dimensional accuracy, surface quality, etc.

[0020] S19: Generate NC code: Convert the optimized tool path into NC code recognizable by the NC machine tool for actual processing.

[0021] Preferably, in S2, when installing the thin-walled part, the mold core shaft is placed into the inner cavity and the position is adjusted so that it fits tightly with the thin-walled part, and the size of the reserved gap is measured and controlled to ensure that it is 0.03 mm.

[0022] Preferably, S3 first selects a suitable cutting tool, then determines cutting parameters, and then performs cutting processing;

[0023] During the cutting process, attention should be paid to controlling the cutting force and cutting heat to avoid deformation or thermal damage of thin-walled parts, monitoring the processing status during the cutting process, and inspecting the size and shape of the processed thin-walled parts.

[0024] Preferably, S4 comprises the following steps:

[0025] S41: Complete deep hole processing of the inner hole of the workpiece;

[0026] S42: Finish turning the outer circle;

[0027] S43: Improve the manufacturing accuracy of the mandrel;

[0028] S44: self-driving soft gripper;

[0029] S45: Improve positioning accuracy.

[0030] Preferably, S5 includes five aspects: trial processing of tools of various materials, comparison of trial processing results, reasonable selection of tool geometric parameters, determination of tool wear resistance, and minimization of the impact of tool wear.

[0031] Preferably, the S1 theoretical simulation tool path also includes simulating and optimizing the clamping method of the thin-walled part to ensure stability during the processing.

[0032] Preferably, in S2, the manufacture of the high-precision mold mandrel adopts advanced processing technology and equipment to ensure its accuracy and consistency

[0033] Preferably, in S3 cutting processing, a suitable cutting fluid is selected according to the material properties of the thin-walled workpiece to improve the cutting effect and reduce tool wear.

[0034] Preferably, in S4, online monitoring technology is used to monitor parameters in the processing process, such as cutting force, temperature, etc. in real time, and timely adjustments and optimizations are made according to the monitoring results.

[0035] Compared with the prior art, the present invention has the following beneficial effects:

[0036] In the present invention, through trial processing and comparison of cutting tools made of various materials, the geometric parameters and wear resistance of the cutting tools are rationally selected to minimize the influence of cutting tool wear.

[0037] In the present invention, after the inner hole of the workpiece is completed by deep hole, the outer circle is precision turned, so as to improve the manufacturing accuracy of the mandrel and the self-turning soft claws and improve the positioning accuracy.

[0038] In the present invention, a high-precision mold core shaft is used to make the mold core shaft consistent with the shape of the product inner cavity, and a 0.03mm gap is reserved to ensure smaller deformation and vibration during the processing process. At the same time, the mold core shaft can partially absorb the cutting heat to keep the thermal deformation of the tool and the product small. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] Figure 1 It is a schematic diagram of the process of the present invention. DETAILED DESCRIPTION

[0040] The following embodiments of the present invention are described in further detail in conjunction with the accompanying drawings and examples. The following examples are used to illustrate the present invention, but are not intended to limit the scope of the present invention.

[0041] See also Figure 1 The present invention provides a method for processing a complex thin-walled part, comprising the following steps:

[0042] S1: Theoretical simulation of tool path, theoretically using MASTERCAME software to simulate and analyze the cutting path of cutting tools on thin-walled parts and compile CNC programs;

[0043] S2: Use high-precision mold mandrel to make the mold mandrel consistent with the shape of the product cavity, and reserve a gap to ensure minimal deformation and vibration during the processing. At the same time, the mold mandrel can partially absorb the cutting heat to keep the thermal deformation of the tool and product small;

[0044] S3: Cutting process, the cutting tool processes the thin-walled part according to the CNC program. During the cutting process, the cutting tool continuously moves on the surface of the thin-walled part. The high-speed rotation of the product makes the excitation frequency of the cutting tool much higher than the natural frequency of the machine tool, thereby reducing the vibration of the process system. During the cutting process, the side cutter of the tool cuts the thin-walled part. When cutting the inner contour, the cutting tool cuts from the outside to the inside (forward), and when cutting the outer contour, the cutting tool cuts from the inside to the outside (reverse);

[0045] S4: After the inner hole of the workpiece is completed by deep hole, the outer circle is finely turned. In deep hole processing, factors such as ellipse, taper and runout are inevitable, which affect the coaxiality and runout of the outer circle. Improve the manufacturing accuracy of the mandrel and self-turning soft claws to improve positioning accuracy;

[0046] S5: Since thin-walled workpieces are long and the cutting time is very long, the vibration during the cutting process causes the tool to wear greatly, thus affecting the dimensional accuracy of the workpiece. Through trial processing and comparison of tools made of various materials, the tool geometry parameters and wear resistance are reasonably selected to minimize the impact of tool wear.

[0047] Through theoretical simulation, possible problems such as tool interference, vibration, deformation, etc. can be predicted before actual processing, and corresponding optimization adjustments can be made to improve processing efficiency and quality. Trial and error in actual processing may waste time and materials, while theoretical simulation can make multiple attempts in a virtual environment to find the best processing solution and reduce the cost of trial and error. The simulated tool path can more accurately determine the tool path and cutting parameters, which helps to ensure the dimensional accuracy and shape accuracy of thin-walled parts. Through simulation, the feasibility of the processing process can be evaluated, potential problems can be discovered in advance, and corresponding measures can be taken to solve them to avoid unexpected situations in actual processing. Simulation can help select appropriate tool geometry parameters and wear resistance to minimize tool wear during processing, extend tool life, and reduce processing costs. Reasonable tool path planning can reduce processing time and idle tool travel and improve production efficiency. Theoretical simulation results can provide a basis for production planning and scheduling, making the entire processing process more orderly and efficient. In summary, the S1 theoretical simulation tool path plays an important role in the processing of complex thin-walled parts, which can improve processing quality, reduce costs, ensure feasibility, and provide strong support for subsequent actual processing.

[0048] S2 uses a high-precision mold mandrel to make the mold mandrel consistent with the shape of the product's inner cavity, and a reserved gap makes the mold mandrel consistent with the shape of the product's inner cavity, which can better support and fix thin-walled parts during processing and reduce deformation, thereby ensuring the shape accuracy of thin-walled parts. The reserved gap can avoid interference fit between the mandrel and the thin-walled parts, reduce vibration and stress concentration during processing, and improve processing stability. The high-precision mold mandrel and reasonable gap design are conducive to accurate clamping and positioning of thin-walled parts, ensuring consistency and repeatability of processing. The appropriate gap can reduce friction and collision between the mandrel and thin-walled parts, and reduce the risk of damage to the surface of thin-walled parts. Stable clamping and positioning can reduce adjustment and pause time during processing and improve processing efficiency. By adjusting the mold mandrel and gap, it can adapt to the processing of thin-walled parts of different shapes and sizes, increasing the versatility of the processing method. S2 uses a high-precision mold mandrel and reserves a gap, which is of great significance for ensuring the processing quality of complex thin-walled parts and improving processing stability and efficiency.

[0049] Through S3 cutting, excess material can be removed from thin-walled parts to achieve the required shape and size. Reasonable cutting parameters and tool selection can ensure the accuracy and smoothness of the machined surface and meet the quality requirements of complex thin-walled parts. Accurate cutting can minimize material waste and improve material utilization. According to the material characteristics of thin-walled parts, suitable cutting processes and tools can be selected to effectively process thin-walled parts of various materials. Under the premise of ensuring processing quality, cutting can improve processing efficiency by optimizing parameters such as cutting speed and feed rate. For thin-walled parts with complex shapes, cutting can achieve complex contour processing through technical means such as multi-axis linkage. The surface quality of thin-walled parts after cutting is good, which is conducive to subsequent surface treatment, assembly and other processes.

[0050] S4 first completes the inner hole processing and then fine turning the outer circle, which can better ensure the coaxiality and roundness of the workpiece, thereby improving the overall processing accuracy. After the inner hole processing, the internal structure of the workpiece is relatively stable. When the outer circle processing is performed, the deformation caused by cutting force can be reduced. By improving the manufacturing accuracy of the mandrel and the self-turning soft jaws, the workpiece can be fixed more accurately to ensure that the position of the workpiece does not shift during the processing process, further improving the processing accuracy. According to the situation of the inner hole processing, the reasonable selection of tool geometric parameters and wear resistance can extend the tool life and reduce the impact of tool wear on the processing quality. Reasonable processing sequence can avoid repeated clamping and adjustment, save processing time, and improve production efficiency. This step-by-step processing method is suitable for the processing of various complex thin-walled parts and can meet the processing requirements of different workpieces.

[0051] S5 can find the most suitable tool for processing the complex thin-walled parts through trial processing and comparison of tools made of various materials, improve processing efficiency and quality, and reasonably select tool geometry parameters and wear resistance to extend tool life and reduce the impact of tool wear on processing accuracy and surface quality. Appropriate tool selection and parameter setting can reduce cutting force, vibration and deformation, and improve the stability of the processing process. For thin-walled parts made of different materials, suitable tools can be selected according to the trial processing results to ensure smooth processing, reduce tool replacement frequency and wear, reduce production costs, improve production efficiency, minimize the impact of tool wear, and help ensure the dimensional accuracy, shape accuracy and surface quality of thin-walled parts. Selecting suitable tools and parameters can increase cutting speed and feed rate, thereby improving production efficiency.

[0052] S1 theoretical simulation toolpath includes the following:

[0053] S11: Model thin-walled parts: Use computer-aided design (CAD) software to create a three-dimensional model of the thin-walled parts to accurately represent their shape, size, and features;

[0054] S12: Determine the processing technology; according to the material, shape and requirements of the thin-walled parts, determine the appropriate processing technology, such as cutting method, tool type, feed speed, etc.;

[0055] S13: Tool path planning: Use CAM (computer-aided manufacturing) software to plan the tool path according to the machining process. This includes determining the tool entry point, cutting direction, cutting depth, etc.

[0056] S14: Simulate the cutting process: Use CAM software to simulate the cutting process to predict possible problems that may occur during the processing, such as tool interference, vibration, deformation, etc.

[0057] S15: Optimize toolpath: According to the simulation results, optimize the toolpath to avoid potential problems and improve machining efficiency and quality;

[0058] S16: Consider machining allowance: Determine the distribution of machining allowance of thin-walled parts to ensure that the final size and shape meet the requirements;

[0059] S17: Analyze cutting forces and temperatures: Evaluate the cutting forces and temperature distribution generated during the cutting process to ensure that no damage or deformation is caused to thin-walled parts;

[0060] S18: Verify processing feasibility: Check whether the simulation results meet the processing requirements, such as dimensional accuracy, surface quality, etc.

[0061] S19: Generate NC code: Convert the optimized tool path into NC code recognizable by the NC machine tool for actual processing.

[0062] In S2, when installing the thin-walled part, place the mold core shaft into the inner cavity and adjust the position so that it fits tightly with the thin-walled part. Measure and control the size of the reserved gap to ensure that it is 0.03 mm.

[0063] S3 first selects a suitable cutting tool, then determines the cutting parameters, and then performs cutting processing. During the cutting process, pay attention to controlling the cutting force and cutting heat to avoid deformation or thermal damage of thin-walled parts, monitor the processing status during the cutting process, and inspect the size and shape of the processed thin-walled parts.

[0064] S4 includes the following steps:

[0065] S41: Complete deep hole processing of the inner hole of the workpiece, use appropriate processing methods and tools to perform deep hole processing on the inner hole of the thin-walled part to ensure that the size and shape of the inner hole meet the requirements;

[0066] S42: Finish turning the outer circle. After deep hole processing is completed, the outer circle is finished. This step aims to further improve the accuracy and surface quality of the outer circle.

[0067] S43: Improve the manufacturing accuracy of the mandrel by improving the manufacturing process or adopting a higher precision processing method. The high-precision mandrel can better cooperate with thin-walled parts and provide more stable support and positioning;

[0068] S44: Self-turning soft jaws, self-turning the soft jaws of the machine tool to adapt to the shape and size of thin-walled parts. Self-turning soft jaws can improve the positioning accuracy of the workpiece and reduce clamping errors;

[0069] S45: Improve positioning accuracy. Through the comprehensive application of the above measures, the positioning accuracy of thin-walled parts during processing can be further improved to ensure the accuracy and consistency of processing.

[0070] S5 includes trial processing of tools made of various materials (select tools made of various different materials for trial processing. These tools may have different characteristics, such as hardness, wear resistance, etc.), comparison of trial processing results (compare the results of processing with different tools, including processing quality, efficiency, tool wear, etc.), reasonable selection of tool geometric parameters (select appropriate tool geometric parameters according to the results of trial processing and comparison, such as tool shape, angle, number of blades, etc., to optimize the processing effect), determination of tool wear resistance (determine the tool wear resistance through trial processing and analysis, so as to select tools with better wear resistance in actual processing and reduce the influence of tool wear on processing), and minimization of the influence of tool wear (comprehensively consider factors such as tool material, geometric parameters and wear resistance, and take corresponding measures, such as adjusting cutting parameters, performing tool maintenance, etc., to minimize the influence of tool wear on the processing process and product quality).

[0071] In the S1 theoretical simulation tool path, the clamping method of thin-walled parts is also simulated and optimized to ensure stability during the processing. In S2, the manufacture of high-precision mold mandrels uses advanced processing technology and equipment to ensure its accuracy and consistency. In the S3 cutting process, suitable cutting fluid is selected according to the material properties of thin-walled parts to improve the cutting effect and reduce tool wear. In S4, online monitoring technology is used to monitor the parameters in the processing process in real time, such as cutting force, temperature, etc., and timely adjustments and optimizations are made according to the monitoring results.

[0072] Working principle:

[0073] Step 1: First the inner cavity and then the outer shape, the two ends are processed separately, soft claws are used, and self-machining ensures that the runout is less than 0.02mm;

[0074] Step 2: The shape processing adopts high-precision self-turning mandrel. The shape of the mandrel is consistent with the shape of the inner cavity, and a gap of 0.03mm is left with the product to ensure that the shape processing runout is small, the positioning reference is accurate, and the wall thickness size is consistent. After turning, the mandrel is used in the machining center to mill the shape and drill the inclined oil hole;

[0075] Step 3: Optimize the CNC program, select the processing parameters reasonably, and use high speed and small feed to ensure the product size accuracy and surface roughness. Rough turning parameters: S500r / min, f0.15mm / r, ap2-3mm, fine turning parameters: S800 r / min, f0.05-0.1mm / r, ap0.25-0.5mm;

[0076] Step 4: The processing of lubricating oil channel hole is more difficult. Not only must the position at the bottom of the M5 threaded hole be correct, but also the spatial position of the oil hole at the arc mouth must be correct. Use a tool grinding universal vise to make multiple adjustments in the X, Y, and Z directions to complete the oil hole processing.

[0077] The embodiments of the present invention are given for the purpose of illustration and description, and are not intended to be exhaustive or to limit the invention to the disclosed forms. Many modifications and variations will be apparent to those of ordinary skill in the art. The embodiments are selected and described in order to better illustrate the principles and practical applications of the present invention and to enable those of ordinary skill in the art to understand the present invention and thereby design various embodiments with various modifications suitable for specific uses.

Claims

1. A method for processing complex thin-walled parts, characterized in that: The following steps are involved: S1: theoretical simulation tool path; S2: Use high-precision mold mandrel to make the mold mandrel consistent with the shape of the product cavity, leaving a gap; S3: Cutting process; S4: After the inner hole of the workpiece is completed by deep hole, the outer circle is precision turned to improve the manufacturing accuracy of the mandrel and the self-turning soft claws to improve the positioning accuracy; S5: Through trial processing and comparison of tools made of various materials, reasonable tool geometry parameters and wear resistance are selected to minimize the impact of tool wear.

2. A method for processing a complex thin-walled part as claimed in claim 1, characterized in that: S1 theoretical simulation toolpath includes the following: S11: Model thin-walled parts: Use computer-aided design (CAD) software to create a three-dimensional model of the thin-walled parts to accurately represent their shape, size, and features; S12: Determine the processing technology; according to the material, shape and requirements of the thin-walled parts, determine the appropriate processing technology, such as cutting method, tool type, feed speed, etc.; S13: Tool path planning: Use CAM (computer-aided manufacturing) software to plan the tool path according to the machining process. This includes determining the tool entry point, cutting direction, cutting depth, etc. S14: Simulate the cutting process: Use CAM software to simulate the cutting process to predict possible problems that may occur during the processing, such as tool interference, vibration, deformation, etc. S15: Optimize toolpath: According to the simulation results, optimize the toolpath to avoid potential problems and improve machining efficiency and quality; S16: Consider machining allowance: Determine the distribution of machining allowance of thin-walled parts to ensure that the final size and shape meet the requirements; S17: Analyze cutting forces and temperatures: Evaluate the cutting forces and temperature distribution generated during the cutting process to ensure that no damage or deformation is caused to thin-walled parts; S18: Verify processing feasibility: Check whether the simulation results meet the processing requirements, such as dimensional accuracy, surface quality, etc. S19: Generate NC code: Convert the optimized tool path into NC code recognizable by the NC machine tool for actual processing.

3. A method for processing a complex thin-walled part as claimed in claim 1, characterized in that: In S2, when installing the thin-walled part, place the mold core shaft into the inner cavity and adjust the position so that it fits tightly with the thin-walled part. Measure and control the size of the reserved gap to ensure that it is 0.03 mm.

4. A method for processing a complex thin-walled part as claimed in claim 1, characterized in that: S3 first selects the appropriate cutting tool, then determines the cutting parameters, and then performs the cutting process; During the cutting process, attention should be paid to controlling the cutting force and cutting heat to avoid deformation or thermal damage of thin-walled parts, monitoring the processing status during the cutting process, and inspecting the size and shape of the processed thin-walled parts.

5. A method for processing a complex thin-walled part as claimed in claim 1, characterized in that: S4 includes the following steps: S41: Complete deep hole processing of the inner hole of the workpiece; S42: Finish turning the outer circle; S43: Improve the manufacturing accuracy of the mandrel; S44: self-driving soft gripper; S45: Improve positioning accuracy.

6. A method for processing a complex thin-walled part as claimed in claim 1, characterized in that: S5 includes five aspects: trial processing of tools of various materials, comparison of trial processing results, rational selection of tool geometry parameters, determination of tool wear resistance, and minimization of the impact of tool wear.

7. A method for processing a complex thin-walled part as claimed in claim 1, characterized in that: The S1 theoretical simulation tool path also includes simulation and optimization of the clamping method of thin-walled parts to ensure stability during the processing.

8. A method for processing a complex thin-walled part as claimed in claim 1, characterized in that: In S2, the manufacture of high-precision mold mandrels uses advanced processing technology and equipment to ensure its accuracy and consistency.

9. A method for processing a complex thin-walled part as claimed in claim 1, characterized in that: In S3 cutting, appropriate cutting fluid is selected according to the material properties of thin-walled parts to improve cutting effect and reduce tool wear.

10. A method for processing a complex thin-walled part as claimed in claim 1, characterized in that: In S4, online monitoring technology is used to monitor the parameters in the processing process, such as cutting force, temperature, etc. in real time, and timely adjustments and optimizations are made based on the monitoring results.

Images