Control method for automatic switching of end face turning and milling

Abstract

The invention discloses a turning and milling switching technology, and aims to provide an end face turning and milling automatic switching control method which is characterized by comprising the following steps: S1, monitoring turning and milling machine tool modes in real time; s2, transmitting real-time data to a central control unit; s3, switching mode judgment; s4, controlling conversion of turning and milling modes; s5, stability monitoring in the turning and milling mode process; s6, optimizing a dynamic processing path; s7, thermal deformation compensation control; and S8, final detection. Compared with the prior art, the end face turning and milling automatic switching control method has the advantages that dynamic optimization of turning and milling automatic switching combined machining is achieved by establishing a full-process intelligent monitoring and self-adaptive control system; the invention is suitable for the technical field of turning and milling switching.

Description

Technical Field

[0001] The present invention relates to a turning and milling switching technology, and more specifically, to a control method for automatic switching between end face turning and milling. Background Art

[0002] As the high-end equipment manufacturing industry develops towards precision and complexity, higher requirements are placed on the processing quality and efficiency of special-shaped end face parts; in traditional processing methods, turning and milling processes are usually performed independently: turning is suitable for large allowance removal and rotational body processing, but it is easy to produce tool marks when forming complex curved surfaces; although milling can achieve high-precision contour processing, it has bottlenecks such as long tool paths and low material removal rates; especially in the end face processing of typical parts such as aerospace engine blades and new energy vehicle gearbox housings, it is often necessary to alternate between the two processes, but the existing technology generally uses manual judgment on the switching timing, resulting in frequent interruptions in the processing process and difficulty in eliminating accumulated errors; the more prominent contradiction is that when the workpiece has non-uniform allowance distribution, a single processing method is prone to cause local overcutting or undercutting, and traditional CNC systems lack real-time allowance analysis and dynamic process decision-making capabilities. Summary of the Invention

[0003] In view of the shortcomings of the prior art, the present invention aims to provide a control method for automatic switching between end face turning and milling.

[0004] To achieve the above object, the present invention provides the following technical solution: a control method for automatic switching between end turning and milling, comprising the following steps:

[0005] S1, real-time monitoring of turning and milling machine modes:

[0006] Initialize the machine tool parameters, set the initial positions of the turning and milling tools, load the 3D model of the workpiece into the central control unit, establish the workpiece coordinate system, monitor the current operating status of the machine tool through the sensor unit, and use a high-precision 3D laser scanner to perform a full-area scan of the workpiece end face to obtain the actual end face contour data. This data is compared with the theoretical model to generate a machining allowance distribution cloud map. Based on the cloud map data, the maximum machining allowance value for each area is calculated. Then, the central control unit determines whether it is necessary to switch between turning and milling modes based on the preset parameter thresholds.

[0007] S2. Real-time data transmission to the central control unit:

[0008] The sensing unit transmits the monitoring data to the central control unit, which analyzes it through the data processing unit to form a real-time feedback mechanism to determine and adjust the machine tool working mode in real time. If an abnormality or interruption occurs during the data transmission process, the central control unit will trigger an alarm and automatically switch to the backup data transmission method for data recovery.

[0009] S3, switch mode judgment:

[0010] Based on real-time data, including but not limited to turning force, milling force, and feed rate, the central control unit comprehensively analyzes the real-time data to determine whether to switch the processing mode; according to the real-time Brinell hardness value A measured by the on-line hardness detector, the turning force threshold Lc and the milling force threshold Lx are dynamically calculated, satisfying: Lc = 0.8A + 120 ± 5% N, Lx = 1.2A - 50 ± 3% N; the judgment method is as follows:

[0011] If L1 > 1.05Lc and L2 < 0.95Lx last for 5 s, trigger the turning mode priority;

[0012] If L2 > 1.1Lx and L1 < 0.9Lc are sampled continuously three times, activate the judgment of the milling mode forced switching mechanism;

[0013] S4. Control of turning and milling mode conversion:

[0014] During the process of switching modes, the central control unit adjusts through control signals, including but not limited to the feed direction of the tool, cutting method, and spindle speed, and ensures a smooth switch between the two modes;

[0015] S5. Stability monitoring during turning and milling modes:

[0016] During turning / milling, the sensing unit synchronously collects vibration spectrum data, extracts characteristic frequency components through Fourier transform, and performs matching analysis with the tool wear characteristic library. When the amplitude of the third harmonic exceeds 15% of the reference value, a tool change warning is generated to remind the staff;

[0017] S6. Dynamic machining path optimization:

[0018] According to the real-time remaining material distribution cloud map, the material removal rate of the remaining machining area is calculated in segments. If the difference in the remaining material between adjacent areas exceeds 30% of the maximum remaining material, a transition cutting path is automatically inserted, and a smooth tool path is generated by B-spline curve fitting to ensure a uniform distribution of the cutting load;

[0019] S7. Thermal deformation compensation control:

[0020] In the turning / milling mode, the surface temperature field distribution of the workpiece is monitored by an infrared thermal imager. When the temperature gradient reaches 1.2 times the coefficient of thermal expansion of the material, a compensation algorithm is triggered, and the tool feed trajectory is corrected inversely according to the temperature field distribution;

[0021] S8. Final inspection:

[0022] In the final machining stage, the detection unit is started for integrated detection, and the qualified judgment is made by comprehensively considering three indicators: surface roughness, dimensional accuracy, and geometric tolerance. If any indicator exceeds the tolerance, a spare tool is called to perform repair machining.

[0023] The present invention is further configured such that in the step S3, the switching mode further includes a slope prediction mechanism:

[0024] By calculating the changing slopes of L1 and L2 in real time, if any of the following conditions is satisfied, the mode switching is triggered in advance:

[0025] S31. When the rising slope K of L1 ≥ Ka and the falling slope K of L2 ≤ Kb, if L1 > 1.05Lc and L2 < 0.95Lx, the turning mode is preferentially activated before the condition of lasting for 5 s is reached;

[0026] S32. When the rising slope K of L2 ≥ Ka and the falling slope K of L1 ≤ Kb, if L2 > 1.1Lx and L1 < 0.9Lc, the milling mode is forcibly activated before three consecutive samplings are completed;

[0027] Wherein, Ka is a preset rising slope threshold, Kb is a preset falling slope threshold, and Ka ≥ 10 N / s, Kb ≤ -8 N / s are satisfied.

[0028] The present invention is further configured such that in the step S5, an early warning mechanism is set in the vibration spectrum analysis, including:

[0029] Minor early warning: When the basic vibration amplitude of the equipment exceeds 1.2 times the allowable value, the central control unit automatically reduces the feed rate by 20% and increases the coolant flow rate;

[0030] Medium early warning: When high-frequency vibration is detected and the vibration direction changes abnormally, the central control unit immediately controls to stop the machining and generates a tool abnormality alarm so that the staff can check whether the tool is eccentric or swinging;

[0031] Severe early warning: When the spectral entropy value exceeds the range of 0.65 - 0.85, it is determined as a serious abnormality. The central control unit immediately controls to stop the machining and generates an alarm to notify the staff to conduct a comprehensive inspection;

[0032] The early warning mechanism works in coordination with the tool change reminder. When the tool change reminder is generated, it is preferentially processed. When any one of the medium early warning or severe early warning appears in superposition, the central control unit immediately shuts down the machine.

[0033] The present invention is further configured such that in the step S6, the dynamic machining path optimization further includes the following steps:

[0034] When the proportion of the allowance in the central area of the remaining machining area exceeds 60% of the total allowance, a spiral progressive cutting path is preferentially adopted, and the feed per revolution is adjusted in real time based on the Brinell hardness value A. The adjustment ratio is: if the Brinell hardness value A increases by 10 HB each time, the feed rate is reduced by 3% - 5% of the current value.

[0035] The present invention is further configured such that in the S7, the thermal deformation compensation control further includes:

[0036] When the temperature gradient exceeds the threshold, a multi-level compensation strategy is started: the first-level compensation is to linearly correct the tool path according to the coefficient of thermal expansion; if the contour deviation after correction is still greater than 50% of the tolerance band, the second-level compensation is activated, a non-linear temperature decay model is introduced, and the secondary trajectory offset calculation is carried out in combination with the workpiece thermal conductivity and specific heat capacity parameters.

[0037] The present invention is further configured such that in the S8, the fusion detection of the detection unit adopts a decision rule based on confidence weight, which specifically includes the following steps:

[0038] S81. Calculate the qualified comprehensive confidence

[0039] Qualified comprehensive confidence = surface roughness confidence × 0.4 + dimensional accuracy confidence × 0.3 + geometric tolerance confidence × 0.3;

[0040] S82. Calculate the unqualified comprehensive confidence

[0041] Unqualified comprehensive confidence = (1 - surface roughness confidence) × 0.5 + (1 - dimensional accuracy confidence) × 0.3 + (1 - geometric tolerance confidence) × 0.2;

[0042] S83. Make a determination according to the conflict factor

[0043] If the conflict factor R between the qualified comprehensive confidence and the unqualified comprehensive confidence is greater than 0.7, it is determined that the detection result conflicts, and the manual re-inspection process is triggered.

[0044] The beneficial effects of the present invention are:

[0045] 1. Compared with the prior art, the control method for automatic switching between face turning and milling in the present invention realizes the dynamic optimization of turning-milling automatic switching composite machining by establishing a full-process intelligent monitoring and adaptive control system; the global laser scanning and allowance cloud map comparison technology breaks through the limitations of traditional manual measurement, improves the allowance recognition accuracy to the micron level, effectively avoids machining blind spots, enables the system to perceive the actual machining state of the workpiece in real time and autonomously determine the timing of mode switching; through multi-dimensional sensing data fusion analysis, the system can dynamically identify the abnormal cutting force caused by changes in material properties, effectively preventing the risk of tool overload; the spectrum feature matching technology is introduced in the machining stability monitoring, which can early warn of tool wear and assembly abnormalities, significantly improving the equipment reliability; the path optimization module adopts an adaptive segmentation strategy, realizing the balanced distribution of machining load while ensuring the cutting efficiency, and avoiding surface quality defects caused by local stress concentration; the thermal deformation compensation mechanism offsets the influence of temperature gradient on machining accuracy through reverse trajectory correction technology, improving the geometric tolerance control ability under complex working conditions; the multi-index fusion criterion design in the final inspection stage strengthens the comprehensiveness of quality control, ensuring that the product qualification rate is stable at a high level.

[0046] 2. The control method for automatic switching between face turning and milling in the present invention can accurately capture the dynamic feature changes in the machining process through the double-slope collaborative analysis technology, and can make predictive adjustments in time under working conditions such as sudden changes in material hardness or tool abnormalities, preventing misjudgment caused by instantaneous parameter fluctuations; this mechanism is especially suitable for complex curved surface parts with uneven allowance distribution, and ensures that the cutting parameters are always in the optimal working range through trend prediction; this forward-looking control strategy not only improves the machining efficiency, but also greatly reduces the risk of tool loss caused by mode switching delay, providing a more reliable process guarantee for high-precision machining.

[0047] 3. In the present invention, the hierarchical vibration early warning system realizes the refined management of equipment status monitoring and constructs a multi-level safety protection network; the three-level early warning standard corresponds to different risk levels, which can not only timely contain the development of minor abnormalities, but also quickly isolate serious faults; the speed adaptive adjustment function effectively suppresses the expansion of vibration through a dynamic speed reduction strategy while ensuring the continuity of machining; the introduction of the spectrum entropy value analysis technology enhances the fault feature recognition ability under complex working conditions, and can accurately distinguish normal cutting vibration from equipment abnormal vibration; the collaborative processing mechanism optimizes the alarm response process through priority management, maximizing the maintenance of production continuity while ensuring equipment safety; this technical solution is especially suitable for long-cycle continuous machining scenarios, and significantly extends the tool service life and reduces the unplanned downtime through an intelligent vibration suppression strategy, providing a reliable technical guarantee for unmanned machining.

[0048] 4. In the present invention, the optimal cutting strategy is automatically selected through the identification of material distribution characteristics; the spiral progressive path planning effectively reduces the high cutting resistance in the central region and avoids the tool yaw problem caused by traditional equidistant cutting; the dynamic feed adjustment mechanism based on material hardness realizes the intelligent matching of cutting parameters and workpiece characteristics, ensuring cutting stability while guaranteeing machining efficiency; this solution is particularly suitable for the precision machining of heterogeneous materials or workpieces after heat treatment, effectively suppressing the surface quality fluctuations caused by hardness fluctuations through real-time parameter optimization; the path smoothing processing technology significantly improves the continuity of the tool movement trajectory, reduces the mechanical impact caused by sudden stops and starts, extends the service life of the machine tool transmission components while improving the surface finish, and provides technical support for the efficient and precision machining of complex parts. BRIEF DESCRIPTION OF THE DRAWINGS

[0049] Figure 1 It is a flowchart of the control method for automatic switching between end face turning and milling of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0050] Refer to Figure 1 The embodiments of the control method for automatic switching between end face turning and milling of the present invention are further described.

[0051] For ease of description, spatial relative terms such as "upper", "lower", "left", "right", etc. are used in the embodiments to describe the relationship of one element or feature shown in the drawings relative to another element or feature. It should be understood that, in addition to the orientations shown in the drawings, the spatial terms are intended to include different orientations during the use or operation of the device. For example, if the device in the drawings is inverted, the element described as being "under" another element or feature will be located "above" the other element or feature. Therefore, the exemplary term "lower" can include both upper and lower orientations. The device can be positioned in other ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein can be interpreted accordingly.

[0052] Moreover, relative relationship terms such as "first" and "second" are only used to distinguish one component with the same name from another, and do not necessarily require or imply any such actual relationship or order between these components.

[0053] Figure 1 A control method for automatic switching between end face turning and milling is shown, including the following steps:

[0054] S1. Real-time monitoring of the turning and milling machine tool modes:

[0055] Initialize the machine tool parameters, set the initial positions of the turning tool and the milling tool, load the 3D model of the workpiece into the central control unit, establish the workpiece coordinate system, monitor the current operating state of the machine tool through the sensing unit, conduct a full-field scan of the workpiece end face using a high-precision 3D laser scanner, obtain the actual contour data of the end face, compare it with the theoretical model, generate a machining allowance distribution cloud map, calculate the maximum machining allowance value for each region based on the cloud map data, and then determine whether to switch between turning and milling modes currently according to the preset parameter thresholds through the central control unit;

[0056] S2. Transmit real-time data to the central control unit:

[0057] The sensing unit transmits the monitored data to the central control unit, and the central control unit block analyzes it through the data processing unit to form a real-time feedback mechanism, and judges and adjusts the machine tool working mode in real time; if an abnormality or interruption occurs during the data transmission process, the central control unit will trigger an alarm and automatically switch to the backup data transmission method for data recovery;

[0058] S3. Judgment of mode switching:

[0059] Based on the real-time data, including but not limited to turning force, milling force, and feed rate, the central control unit comprehensively analyzes the real-time data to judge whether to switch the machining mode; according to the real-time Brinell hardness value A measured by the on-line hardness detector, dynamically calculate the turning force threshold Lc and the milling force threshold Lx, satisfying: Lc = 0.8A + 120 ± 5% N, Lx = 1.2A - 50 ± 3% N; the judgment method is:

[0060] If L1 > 1.05Lc and L2 < 0.95Lx last for 5 s, trigger the turning mode priority;

[0061] If L2 > 1.1Lx and L1 < 0.9Lc for three consecutive samples, activate the judgment of the milling mode forced switching mechanism;

[0062] S4. Control of turning and milling mode conversion:

[0063] During the process of mode switching, the central control unit adjusts through control signals, including but not limited to the feed direction of the tool, cutting method, and spindle speed, and ensures a smooth switch between the two modes;

[0064] S5. Stability monitoring during turning and milling modes:

[0065] During turning / milling, the sensing unit synchronously collects vibration spectrum data, extracts the characteristic frequency components through Fourier transform, and conducts matching analysis with the tool wear feature library. When the amplitude of the third harmonic exceeds 15% of the reference value, a tool change warning is generated to remind the staff; among them, the Fourier transform is embedded in the system;

[0066] S6. Dynamic machining path optimization:

[0067] According to the real-time allowance distribution cloud map, the material removal rate of the remaining machining area is calculated in segments. If the allowance difference between adjacent areas exceeds 30% of the maximum allowance, a transitional cutting path is automatically inserted, and a smooth tool path is generated by fitting with a Bessel curve to ensure uniform distribution of the cutting load; among them, the Bessel curve fitting is embedded in the system.

[0068] S7. Thermal deformation compensation control:

[0069] In the turning / milling mode, the surface temperature field distribution of the workpiece is monitored by an infrared thermal imager. When the temperature gradient reaches 1.2 times the thermal expansion coefficient of the material, a compensation algorithm is triggered, and the tool feed trajectory is corrected in reverse according to the temperature field distribution.

[0070] S8. Final inspection:

[0071] In the final machining stage, the detection unit is started for integrated detection, and the qualification is judged comprehensively based on three indicators: surface roughness, dimensional accuracy, and geometric tolerance. If any indicator exceeds the standard, a spare tool is called to perform repair machining.

[0072] By establishing a full-process intelligent monitoring and adaptive control system, the dynamic optimization of turning-milling automatic switching composite machining is realized; the global laser scanning and allowance cloud map comparison technology breaks through the limitations of traditional manual measurement, improves the allowance recognition accuracy to the micron level, effectively avoids machining blind spots, enables the system to perceive the actual machining state of the workpiece in real time and make autonomous decisions on the mode switching timing; through multi-dimensional sensing data fusion analysis, the system can dynamically identify the abnormal cutting force caused by the change of material properties, effectively prevent the risk of tool overload; in the aspect of machining stability monitoring, the spectrum feature matching technology is introduced, which can early warn of tool wear and assembly abnormalities, significantly improve the equipment reliability; the path optimization module adopts an adaptive segmentation strategy, which realizes the balanced distribution of machining load while ensuring the cutting efficiency, and avoids surface quality defects caused by local stress concentration; the thermal deformation compensation mechanism offsets the influence of temperature gradient on machining accuracy through reverse trajectory correction technology, improving the geometric tolerance control ability under complex working conditions; the multi-index fusion criterion design in the final inspection stage strengthens the comprehensiveness of quality control, ensuring that the product qualification rate is stable at a high level.

[0073] In the above-mentioned S3, the switching mode further includes a slope prediction mechanism:

[0074] By calculating the change slopes of L1 and L2 in real time, if any of the following conditions is met, the mode switching is triggered in advance:

[0075] S31. When the rising slope K of L1 ≥ Ka and the falling slope K of L2 ≤ Kb, if L1 > 1.05Lc and L2 < 0.95Lx, the turning mode is preferentially activated before the condition of lasting for 5 s is reached;

[0076] S32. When the rising slope K of L2 ≥ Ka and the falling slope K of L1 ≤ Kb, if L2 > 1.1Lx and L1 < 0.9Lc, the milling mode is forcibly activated before three consecutive samplings are completed;

[0077] Among them, Ka is a preset rising slope threshold, Kb is a preset falling slope threshold, and Ka ≥ 10 N / s, Kb ≤ -8 N / s are satisfied;

[0078] Through the double-slope collaborative analysis technology, the dynamic characteristic changes in the machining process can be accurately captured, and predictive adjustments can be made in time under working conditions such as sudden changes in material hardness or tool abnormalities, preventing misjudgments caused by instantaneous parameter fluctuations; this mechanism is particularly suitable for complex curved surface parts with uneven machining allowance distribution, and ensures that the cutting parameters are always in the optimal working range through trend prediction; this forward-looking control strategy not only improves the machining efficiency, but also greatly reduces the risk of tool wear caused by mode switching delay, providing a more reliable process guarantee for high-precision machining.

[0079] In the above-mentioned S5, a warning mechanism is set in the vibration spectrum analysis, including:

[0080] Minor warning: When the basic vibration amplitude of the equipment exceeds 1.2 times the allowable value, the central control unit automatically reduces the feed speed by 20% and increases the coolant flow rate;

[0081] Medium warning: When high-frequency vibration is detected and the vibration direction changes abnormally, the central control unit immediately controls the machining to stop and generates a tool abnormality alarm so that the staff can check whether the tool is eccentric or swinging;

[0082] Severe warning: When the spectral entropy value exceeds the range of 0.65 - 0.85, it is determined as a serious abnormality. The central control unit immediately controls the machining to stop and generates an alarm to notify the staff to conduct a comprehensive inspection;

[0083] The warning mechanism works in coordination with the tool change reminder. When the tool change reminder is generated, it is preferentially processed. When any one of the medium warning or severe warning appears superimposed, the central control unit immediately shuts down the machine;

[0084] The hierarchical vibration warning system realizes the refined management of equipment status monitoring and constructs a multi-level safety protection network; the three-level warning standard corresponds to different risk levels, which can not only timely contain the development of minor anomalies but also quickly isolate serious faults; the speed adaptive adjustment function effectively suppresses the expansion of vibration through a dynamic speed reduction strategy while ensuring the continuity of processing; the introduction of the spectral entropy value analysis technology enhances the fault feature recognition ability under complex working conditions and can accurately distinguish normal cutting vibration from equipment abnormal vibration; the collaborative processing mechanism optimizes the alarm response process through priority management and maximally maintains production continuity while ensuring equipment safety; this technical solution is particularly applicable to long-cycle continuous processing scenarios, significantly extends the tool life through an intelligent vibration suppression strategy, reduces unplanned downtime, and provides a reliable technical guarantee for unattended processing.

[0085] In the above S6, the dynamic machining path optimization further includes the following steps:

[0086] When the proportion of the remaining allowance in the central area of the remaining machining area exceeds 60% of the total allowance, a spiral progressive cutting path is preferentially adopted, and the feed per revolution is adjusted in real time based on the Brinell hardness value A. The adjustment ratio is: if the Brinell hardness value A increases by 10 HB each time, the feed is reduced by 3%-5% of the current value.

[0087] Automatically select the optimal cutting strategy through material distribution feature recognition; the spiral progressive path planning effectively reduces the high cutting resistance in the central area and avoids the tool yaw problem caused by traditional equidistant cutting; the dynamic feed adjustment mechanism based on material hardness realizes the intelligent matching of cutting parameters and workpiece characteristics, ensures cutting stability while guaranteeing processing efficiency; this solution is particularly applicable to the precision machining of heterogeneous materials or workpieces after heat treatment, effectively suppresses the surface quality fluctuation caused by hardness fluctuation through real-time parameter optimization; the path smoothing processing technology significantly improves the continuity of the tool movement trajectory, reduces the mechanical impact caused by sudden stops and starts, extends the service life of the machine tool transmission components while improving the surface finish, and provides a technical guarantee for the high-efficiency and precision machining of complex parts.

[0088] In the above S7, the thermal deformation compensation control further includes:

[0089] When the temperature gradient exceeds the threshold, start a multi-level compensation strategy: the first-level compensation is to linearly correct the tool path according to the coefficient of thermal expansion; if the contour deviation after correction is still greater than 50% of the tolerance zone, then activate the second-level compensation, introduce a non-linear temperature decay model, and perform a secondary trajectory offset calculation in combination with the workpiece thermal conductivity and specific heat capacity parameters.

[0090] A hierarchical thermal deformation compensation system is constructed, significantly improving the machining precision control ability under the interference of the temperature field; the progressive design of the secondary compensation mechanism takes into account both the calculation efficiency and the compensation precision, and automatically activates the high-order compensation algorithm when the linear compensation is insufficient to correct the deformation; the introduction of the non-linear temperature attenuation model fully considers the spatio-temporal distribution characteristics of the influence of material heat conduction characteristics on deformation, realizing a more accurate prediction of trajectory deviation; this solution effectively solves the problem of insufficient adaptability of traditional thermal compensation methods in complex thermal fields, and is particularly suitable for precision machining of heat-sensitive workpieces such as thin-walled parts and composite materials; through the intelligent switching of the dynamic compensation strategy, the system can achieve sub-micron form and position precision control on the premise of ensuring real-time performance, significantly reducing the rejection rate caused by thermal deformation, and providing important technical support for the construction of a high-precision constant temperature machining environment.

[0091] In S8, the detection unit fusion detection adopts a decision rule based on confidence weight, which specifically includes the following steps:

[0092] S81. Calculate the qualified comprehensive confidence

[0093] Qualified comprehensive confidence = surface roughness confidence × 0.4 + dimensional accuracy confidence × 0.3 + geometric tolerance confidence × 0.3;

[0094] S82. Calculate the unqualified comprehensive confidence

[0095] Unqualified comprehensive confidence = (1 - surface roughness confidence) × 0.5 + (1 - dimensional accuracy confidence) × 0.3 + (1 - geometric tolerance confidence) × 0.2;

[0096] S83. Make a judgment according to the conflict factor

[0097] If the conflict factor R between the qualified comprehensive confidence and the unqualified comprehensive confidence is > 0.7, it is determined that the detection result conflicts and the manual re-inspection process is triggered;

[0098] The scientific detection decision is realized by constructing a multi-dimensional quality evaluation system; the confidence weighting algorithm effectively integrates the process importance of different detection indexes, avoiding the misjudgment risk caused by the abnormality of a single parameter; the conflict factor judgment mechanism provides a scientific decision basis for complex quality states, and transfers to manual processing in time when the system self-checking shows contradictory conclusions, ensuring the reliability of quality judgment; the present invention applies the fuzzy decision theory to the machining quality evaluation, significantly improving the accurate judgment ability of marginal qualified products; it is particularly suitable for the final inspection link of high-value parts, reducing the missed inspection rate while avoiding the waste of resources caused by over-inspection; by establishing a direct linkage mechanism between the detection result and the repair machining, the closed-loop processing of quality problems is realized, providing a standardized solution for the quality control module of the intelligent manufacturing system.

[0099] The above are only the preferred embodiments of the present invention, and are not intended to limit the present invention. Any ordinary changes and substitutions made by those skilled in the art within the scope of the technical solution of the present invention shall be included within the protection scope of the present invention.

Claims

1. A control method for automatic switching between end face turning and milling, characterized in that: It includes the following steps: S1. Real-time monitoring of lathe and milling machine modes: Initialize the machine tool parameters, set the initial positions of the turning tool and the milling tool, load the 3D model of the workpiece into the central control unit, establish the workpiece coordinate system, monitor the current operating state of the machine tool through the sensing unit, perform a global scan of the workpiece end face with a high-precision 3D laser scanner, obtain the actual contour data of the end face, compare it with the theoretical model, generate a machining allowance distribution cloud map, calculate the maximum machining allowance value of each area according to the cloud map data, and then judge whether it is necessary to switch the lathe and milling modes currently through the central control unit according to the preset parameter thresholds; S2. Transmit real-time data to the central control unit: The sensing unit transmits the monitored data to the central control unit, and the central control unit block analyzes it through the data processing unit to form a real-time feedback mechanism, and judges and adjusts the machine tool working mode in real time; if an abnormality or interruption occurs during the data transmission process, the central control unit will trigger an alarm and automatically switch to the backup data transmission method for data recovery; S3. Judgment of mode switching: According to the real-time data, including but not limited to turning force, milling force, and feed rate, the central control unit comprehensively analyzes the real-time data to judge whether it is necessary to switch the machining mode; according to the real-time Brinell hardness value A measured by the online hardness tester, dynamically calculate the turning force threshold Lc and the milling force threshold Lx, satisfying: Lc = 0.8A + 120 ± 5% N, Lx = 1.2A - 50 ± 3% N; the judgment method is: If L1 > 1.05Lc and L2 < 0.95Lx last for 5 s, trigger the turning mode priority; If L2 > 1.1Lx and L1 < 0.9Lc are sampled continuously three times, activate the milling mode forced switching mechanism judgment; S4. Control of lathe and milling mode conversion: During the mode switching process, the central control unit adjusts through control signals, including but not limited to the feed direction of the tool, cutting method, and spindle speed, and ensures a smooth switch between the two modes; S5. Stability monitoring during lathe and milling modes: During turning / milling, the sensing unit synchronously collects vibration spectrum data, extracts the characteristic frequency components through Fourier transform, and performs matching analysis with the tool wear characteristic library. When the amplitude of the third harmonic exceeds the reference value by 15%, generate a tool change warning to remind the staff; S6. Dynamic machining path optimization: According to the real-time allowance distribution cloud map, calculate the material removal rate of the remaining machining area in segments. If the allowance difference between adjacent areas exceeds 30% of the maximum allowance, automatically insert a transition cutting path, and generate a smooth tool path through Bezier curve fitting to ensure uniform distribution of the cutting load; S7. Thermal deformation compensation control: In the lathe / milling mode, monitor the surface temperature field distribution of the workpiece through an infrared thermal imager. When the temperature gradient reaches 1.2 times the material thermal expansion coefficient, trigger the compensation algorithm and reverse correct the tool feed trajectory according to the temperature field distribution; S8. Final inspection: At the final machining stage, start the detection unit for integrated detection, and make a qualified judgment by comprehensively considering three indicators: surface roughness, dimensional accuracy, and form and position tolerance. If any indicator exceeds the standard, call the backup tool for repair machining.

2. The control method for automatic switching between end face turning and milling according to claim 1, wherein In S3, the mode switching further includes a slope prediction mechanism: By calculating the change slopes of L1 and L2 in real time, if any of the following conditions are met, the mode switch is triggered in advance: S31. When the rising slope K of L1 ≥ Ka and the falling slope K of L2 ≤ Kb, if L1 > 1.05Lc and L2 < 0.95Lx, the turning mode is preferentially activated before the condition of lasting for 5 s is reached; S32. When the rising slope K of L2 ≥ Ka and the falling slope K of L1 ≤ Kb, if L2 > 1.1Lx and L1 < 0.9Lc, the milling mode is forcibly activated before three consecutive samplings are completed; Among them, Ka is the preset rising slope threshold, Kb is the preset falling slope threshold, and Ka ≥ 10 N / s, Kb ≤ -8 N / s are satisfied.

3. A control method for automatic switching between end face turning and milling according to claim 1, characterized in that, In the above S5, an early warning mechanism is set in the vibration spectrum analysis, including: Minor early warning: When the basic vibration amplitude of the equipment exceeds 1.2 times the allowable value, the central control unit automatically reduces the feed speed by 20% and increases the coolant flow rate; Moderate early warning: When high-frequency vibration is detected and the vibration direction changes abnormally, the central control unit immediately controls the machining to stop and generates a tool abnormality alarm so that the staff can check whether the tool is eccentric or swinging; Severe early warning: When the spectrum entropy value exceeds the range of 0.65 - 0.85, it is determined as a serious abnormality. The central control unit immediately controls the machining to stop and generates an alarm to notify the staff to conduct a comprehensive inspection; The early warning mechanism works in coordination with the tool change reminder. When the tool change reminder is generated, it is preferentially processed. When any one of the moderate early warning or severe early warning appears superimposed, the central control unit immediately shuts down the machine.

4. A control method for automatic switching between end face turning and milling according to claim 1, characterized in that, In the above S6, the dynamic machining path optimization further includes the following steps: When the proportion of the remaining allowance in the central area of the remaining machining area exceeds 60% of the total allowance, a spiral progressive cutting path is preferentially adopted, and the feed per revolution is adjusted in real time based on the Brinell hardness value A. The adjustment ratio is: if the Brinell hardness value A increases by 10 HB each time, the feed is reduced by 3% - 5% of the current value.

5. A control method for automatic switching between end face turning and milling according to claim 1, characterized in that, In the above S7, the thermal deformation compensation control further includes: When the temperature gradient exceeds the threshold, a multi-level compensation strategy is started: the first-level compensation is to linearly correct the tool path according to the coefficient of thermal expansion; if the profile deviation after correction is still greater than 50% of the tolerance zone, the second-level compensation is activated, a non-linear temperature decay model is introduced, and a secondary trajectory offset calculation is performed in combination with the workpiece thermal conductivity and specific heat capacity parameters.

6. A control method for automatic switching between end face turning and milling according to claim 1, characterized in that, In the above S8, the detection unit fusion detection adopts a decision rule based on confidence weights, specifically including the following steps: S81. Calculate the qualified comprehensive confidence Qualified comprehensive confidence = surface roughness confidence × 0.4 + dimensional accuracy confidence × 0.3 + geometric tolerance confidence × 0.3; S82. Calculate the unqualified comprehensive confidence Unqualified comprehensive confidence = (1 - surface roughness confidence) × 0.5 + (1 - dimensional accuracy confidence) × 0.3 + (1 - geometric tolerance confidence) × 0.2; S83. Make a determination according to the conflict factor If the conflict factor R between the qualified comprehensive confidence and the unqualified comprehensive confidence > 0.7, it is determined that the detection result conflicts and an artificial re-inspection process is triggered.

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