Milling method based on reciprocating motion of milling cutter

Abstract

The invention discloses a milling method based on reciprocating motion of a milling cutter, and relates to the technical field of aero-engines. Initial cutting parameters are set; determining the maximum cutting depth L1 of the current milling cutter, and dividing a finish machining part L2 and a rough machining part L3 of the milling cutter; positioning the milling cutter to an initial position; the milling cutter starts to mill, the milling cutter performs axial reciprocating motion in the milling process, rough machining is performed on the part by utilizing the rough machining part L3 of the milling cutter, and meanwhile, cutting parameters are adjusted in real time by utilizing self-adaptive software; and the milling cutter starts to mill according to the current cutting parameters, and finish machining is conducted on the part through the finish machining part L2 in the milling process. The axial position of the milling cutter is dynamically adjusted in the 2D contour milling process, the abrasion of the milling cutter can be effectively reduced, the service life of the milling cutter is prolonged, the machining precision and the surface quality are not affected while the service life of the milling cutter is prolonged, the defect that an operator manually adjusts length cutter compensation can be overcome, and the tedious steps of programming of technologists can be simplified.

Description

Technical Field

[0001] The invention belongs to the technical field of aviation engines, and in particular relates to a milling method based on the reciprocating motion of a milling cutter. Background Art

[0002] In aircraft engine manufacturing, key components such as turbine disks and blisks are typically manufactured from high-strength, heat-resistant alloys to meet performance requirements under extreme high-temperature, high-pressure, and high-speed operating conditions. However, the high hardness, low thermal conductivity, and strong tendency to work hardening of these materials pose challenges to traditional milling processes, including severe cutter wear, low machining efficiency, and difficulty maintaining surface integrity. Thin-walled structures such as lacework (e.g., on blisks and turbine disks) or through-holes in cylindrical parts are particularly susceptible to deformation during milling due to cutting forces, residual stresses, or thermal deformation, as well as abnormal tool wear and even dimensional deviations caused by part and tool chatter. Therefore, a high-precision, low-cutting-force lacework layering (layering along the tool axis and radially along the part allowance) milling strategy (Trochoidal Milling) is required. This technology utilizes a spiral milling cutter path with a small depth of cut and high feed, combined with dynamic cutting force control, to significantly reduce radial cutting forces, thereby minimizing the risk of deformation in thin-walled parts while simultaneously improving material removal rates and extending cutter life.

[0003] Take the milling of lace as an example: existing lace milling methods generally rely on manually changing the milling cutter length compensation value or manually adjusting the cutting depth of the tool axis to enable the use of different cutting edge areas of the milling cutter. However, manually changing the milling cutter length compensation value is risky and can easily cause quality accidents. In addition, manual adjustment of the cutting depth requires the technician to add a milling cutter axial movement point to the program, which is a huge and complex task. Moreover, after the effective cutting edge length of the milling cutter is changed, the modified program will not match the milling cutter cutting edge length. In addition, during the manual adjustment process, the adjustment is usually made in integer multiples of the lace wall thickness plus 1mm, which means that part of the tool's cutting edge will not be effectively used, increasing tool costs. Summary of the Invention

[0004] In response to the shortcomings of the existing technology, the present invention proposes a milling method based on the reciprocating motion of the milling cutter. By dynamically adjusting the axial position of the milling cutter during the milling of the 2D contour, the wear of the milling cutter can be effectively reduced, and the service life of the milling cutter can be extended. While extending the life of the milling cutter, the processing accuracy and surface quality will not be affected. It can also simplify the operator's manual adjustment of the length tool compensation and simplify the tedious programming steps of the process personnel.

[0005] The technical solution of the present invention is:

[0006] The first aspect of the present invention provides a milling method based on the reciprocating motion of a milling cutter, including the following steps:

[0007] Set initial cutting parameters, including cutting speed, feed speed, and cutting width;

[0008] Based on the interference between the milling cutter and the part, determine the maximum cutting depth L1 of the current milling cutter, and divide the finishing part L2 and roughing part L3 of the milling cutter within the range of the maximum cutting depth L1 of the milling cutter;

[0009] Position the milling cutter at the initial position;

[0010] The milling cutter starts milling according to the initial cutting parameters. During the milling process, the milling cutter moves axially back and forth, uses its roughing part L3 to rough the part, and at the same time uses adaptive software to adjust the cutting parameters in real time;

[0011] Set the cutting parameters for finishing, and continue to mill and finish the part using the finishing part L2 according to the cutting parameters for finishing, thus completing the milling.

[0012] Further, the maximum cutting depth L1 of the milling cutter is the maximum axial depth of the milling cutter when there is no interference between the milling cutter and the part;

[0013] The finishing part L2 of the milling cutter is an interval with a length of the part wall thickness dimension plus a set distance R3 along the axial direction of the milling cutter from the vertex position in the range of the maximum cutting depth L1 of the milling cutter;

[0014] The roughing part L3 is located below the finishing part L2 and is an interval between the position set at a distance R3 from the bottom of the milling cutter and the lower edge of the finishing part L2.

[0015] Further, the method for determining the initial position is: when the lower edge of the milling cutter and the upper surface of the lace of the part are in the same plane, the relative position between the milling cutter and the lace is 0, the lower edge of the milling cutter is negative when it is below the upper surface of the lace, and positive when it is above the upper surface of the lace. The initial position is at the position of -(R2 + R3), where R2 is the part wall thickness and R3 is a set distance.

[0016] Further, the specific axial reciprocating motion is: when R4 >= R1, the milling cutter reciprocates axially between -(R2 + R3) and -(R1 - R2 - R3), and the axial reciprocating speed of the milling cutter is R5; when R4 < R1, the milling cutter reciprocates axially between -(R2 + R3) and -(R4 - R2 - R3), and the axial reciprocating speed of the milling cutter is R5, where R1 = L1 is the maximum cutting depth of the milling cutter and R4 is the length of the milling cutter blade.

[0017] Further, the real-time adjustment of the cutting parameters by the adaptive software is specifically as follows: Through sensors, the vibration and cutting force of the milling cutter are monitored in real time, and the adaptive software adjusts the cutting speed and feed speed of the milling cutter according to the vibration and cutting force of the milling cutter.

[0018] Further, the finish machining of the part by using the finish machining part L2 during the milling process is specifically as follows: When R4 >= R1, the milling cutter performs finish machining of the part contour at the -R1 position; when R4 < R1, the milling cutter performs finish machining of the part contour at the -R4 position.

[0019] A second aspect of the present invention provides an electronic device, including: a processor, a memory, and a bus. The memory stores machine-readable instructions executable by the processor. When the electronic device runs, the processor communicates with the memory through the bus. When the machine-readable instructions are executed by the processor, the steps of a milling method based on the reciprocating motion of the milling cutter are executed.

[0020] A third aspect of the present invention provides a computer-readable storage medium. A computer program is stored in the computer-readable storage medium. When the computer program is run by a processor, the steps of a milling method based on the reciprocating motion of the milling cutter are executed.

[0021] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0022] (1) Combination of dynamic axial adjustment and wear control: Combining dynamic axial adjustment technology with milling cutter wear control, by adjusting the axial position of the milling cutter in real time, uniform wear within the available range of the cutting edge can be achieved, effectively reducing the wear of the milling cutter, extending the service life of the milling cutter, reducing the replacement frequency and cost of the milling cutter, reducing the downtime replacement time caused by milling cutter wear, and improving the processing efficiency.

[0023] (2) Intelligent adjustment based on state monitoring: By monitoring the state of the milling cutter and cutting conditions in real time, and optimizing the cutting parameters, it is ensured that while extending the life of the milling cutter, the machining accuracy and surface quality are not affected; by using the position of the finish machining cutting edge of the milling cutter, the rigidity of the milling cutter can be improved, and it is easier to ensure the machining accuracy of the part.

[0024] (3) Canceling the traditional processing method of manually modifying the tool compensation for layer-by-layer cutting, eliminating the method of programmers manually inserting the axial position points of the milling cutter, simplifying the working steps of programmers, and improving work efficiency; also avoiding the processing hazards caused by operators manually modifying the tool compensation; avoiding the non-uniformity of manually inserting the axial position points of the milling cutter, making the axial displacement proportional to the 2D plane movement.

[0025] (4) Due to the back grinding of the milling cutter, the cutting edge length of the milling cutter is different. If the milling cutter with a cutting edge smaller than the maximum cutting depth is replaced, the original manual adjustment program will not be suitable for the current milling cutter. The parametric program avoids the problem of reprogramming.

[0026] (5) Through the vibration statistics of the adaptive system, it can be analyzed that the reciprocating movement of the tool axis can effectively reduce the vibration amplitude of the spindle tool when milling the penetrating features of thin-walled parts (such as lace and through holes). The reduction of the tool vibration amplitude can effectively increase the service life of the tool. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0028] Figure 1 This is a flow chart of a milling method based on the reciprocating motion of a milling cutter in an embodiment of the present invention;

[0029] Figure 2 This is a schematic diagram of dynamic axial adjustment in an embodiment of the present invention;

[0030] Figure 3 Schematic diagram of the cutting part of the milling cutter in an embodiment of the present invention. DETAILED DESCRIPTION

[0031] The present invention is described in detail below with reference to the accompanying drawings and embodiments.

[0032] A milling method based on the reciprocating motion of the milling cutter, such as Figure 1 and Figure 2 As shown, the following steps are included:

[0033] Step 1: Set the initial cutting parameters, including cutting speed, feed rate, and cutting width, based on the workpiece material and processing requirements;

[0034] Step 2: Based on the interference between the milling cutter and the part, determine the maximum cutting depth L1 of the current milling cutter, and divide the milling cutter into the finishing part L2 and the roughing part L3 within the maximum cutting depth L1 of the milling cutter to minimize the wear of the milling cutter and maximize the accuracy of the part. Figure 3 As shown;

[0035] The maximum cutting depth L1 of the milling cutter is the maximum axial depth of the milling cutter when there is no interference between the milling cutter and the part;

[0036] The finish machining part L2 of the milling cutter is an interval with a length of the part wall thickness dimension plus a set distance R3 along the axial direction of the milling cutter from the vertex position in the maximum cutting depth L1 range of the milling cutter. In this embodiment, the set distance is 0.5 - 1 mm;

[0037] The rough machining part L3 is located below the finish machining part L2 and is an interval from the position set with a distance R3 from the bottom of the milling cutter to the lower edge of the finish machining part L2. In this embodiment, the set distance is 0.5 - 1 mm;

[0038] In this embodiment, the maximum cutting depth L1 of the milling cutter satisfies:

[0039] L1 = part wall thickness + (0.5 - 1) + rough machining part + (0.5 - 1)

[0040] Step 3: Position the milling cutter to the initial position;

[0041] The method for determining the initial position is as follows: When the lower edge of the milling cutter is on the same plane as the upper surface of the lace of the part, the relative position between the milling cutter and the lace is 0. It is negative when the lower edge of the milling cutter is below the upper surface of the lace and positive when it is above the upper surface of the lace. The initial position is at the position of -(R2 + R3), where R2 is the part wall thickness and R3 is the set distance;

[0042] Step 4: The milling cutter starts milling according to the initial cutting parameters. During the milling process, the milling cutter moves axially back and forth, uses its rough machining part L3 to rough machine the part, and at the same time uses the adaptive software to adjust the cutting parameters in real time;

[0043] The specific axial reciprocating movement is as follows: When R4 >= R1, the milling cutter reciprocates axially between -(R2 + R3) and -(R1 - R2 - R3), and the axial reciprocating movement speed of the milling cutter is R5; when R4 < R1, the milling cutter reciprocates axially between -(R2 + R3) and -(R4 - R2 - R3), and the axial reciprocating movement speed of the milling cutter is R5, where R1 = L1 is the maximum cutting depth of the milling cutter and R4 is the length of the milling cutter blade;

[0044] The specific real - time adjustment of the cutting parameters using the adaptive software is as follows: Through the sensors installed on the CNC machining center, the vibration and cutting force of the milling cutter are monitored in real time, the current machining vibration state and wear degree of the milling cutter are evaluated, and the adaptive software adjusts the cutting speed and feed speed according to the vibration and cutting force of the milling cutter to achieve the purpose of improving machining efficiency and prolonging the life of the milling cutter;

[0045] Axial cutting depth: By dynamically adjusting the axial cutting depth in rough machining (with axial reciprocating movement), it is possible to avoid excessive wear of the milling cutter at a certain position. In traditional milling, the axial cutting depth is usually fixed, which may lead to excessive use of the milling cutter in certain areas. In this invention, by adjusting the axial cutting depth in real-time during rough machining, the wear of the milling cutter becomes more uniform, extending the service life of the milling cutter;

[0046] Feed rate: According to the current state of the milling cutter and cutting conditions, an adaptive machining software is used to automatically adjust the feed rate to avoid overheating and accelerated wear of the milling cutter caused by too high speed.

[0047] Cutting speed: By adjusting the cutting speed, the cutting temperature is controlled to reduce thermal wear. In high-speed cutting, due to the drastic change in temperature, cemented carbide milling cutters are prone to cracking due to thermal stress, and the service life is reduced by 30% - 50%. The axial movement of the milling cutter shaft can effectively control the cutting temperature and reduce the influence of thermal stress;

[0048] Step 5: Set the cutting parameters for finish machining, and continue to perform milling finish machining on the part using the finish machining part L2 according to the cutting parameters for finish machining to complete the milling.

[0049] Specifically: When R4 >= R1, the milling cutter performs finish machining of the part contour at the -R1 position; when R4 < R1, the milling cutter performs finish machining of the contour program at the -R4 position;

[0050] The effects achieved by the method proposed in this embodiment in practice:

[0051] Extension of milling cutter life: Through dynamic axial adjustment, the life of the milling cutter can be extended by 75%, from the traditional 120 minutes to 210 minutes;

[0052] Improvement of surface quality: By optimizing the cutting parameters, the surface roughness can be reduced by 50%, from 3.2 μm to 1.6 μm;

[0053] Improvement of finish machining efficiency: By using a dedicated finish machining part, the original machining method of machining once and finishing twice is changed to a method that is qualified after one machining, improving the machining efficiency by 67%;

[0054] Reduction of the chipping rate of the milling cutter: Through dynamic adjustment, the chipping rate at the corner can be reduced by 82%, from 18% to 3.2%;

[0055] Reduction of energy consumption: By optimizing the cutting parameters, the energy consumption per piece can be reduced by 18%, from 2.8 kWh to 2.3 kWh.

[0056] This embodiment also provides an electronic device, comprising: a processor, a memory and a bus, wherein the memory stores machine-readable instructions executable by the processor. When the electronic device is running, the processor and the memory communicate through the bus, and when the machine-readable instructions are executed by the processor, the steps of the milling method based on the reciprocating motion of the milling cutter are performed.

[0057] This embodiment further provides a computer-readable storage medium, in which a computer program is stored. When the computer program is executed by a processor, the steps of the milling method based on the reciprocating motion of the milling cutter are executed.

Claims

1. A milling method based on the reciprocating motion of a milling cutter, characterized in that: It includes the following steps: Set initial cutting parameters, including cutting speed, feed speed, and cutting width; Based on the interference between the milling cutter and the part, determine the maximum cutting depth L1 of the current milling cutter, and divide the finishing part L2 and roughing part L3 of the milling cutter within the range of the maximum cutting depth L1 of the milling cutter; Position the milling cutter to the initial position; The milling cutter starts milling according to the initial cutting parameters. During the milling process, the milling cutter moves axially back and forth, uses its roughing part L3 to rough-machine the part, and at the same time uses adaptive software to adjust the cutting parameters in real time; Set the cutting parameters for finishing, and continue to mill and finish the part using the finishing part L2 according to the cutting parameters for finishing to complete the milling.

2. A milling method based on reciprocating motion of a milling cutter according to claim 1, characterized in that: The maximum cutting depth L1 of the milling cutter is the maximum axial depth of the milling cutter when there is no interference between the milling cutter and the part; The finishing part L2 of the milling cutter is an interval with a length equal to the wall thickness of the part plus a set distance R3 along the axial direction of the milling cutter from the vertex position within the range of the maximum cutting depth L1 of the milling cutter; The roughing part L3 is located below the finishing part L2 and is an interval between the position set at a distance R3 from the bottom of the milling cutter and the lower edge of the finishing part L2.

3. The milling method based on the reciprocating motion of the milling cutter according to claim 1, characterized in that: The method for determining the initial position is as follows: When the lower edge of the milling cutter and the upper surface of the lace of the part are in the same plane, the relative position between the milling cutter and the lace is 0. When the lower edge of the milling cutter is below the upper surface of the lace, it is negative, and when it is above the upper surface of the lace, it is positive. The initial position is at the position of -(R2 + R3), where R2 is the wall thickness of the part and R3 is a set distance.

4. The milling method based on the reciprocating motion of the milling cutter according to claim 1, characterized in that: The specific axial reciprocating movement is as follows: When R4 >= R1, the milling cutter reciprocates axially between -(R2 + R3) and -(R1 - R2 - R3), and the axial reciprocating movement speed of the milling cutter is R5; when R4 < R1, the milling cutter reciprocates axially between -(R2 + R3) and -(R4 - R2 - R3), and the axial reciprocating movement speed of the milling cutter is R5, where R1 = L1 is the maximum cutting depth of the milling cutter and R4 is the length of the milling cutter blade.

5. The milling method based on the reciprocating motion of the milling cutter according to claim 1, characterized in that: The specific real-time adjustment of the cutting parameters using adaptive software is as follows: Through sensors, the vibration and cutting force of the milling cutter are monitored in real time, and the adaptive software adjusts the cutting speed and feed speed of the milling cutter according to the vibration and cutting force of the milling cutter.

6. The milling method based on the reciprocating motion of the milling cutter according to claim 1, characterized in that: The specific finishing of the part using the finishing part L2 during the milling process is as follows: When R4 >= R1, the milling cutter performs finishing of the part contour at the position of -R1; when R4 < R1, the milling cutter performs finishing of the part contour at the position of -R4.

7. An electronic device, characterized in that: It includes: A processor, a memory, and a bus. The memory stores machine-readable instructions executable by the processor. When the electronic device runs, the processor communicates with the memory through the bus. When the machine-readable instructions are executed by the processor, the steps of a milling method based on the reciprocating movement of a milling cutter according to any one of claims 1 - 6 are executed.

8. A computer-readable storage medium, characterized in that The computer-readable storage medium stores a computer program, and when the computer program is executed by a processor, the steps of the milling method based on the reciprocating motion of the milling cutter as claimed in any one of claims 1 to 6 are executed.

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