A multi-index fusion tool service life detection method

Abstract

The application provides a multi-index fused tool service life detection method, which comprises the following steps: continuously grinding a metal material workpiece by using a tool, so that the tool is gradually worn in the experiment process, the cutting force is measured, and the machining quality of the workpiece changes with the tool wear condition; observing the machining surface quality of the workpiece under different tool wear conditions and grinding distances and measuring the roughness of the workpiece; observing and measuring the tool wear form, material adhesion rate and wear height of the tool under different tool wear conditions and grinding distances; fusing the multi-indexes of the cutting force, the roughness of the workpiece, the material adhesion rate and the wear height of the tool to detect the tool service life; through the above steps, the tool wear condition can be analyzed, the tool service life is determined, the consistency, accuracy and practicability are achieved, the tool utilization rate can be improved, and then the machining quality and the production efficiency are improved.

Description

Technical Field

[0001] This application belongs to the field of tool life testing technology, and particularly relates to a method for testing tool life by integrating multiple indicators. Background Technology

[0002] Titanium alloys, nickel-based superalloys, and other materials are widely used in the manufacture of aerospace components. Due to the high requirements for machining quality, grinding is the primary process for precision machining. However, during grinding, the cutting tool wears down continuously, and workpiece material adheres to the tool surface, leading to deterioration in grinding performance and machining accuracy, increased machining instability, and consequently, poor workpiece surface quality, significantly impacting the service performance of the parts. Measuring tool life under different operating conditions can prevent severely worn tools from continuing to be used. Therefore, obtaining tool life is a key factor affecting machining quality and production efficiency, and accurate and effective tool life measurement is crucial for the precision machining of parts.

[0003] Currently, tool life is mainly determined by the amount of flank wear exceeding the dulling standard by 0.3mm or by the appearance of obvious chipping and breakage. However, for grinding tools and grinding wheels, the failure modes of the tools are different, making it difficult to determine their life by the above method. Instead, it is mainly judged by detecting the tool wear condition.

[0004] In the field of relative technology, the detection methods for tool wear are mainly based on vibration signals, image processing, acoustic emission signals, etc. However, each method has its own limitations in its recognition mode, making it difficult to accurately identify the tool wear condition and directly determine the tool life. It also cannot guide the selection of parameters that affect machining 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 testing, this application proposes a tool life testing method that integrates multiple indicators.

[0006] This application provides a multi-index fusion method for detecting tool life, the method comprising:

[0007] Step A: Use a cutting tool to continuously machine a metal workpiece, allowing the tool to wear down gradually during the experiment. Measure the cutting force and observe how the workpiece's machining quality changes with the tool's wear condition.

[0008] Step B: Observe and measure the surface quality and roughness of the workpiece under different tool wear conditions and grinding paths using surface observation methods;

[0009] Step C: Observe and measure the wear pattern, material adhesion rate and wear height of the tool under different tool wear conditions and grinding paths using observation methods;

[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 machining parameters.

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

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

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

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

[0015] Preferably, the observation method in step C refers to scanning electron microscopy, EDS energy dispersive spectroscopy, or diameter measurement.

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

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

[0018] 1) Plot the machining cutting force and cutting force growth rate curves under different cutting paths. The magnitude of the cutting force reflects the tool wear state, and the cutting force growth rate reflects the instantaneous impact caused by tool wear, i.e., the instability of machining.

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

[0020] 3) Plot the surface roughness curves of the workpiece under different cutting paths. In the stage from the initial wear to the stable wear of the tool, the roughness changes tend to be stable. In the stage from the stable wear to the severe wear of the tool, the roughness changes drastically and exceeds the requirements of the machining quality index, which reflects the tool life.

[0021] 4) Observe the wear patterns of the cutting tool, including abrasive grain breakage, abrasive grain wear, abrasive grain shedding, and grinding wheel adhesion. Among them, abrasive grain breakage refers to the appearance of irregular pits or small cracks at the tip of the abrasive grains; abrasive grain wear refers to the smooth surface of the abrasive grains and a decrease in height; abrasive grain shedding refers to the leaving of pits on the grinding wheel matrix material; and grinding wheel adhesion refers to the adhesion of workpiece material to the abrasive grains or between abrasive grains. Determine the failure mode of the cutting tool.

[0022] 5) Measure the material adhesion rate, wear height, and high wear rate of the cutting tool, and plot their curves under different cutting paths; among them, the material adhesion rate reflects the degree of adhesion of the grinding wheel, and the wear height and high wear rate reflect the abrasive grain breakage, abrasive grain wear, and abrasive grain shedding, to determine the degree of tool wear.

[0023] Preferably, the tool life detection mentioned 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, which increases the instability of the machining process;

[0025] 2) When the surface roughness Sa of the workpiece is greater than 1.6 μm, the damage to the surface caused by the 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 severely adhered to the gap between the abrasive grains, which affects the tool's machining accuracy. At the same time, the tool's grinding performance deteriorates, and the adhering material peels off and deposits on the machined surface, so the machining 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 tool loses its cutting ability.

[0028] Preferably, the guidance on selecting machining parameters in step D refers to accurately obtaining the tool life under different machining parameters by using multi-index fusion detection of tool life, and then selecting appropriate machining parameters based on the needs of machining quality and production efficiency.

[0029] The beneficial technical effects of this application are as follows:

[0030] This application provides a multi-index fusion method for tool life detection, which can obtain tool wear conditions with higher consistency and accuracy, thereby determining tool life and achieving optimized control of machining quality and production efficiency. Attached Figure Description

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

[0032] Figure 2 These are the surface morphologies of workpieces under different tool wear conditions according to embodiments of the present invention;

[0033] Figure 3 This refers to the surface roughness of the workpiece under different grinding paths according to embodiments of the present invention;

[0034] Figure 4 This describes the condition of the cutting tool under different tool wear conditions according to embodiments of the present invention;

[0035] Figure 5 This refers to the workpiece material adhesion rate of the tool under different grinding paths in this embodiment of the invention;

[0036] Figure 6 These are the tool wear height and high wear rate under different grinding paths in embodiments of the present invention. Detailed Implementation

[0037] This application provides a multi-index fusion method for detecting tool life. The method includes the following steps: Continuous grinding of a metal workpiece using a tool, allowing the tool to gradually wear down during the experiment; measuring the cutting force; observing the changes in workpiece machining quality as the tool wears; observing the workpiece surface quality and measuring its roughness under different tool wear conditions and grinding distances; observing and measuring the tool wear pattern, material adhesion rate, and wear height under different tool wear conditions and grinding distances; and fusing multiple indicators—cutting force, workpiece roughness, tool material adhesion rate, and wear height—to detect tool life. Through these steps, the results can analyze tool wear conditions and determine tool life, exhibiting consistency, accuracy, and practicality. This can improve tool utilization, thereby improving machining quality and production efficiency.

[0038] This application provides a multi-index fusion method for detecting tool life, comprising the following steps:

[0039] A. A cutting tool is used to continuously machine a metal workpiece, allowing the tool to wear down gradually during the experiment. The cutting force is measured, and the machining quality of the workpiece changes as the tool wears down.

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

[0041] C. Observe and measure the wear pattern, 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 machining parameters;

[0043] In step A, the cutting tool can be a grinding wheel with different abrasive materials, abrasive bonding methods, and grit sizes.

[0044] In step A, the metal workpiece can be a difficult-to-grind material such as titanium alloys or nickel-based high-temperature alloys of different grades.

[0045] In step A, the cutting force refers to the magnitude of the grinding force in the direction of the tool's cutting speed.

[0046] The surface observation methods mentioned in step B refer to metallographic microscopy, roughness meter method, and white light interferometry.

[0047] The observation methods mentioned in step C refer to scanning electron microscopy, EDS energy dispersive spectroscopy, and diameter measurement.

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

[0049] In step D, the multi-indicator fusion refers to:

[0050] 1) Plot the machining cutting force and cutting force growth rate curves under different cutting paths. The magnitude of the cutting force can reflect the tool wear state, and the cutting force growth rate can reflect the instantaneous impact caused by tool wear, i.e., the instability of machining.

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

[0052] 3) Plot the surface roughness curves of the workpiece under different cutting paths. In the stage from the initial wear to the stable wear of the tool, the roughness changes tend to be stable. In the stage from the stable wear to the severe wear of the tool, the roughness changes drastically and exceeds the requirements of the machining quality index, which reflects the tool life.

[0053] 4) Observe the wear patterns of the cutting tool, including abrasive grain breakage, abrasive grain wear, abrasive grain shedding, and grinding wheel adhesion. Abrasive grain breakage refers to irregular pits or small cracks appearing at the tips of the abrasive grains. Abrasive grain wear refers to the abrasive grain surface becoming smooth and its height decreasing. Abrasive grain shedding refers to pits being left on the grinding wheel matrix material. Grinding wheel adhesion refers to the workpiece material adhering to the abrasive grains or between abrasive grains. Determine the failure mode of the cutting tool.

[0054] 5) Measure the tool material adhesion rate, wear height and high wear rate, and plot their curves under different cutting paths. The material adhesion rate reflects the degree of adhesion of the grinding wheel, while the wear height and high wear rate reflect the abrasive grain breakage, abrasive grain wear and abrasive grain shedding, to determine the degree of tool wear.

[0055] In step D, the term "detecting the tool's lifespan" 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, which increases the instability of the machining process;

[0057] 2) When the surface roughness Sa of the workpiece is greater than 1.6 μm, the damage to the surface caused by the 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 severely adhered to the gap between the abrasive grains, which affects the tool's machining accuracy. At the same time, the tool's grinding performance deteriorates, and the adhering material peels off and deposits on the machined surface, so the machining 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 tool loses its cutting ability;

[0060] In step D, the guidance for selecting machining parameters refers to accurately obtaining the tool life under different machining parameters by using multi-index fusion detection of tool life, and then selecting appropriate machining parameters based on the needs of machining quality and production efficiency.

[0061] In other embodiments of this application, a multi-index fusion method for detecting tool life includes the following steps:

[0062] Step 1: Use a cutting tool to continuously machine the metal workpiece, allowing the tool to wear down gradually during the experiment. Measure the cutting force and observe how the workpiece's machining quality changes with the tool's 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 stage of tool wear, the abrasive wear and breakage are severe, the cutting force is large, and it gradually decreases. In the stable wear stage, the cutting force is stable and low. In the severe wear stage, the cutting force increases, and the growth rate exceeds 40%, making the machining process unstable.

[0064] Step 2: Observe the surface quality of the workpiece under different tool wear conditions using white light interferometry, and measure and plot 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 machining quality is stable, the surface is relatively flat, while when the machining quality is poor, there is a 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. In the stage from the initial wear of the tool to the stable wear stage, the roughness decreases slightly and the change tends to be stable. In the stage 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 requirements.

[0067] Step 3: Observe the wear pattern of the tool under different tool wear conditions using 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 wears, the abrasive grains are relatively evenly distributed and the edges are intact. After the tool wears, abrasive grain wear, abrasive grain breakage, abrasive grain detachment and grinding wheel adhesion occur. Overall, the abrasive grain density and cutting edge height of the grinding wheel are greatly reduced, and there is material adhesion between the abrasive grains.

[0069] Step 4: Measure the adhesion rate of the tool to the workpiece material under different grinding paths using EDS energy dispersive spectroscopy.

[0070] refer to Figure 5 The workpiece material adhesion rate of the tool under different grinding paths is shown in the figure. As the cutting path increases, 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 under different grinding paths using the diameter measurement method. The height of the intact abrasive grain is determined to be about 80 μm by scanning electron microscopy. The height wear rate is then calculated.

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

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

Claims

1. A method for detecting the service life of cutting tools by integrating multiple indicators, characterized in that, The method includes: Step A: Use a cutting tool to continuously machine a metal workpiece, allowing the tool to wear down gradually during the experiment. Measure the cutting force and observe how the workpiece's machining quality changes with the tool's wear condition. Step B: Observe and measure the surface quality and roughness of the workpiece under different tool wear conditions and grinding paths using surface observation methods; Step C: Observe and measure the wear pattern, material adhesion rate and wear height of the tool under different tool wear conditions and grinding paths using observation methods; 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 machining parameters; In step D, the multi-indicator fusion refers to: 1) Plot the machining cutting force and cutting force growth rate curves under different cutting paths. The magnitude of the cutting force reflects the tool wear state, and the cutting force growth rate reflects the instantaneous impact caused by tool wear, i.e., the instability of machining. 2) Comparing the workpiece surface finish under different tool wear conditions, the finish is poor in the initial tool wear stage, stable in the steady wear stage, and poor in the severe wear stage. Therefore, the change in surface finish reflects the different stages of tool wear. 3) Plot the surface roughness curves of the workpiece under different cutting paths. In the stage from the initial wear to the stable wear of the tool, the roughness changes tend to be stable. In the stage from the stable wear to the severe wear of the tool, the roughness changes drastically and exceeds the requirements of the machining quality index, which reflects the tool life. 4) Observe the tool wear pattern, including abrasive grain breakage, abrasive grain wear, abrasive grain shedding, and grinding wheel adhesion; among them, abrasive grain breakage refers to the appearance of irregular pits or fine cracks at the tip of the abrasive grains, abrasive grain wear refers to the abrasive grain surface becoming smooth and the height decreasing, abrasive grain shedding refers to leaving pits on the grinding wheel matrix material, and grinding wheel adhesion refers to the workpiece material adhering to the abrasive grains or between abrasive grains, to determine the tool failure mode; 5) Measure the material adhesion rate, wear height, and high wear rate of the cutting tool, and plot their curves under different cutting paths; among them, the material adhesion rate reflects the degree of adhesion of the grinding wheel, and the wear height and high wear rate reflect the abrasive grain breakage, abrasive grain wear, and abrasive grain shedding, to determine the degree of tool wear.

2. The method as described in claim 1, characterized in that, The cutting tool mentioned in step A is a grinding wheel with different abrasive materials, abrasive bonding methods, and grit sizes.

3. The method as described in claim 1, characterized in that, The metal workpieces mentioned in step A are difficult-to-grind materials such as titanium alloys and nickel-based high-temperature alloys of different grades.

4. The method as described in claim 1, characterized in that, The cutting force mentioned in step A refers to the magnitude of the grinding force in the direction of the tool's cutting speed.

5. The method as described in claim 1, characterized in that, The surface observation methods mentioned in step B refer to metallographic microscopy, roughness meter method, and white light interferometry.

6. The method as described in claim 1, characterized in that, The observation methods mentioned in step C refer to scanning electron microscopy, energy dispersive spectroscopy (EDS), and diameter measurement.

7. The method as described in claim 1, characterized in that, The material adhesion rate mentioned in step C refers to the proportion of workpiece material adhered to the grinding wheel, and the wear height refers to the height difference before and after tool wear.

8. The method as described in claim 1, characterized in that, The tool life test mentioned 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, which increases the instability of the machining process; 2) When the surface roughness Sa of the workpiece is greater than 1.6 μm, the damage to the surface caused by the severe wear of the tool cannot meet the processing requirements; 3) When the tool adhesion rate is greater than 15%, the workpiece material is severely adhered to the gap between the abrasive grains, which affects the tool's machining accuracy. At the same time, the tool's grinding performance deteriorates, and the adhering material peels off and deposits on the machined surface, so the machining 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 tool loses its cutting ability.

9. The method as described in claim 8, characterized in that, The guidance on selecting machining parameters mentioned in step D refers to obtaining the tool life under different machining parameters by integrating multiple indicators to detect tool life, and then selecting machining parameters based on the needs of machining quality and production efficiency.

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