Multi-index fusion cutter service life detection method

Abstract

The invention provides a multi-index fused cutter service life detection method, which comprises the following steps that: a cutter is used for continuously grinding a metal material workpiece, so that the cutter is gradually worn in an experiment process, the cutting force is measured, and the machining quality of the workpiece is changed along with the wear condition of the cutter; the quality of the machined surface of the workpiece under different cutter abrasion conditions and grinding paths is observed, and the roughness of the workpiece is measured; observing and measuring different cutter wear conditions and wear forms, material adhesion rates and wear heights of the cutter under the grinding distance; multiple indexes such as cutting force, workpiece roughness, cutter material adhesion rate and abrasion height are fused, and the service life of the cutter is detected; through the steps, the wear condition of the tool can be analyzed, the service life of the tool can be determined, consistency, accuracy and practicability are achieved, the utilization rate of the tool can be increased, and then the machining quality and the production efficiency are improved.

Description

Technical Field

[0001] The present invention relates to the field of tool life detection technology, and in particular to a tool life detection method integrating multiple indicators. Background Art

[0002] Materials such as titanium alloys and nickel-based high-temperature alloys are widely used in the manufacture of parts in the aerospace field. Because of their high requirements for processing quality, grinding technology is mainly used in fine processing. Since the tool will continue to wear and consume during the grinding process, the workpiece material will adhere to the tool surface, resulting in deterioration of grinding performance and processing accuracy, increased processing instability, and then the surface quality of the workpiece will deteriorate, significantly affecting the service performance of the parts; detecting the tool life under different working conditions can avoid the continued processing of severely worn tools. Therefore, obtaining the tool life is a key factor affecting processing quality and production efficiency. Accurately and effectively detecting the tool life is crucial to the precision processing of parts.

[0003] At present, the service life of tools is mainly determined by the wear of the back tool surface being greater than the blunting standard of 0.3mm or the obvious chipping and fracture of the tool. However, for grinding tool wheels, the failure forms of tools are different, and it is difficult to determine their service life by the above method. Instead, it is mainly determined by detecting the wear condition of the tool.

[0004] In relative technology, the detection methods of tool wear are mainly based on vibration signals, image processing, acoustic emission signals and other technologies. However, the recognition mode of each method has its own limitations. It is difficult to accurately identify the tool wear condition and directly determine the tool life. It is impossible to guide the selection of parameters that affect the processing quality and production efficiency. Summary of the invention

[0005] Purpose of the invention: In order to solve the problem of poor consistency and accuracy in tool life detection, this application proposes a tool life detection method that integrates multiple indicators.

[0006] The present application provides a multi-index fusion tool life detection method, the method comprising:

[0007] Step A: Use a tool to continuously process a metal workpiece, so that the tool is gradually worn during the experiment, and the cutting force is measured. The processing quality of the workpiece changes with the wear of the tool;

[0008] Step B, observing and measuring the machining surface quality and roughness of the workpiece under different tool wear conditions and grinding paths by means of a surface observation method;

[0009] Step C, observing and measuring the wear form, material adhesion rate and wear height of the tool under different tool wear conditions and grinding paths by observation method;

[0010] Step D: Integrate multiple indicators such as cutting force, workpiece roughness, tool material adhesion rate and wear height to detect tool life and guide the selection of processing parameters.

[0011] Preferably, the tool in step A is a grinding wheel with different abrasive materials, abrasive bonding methods and grain sizes.

[0012] Preferably, the metal material workpiece in step A is a difficult-to-grind material of titanium alloy or nickel-based high-temperature alloy of different grades.

[0013] Preferably, the cutting force in step A refers to the grinding force in the direction of the tool cutting speed.

[0014] Preferably, the surface observation method in step B refers to metallographic microscopy, roughness meter method, and white light interferometry.

[0015] Preferably, the observation method in step C refers to scanning electron microscopy, EDS energy spectrum analysis, and diameter measurement.

[0016] Preferably, the material adhesion rate in step C refers to the proportion of workpiece material adhering to the grinding wheel, and the wear height refers to the height difference before and after the tool is worn.

[0017] Preferably, the multi-index fusion in step D refers to:

[0018] 1) Draw the cutting force and cutting force growth rate curves under different cutting distances. The cutting force reflects the tool wear state, and the cutting force growth rate reflects the instantaneous impact caused by tool wear, that is, the instability of processing;

[0019] 2) Comparing the workpiece surface processing quality under different tool wear conditions, the processing quality is poor in the initial wear stage of the tool, the processing quality is stable in the stable wear stage, and the processing quality is poor in the severe wear stage. Therefore, the change in surface processing quality reflects the different stages of tool wear;

[0020] 3) Draw the surface roughness curve of the workpiece under different cutting paths. From the initial wear of the tool to the stable wear stage, the roughness change tends to be stable. From the stable wear of the tool to the severe wear stage, the roughness changes sharply and exceeds the processing quality index requirements, which reflects the service life of the tool;

[0021] 4) Observe the tool wear forms, including abrasive crushing, abrasive wear, abrasive shedding and grinding wheel adhesion; among them, abrasive crushing refers to the appearance of irregular pits or fine cracks on the top of the abrasive grains, abrasive wear refers to the flat surface of the abrasive grains and the decrease in height, abrasive shedding refers to the pits left on the grinding wheel base material, and grinding wheel adhesion refers to the adhesion of workpiece materials to the abrasive grains or between the abrasive grains, to determine the tool failure form;

[0022] 5) Measure the tool material adhesion rate, wear height and height wear rate, and draw curves under different cutting distances; among them, the material adhesion rate reflects the degree of grinding wheel adhesion, the wear height and height wear rate reflect the abrasive crushing, abrasive wear and abrasive shedding, and determine the degree of tool wear.

[0023] Preferably, the detection of tool life in step D refers to:

[0024] 1) When the growth rate of cutting force is greater than 40%, the severe wear of the tool causes a large instantaneous impact, increasing the instability of the machining process;

[0025] 2) When the workpiece surface roughness Sa>1.6μm, the damage to the surface caused by severe wear of the tool cannot meet the processing requirements;

[0026] 3) When the tool adhesion rate is greater than 15%, the workpiece material is seriously adhered to the abrasive gap, affecting the tool processing accuracy. At the same time, the tool grinding performance deteriorates, the adhesion is peeled off and deposited on the processed surface, and the processing accuracy and surface quality cannot meet the requirements;

[0027] 4) When the tool height wear rate is greater than 20%, the height and sharpness of the tool cutting edge are greatly reduced, and the cutting ability is lost.

[0028] Preferably, the guiding of the selection of processing parameters in step D means that the tool life under different processing parameters can be accurately obtained by detecting the tool life through multi-index fusion, and then the appropriate processing parameters are selected according to the needs of processing quality and production efficiency.

[0029] Beneficial technical effects of this application:

[0030] The present application provides a multi-index fusion tool life detection method, which can obtain tool wear conditions with higher consistency and accuracy, and thereby determine the tool life, thereby achieving optimal control of processing quality and production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 is a graph of cutting force and cutting force growth rate according to an embodiment of the present invention;

[0032] Figure 2 is the surface morphology of the workpiece under different tool wear conditions of the embodiment of the present invention;

[0033] Figure 3 is the surface roughness of the workpiece under different grinding paths in the embodiment of the present invention;

[0034] Figure 4 is the condition of the tool under different tool wear conditions of the embodiment of the present invention;

[0035] Figure 5 is the workpiece material adhesion rate of the tool under different grinding paths of the embodiment of the present invention;

[0036] Figure 6 : are the wear height and height wear rate of the tool under different grinding distances of the embodiment of the present invention. DETAILED DESCRIPTION

[0037] The present application provides a multi-index integrated tool life detection method, which includes the following steps: using a tool to continuously grind a metal workpiece, so that the tool is gradually worn during the experiment, measuring the cutting force, and the processing quality of the workpiece changes with the tool wear condition; observing the processing surface quality of the workpiece under different tool wear conditions and grinding distances and measuring the roughness of the workpiece; observing and measuring the wear form, material adhesion rate and wear height of the tool under different tool wear conditions and grinding distances; integrating the cutting force, workpiece roughness, tool material adhesion rate and wear height multiple indicators to detect the tool life; through the above steps, the results can analyze the tool wear condition and determine the tool life, with consistency, accuracy and practicality, can improve the utilization rate of the tool, and thus improve the processing quality and production efficiency.

[0038] The present application provides a multi-index fusion tool life detection method, comprising the following steps:

[0039] A. Use the tool to continuously process the metal workpiece, so that the tool gradually wears during the experiment, measure the cutting force, and the processing quality of the workpiece changes with the tool wear condition;

[0040] B. Observe and measure the surface quality and roughness of the workpiece under different tool wear conditions through surface observation methods;

[0041] C. Observe and measure the wear form, material adhesion rate and wear height of the tool under different tool wear conditions through observation methods;

[0042] D. Integrate multiple indicators such as cutting force, workpiece roughness, tool material adhesion rate and wear height to detect tool life and guide the selection of processing parameters;

[0043] The tool in step A may be a grinding wheel with different abrasive materials, abrasive bonding methods and grain sizes.

[0044] The metal material workpiece in step A may be a difficult-to-grind material such as titanium alloys, nickel-based high-temperature alloys, etc. of different grades.

[0045] The cutting force in step A refers to the grinding force in the direction of the tool cutting speed.

[0046] Wherein, the surface observation method described in step B refers to metallographic microscope method, roughness meter method, and white light interferometry method.

[0047] Wherein, the observation method described in step C refers to scanning electron microscopy, EDS energy spectrum analysis, and diameter measurement.

[0048] The material adhesion rate in step C refers to the proportion of workpiece material adhering to the grinding wheel, and the wear height refers to the height difference before and after tool wear.

[0049] The multi-index fusion in step D refers to:

[0050] 1) Draw the cutting force and cutting force growth rate curves under different cutting distances. The cutting force can reflect the tool wear state, and the cutting force growth rate can reflect the instantaneous impact caused by tool wear, that is, the instability of processing;

[0051] 2) Comparing the workpiece surface processing quality under different tool wear conditions, the processing quality is poor in the initial wear stage of the tool, the processing quality is stable in the stable wear stage, and the processing quality is poor in the severe wear stage. Therefore, the change in surface processing quality reflects the different stages of tool wear;

[0052] 3) Draw the surface roughness curve of the workpiece under different cutting paths. From the initial wear of the tool to the stable wear stage, the roughness change tends to be stable. From the stable wear of the tool to the severe wear stage, the roughness changes sharply and exceeds the processing quality index requirements, which reflects the service life of the tool;

[0053] 4) Observe the tool wear forms, including abrasive crushing, abrasive wear, abrasive shedding and grinding wheel adhesion. Abrasive crushing refers to the appearance of irregular pits or fine cracks on the top of the abrasive grains, abrasive wear refers to the flat surface of the abrasive grains and the decrease in height, abrasive shedding refers to the pits left on the grinding wheel base material, and grinding wheel adhesion refers to the adhesion of workpiece materials to the abrasive grains or between the abrasive grains, to determine the tool failure form;

[0054] 5) Measure the tool material adhesion rate, wear height and height wear rate, and draw curves under different cutting distances. The material adhesion rate reflects the degree of grinding wheel adhesion, and the wear height and height wear rate reflect the abrasive particle breakage, abrasive particle wear and abrasive particle shedding to determine the degree of tool wear;

[0055] Wherein, the detection of tool life in step D refers to:

[0056] 1) When the growth rate of cutting force is greater than 40%, the severe wear of the tool causes a large instantaneous impact, increasing the instability of the machining process;

[0057] 2) When the workpiece surface roughness Sa>1.6μm, the damage to the surface caused by severe wear of the tool cannot meet the processing requirements;

[0058] 3) When the tool adhesion rate is greater than 15%, the workpiece material is seriously adhered to the abrasive gap, affecting the tool processing accuracy. At the same time, the tool grinding performance deteriorates, the adhesion is peeled off and deposited on the processed surface, and the processing accuracy and surface quality cannot meet the requirements;

[0059] 4) When the tool height wear rate is greater than 20%, the height and sharpness of the tool cutting edge are greatly reduced, and the cutting ability is lost;

[0060] Among them, the guiding processing parameter selection in step D means that the tool life under different processing parameters can be accurately obtained by detecting the tool life through multi-indicator fusion, and then the appropriate processing parameters are selected according to the needs of processing quality and production efficiency.

[0061] In other embodiments of the present application, a multi-index fusion tool life detection method provided by the present application includes the following steps:

[0062] Step 1: Use a tool to continuously process a metal workpiece, so that the tool gradually wears during the experiment, and measure the cutting force. The processing quality of the workpiece changes with the tool wear condition.

[0063] refer to Figure 1 The cutting force and cutting force growth rate curves under different grinding paths are shown in the figure. In the initial wear stage of the tool, the abrasive wear and crushing are serious, the cutting force is large, and gradually decreases. In the stable wear stage, the cutting force is stable and low. In the severe wear stage, the cutting force increases, the growth rate exceeds 40%, and the processing process is unstable.

[0064] Step 2: Observe the surface quality of the workpiece under different tool wear conditions through white light interferometry, and measure and draw the surface roughness curve of the workpiece under different grinding paths.

[0065] refer to Figure 2 The surface morphology of the workpiece under different tool wear conditions is shown in the figure. When the processing quality is stable, the surface is relatively smooth, and when the processing quality is poor, there is redeposited coating material on the surface.

[0066] refer to Figure 3 The surface roughness of the workpiece under different grinding paths is shown in the figure. Among them, from the initial wear of the tool to the stable wear stage, the roughness decreases slightly and the change tends to be stable. From the stable wear of the tool to the severe wear stage, the roughness increases sharply, Sa exceeds 1.6μm, and the surface quality deteriorates and cannot meet the service performance.

[0067] Step 3: Observe the wear pattern of the tool under different tool wear conditions by scanning electron microscopy.

[0068] refer to Figure 4 The condition of the tool under different tool wear conditions is shown in the figure. Before the tool wear, the abrasive distribution is relatively uniform and the edge is complete. After the tool wear, abrasive wear, abrasive crushing, abrasive shedding and grinding wheel adhesion occur. On the whole, the abrasive density and the cutting edge height of the grinding wheel are greatly reduced, and there is material adhesion between the abrasives.

[0069] Step 4: Measure the workpiece material adhesion rate of the tool under different grinding paths through EDS energy spectrum analysis.

[0070] refer to Figure 5 The workpiece material adhesion rate of the tool under different grinding distances is shown in the figure. With the increase of cutting distance, the material adhesion rate increases. When the material adhesion rate exceeds 15%, the grinding performance deteriorates.

[0071] Step 5: Measure the wear height of the tool at different grinding distances by diameter measurement method, and determine the height of the complete abrasive grains to be about 80 μm by scanning electron microscopy method, and calculate the height wear rate accordingly.

[0072] refer to Figure 6 The wear height and height wear rate of the tool under different grinding distances are shown in the figure. As the cutting distance increases, the wear height increases. When the height wear rate exceeds 20%, the tool cutting edge becomes blunt, the cutting height decreases, and the cutting ability is lost.

[0073] Step 6: Through the multi-state fusion of the above steps, it is determined that the tool life under this working condition is approximately 600mm of grinding distance 3 .

Claims

1. A multi-index fusion tool life detection method, characterized in that: The method comprises: Step A: Use a tool to continuously process a metal workpiece, so that the tool is gradually worn during the experiment, and the cutting force is measured. The processing quality of the workpiece changes with the wear of the tool; Step B, observing and measuring the machining surface quality and roughness of the workpiece under different tool wear conditions and grinding paths by means of a surface observation method; Step C, observing and measuring the tool wear form, material adhesion rate and wear height under different tool wear conditions and grinding paths by observation method; Step D: Integrate multiple indicators such as cutting force, workpiece roughness, tool material adhesion rate and wear height to detect tool life and guide the selection of processing parameters.

2. The method according to claim 1, characterized in that The tool described in step A is a grinding wheel with different abrasive materials, abrasive bonding methods and grain sizes.

3. The method according to claim 1, characterized in that The metal material workpiece described in step A is a difficult-to-grind material of titanium alloy or nickel-based high-temperature alloy of different grades.

4. The method according to claim 1, characterized in that The cutting force described in step A refers to the grinding force in the direction of the tool cutting speed.

5. The method according to claim 1, characterized in that The surface observation method described in step B refers to metallographic microscope method, roughness meter method, and white light interferometry method.

6. The method according to claim 1, characterized in that The observation method in step C refers to scanning electron microscopy, EDS energy spectrum analysis, and diameter measurement.

7. The method according to claim 1, characterized in that The material adhesion rate in step C refers to the proportion of workpiece material adhering to the grinding wheel, and the wear height refers to the height difference before and after the tool is worn.

8. The method according to claim 1, characterized in that The multi-index fusion described in step D refers to: 1) Draw the cutting force and cutting force growth rate curves under different cutting distances. The cutting force reflects the tool wear state, and the cutting force growth rate reflects the instantaneous impact caused by tool wear, that is, the instability of processing; 2) Comparing the workpiece surface processing quality under different tool wear conditions, the processing quality is poor in the initial wear stage of the tool, the processing quality is stable in the stable wear stage, and the processing quality is poor in the severe wear stage. Therefore, the change in surface processing quality reflects the different stages of tool wear; 3) Draw the surface roughness curve of the workpiece under different cutting paths. From the initial wear of the tool to the stable wear stage, the roughness change tends to be stable. From the stable wear of the tool to the severe wear stage, the roughness changes sharply and exceeds the processing quality index requirements, which reflects the service life of the tool; 4) Observe the tool wear forms, including abrasive crushing, abrasive wear, abrasive shedding and grinding wheel adhesion; among them, abrasive crushing refers to the appearance of irregular pits or fine cracks on the top of the abrasive grains, abrasive wear refers to the flat surface of the abrasive grains and the decrease in height, abrasive shedding refers to the pits left on the grinding wheel base material, and grinding wheel adhesion refers to the adhesion of workpiece materials to the abrasive grains or between the abrasive grains, to determine the tool failure form; 5) Measure the tool material adhesion rate, wear height and height wear rate, and draw curves under different cutting distances; among them, the material adhesion rate reflects the degree of grinding wheel adhesion, the wear height and height wear rate reflect the abrasive crushing, abrasive wear and abrasive shedding, and determine the degree of tool wear.

9. The method according to claim 8, characterized in that The detection of tool life in step D refers to: 1) When the growth rate of cutting force is greater than 40%, the severe wear of the tool causes a large instantaneous impact, increasing the instability of the machining process; 2) When the workpiece surface roughness Sa>1.6μm, the damage to the surface caused by severe wear of the tool cannot meet the processing requirements; 3) When the tool adhesion rate is greater than 15%, the workpiece material is seriously adhered to the abrasive gap, affecting the tool processing accuracy. At the same time, the tool grinding performance deteriorates, the adhesion is peeled off and deposited on the processed surface, and the processing accuracy and surface quality cannot meet the requirements; 4) When the tool height wear rate is greater than 20%, the height and sharpness of the tool cutting edge are greatly reduced, and the cutting ability is lost.

10. The method according to claim 9, characterized in that The guiding processing parameter selection in step D means that the tool life under different processing parameters can be accurately obtained by detecting the tool life through multi-index fusion, and then the appropriate processing parameters are selected according to the needs of processing quality and production efficiency.

Images