A milling method based on reciprocating motion of milling cutter

Abstract

This invention discloses a milling method based on the reciprocating motion of a milling cutter, relating to the field of aero-engine technology. Initial cutting parameters are set; the maximum cutting depth L1 of the current milling cutter is determined, and the milling cutter is divided into a finishing section L2 and a roughing section L3; the milling cutter is positioned at its initial position; the milling cutter begins milling, and during the milling process, the milling cutter moves axially reciprocally, using its roughing section L3 to rough-machine the part, while adaptive software adjusts the cutting parameters in real time; the milling cutter begins milling according to the current cutting parameters, and during the milling process, the finishing section L2 is used to finish-machine the part. By dynamically adjusting the axial position of the milling cutter during the milling of a 2D contour, milling cutter wear can be effectively reduced, and the service life of the milling cutter can be extended. While extending the milling cutter life, machining accuracy and surface quality are not affected. It also simplifies the drawbacks of manual adjustment of tool length compensation by the operator and simplifies the tedious programming steps for process engineers.

Description

Technical Field

[0001] This invention belongs to the field of aero-engine technology, and particularly relates to a milling method based on the reciprocating motion of a milling cutter. Background Technology

[0002] In aero-engine manufacturing, key components such as turbine disks and integral bladed disks (Blisks) are typically made of high-strength heat-resistant alloys to meet performance requirements under extreme high-temperature, high-pressure, and high-speed conditions. However, these materials have high hardness, low thermal conductivity, and a high tendency for work hardening, posing challenges to traditional milling processes, including severe cutter wear, low machining efficiency, and difficulty in ensuring surface integrity. This is especially true for thin-walled structures on parts, such as lace-like structures (e.g., those on integral bladed disks and turbine disks) or through holes on cylindrical parts. During milling, these structures are prone to deformation due to cutting forces, residual stress, or thermal deformation. Part and tool chatter can also cause abnormal tool wear and even dimensional deviations. Therefore, a high-precision, low-cutting-force trochoidal milling strategy (tool axis layering and radial layering of part allowance) is required. This technology significantly reduces radial cutting forces through a helical cutter path with small depth of cut and high feed rate, combined with dynamic cutting force control. This reduces the risk of deformation in thin-walled parts, while simultaneously improving material removal rate and extending cutter life.

[0003] Taking milling lace as an example: Existing lace milling methods generally involve manually changing the milling cutter length compensation value or having process engineers manually adjust the cutting depth along the tool axis to utilize different cutting edge areas of the milling cutter. However, manually changing the milling cutter length compensation value is risky and can easily lead to quality accidents. Furthermore, manually adjusting the cutting depth requires process engineers to add milling cutter axial movement points to the program, resulting in a large and complex workload. Also, after changing the effective cutting edge length of the milling cutter, the modified program may become mismatched with the milling cutter's cutting edge length. Moreover, during manual adjustment, adjustments are typically made in integer multiples of the lace wall thickness plus 1mm, leaving some cutting edges unused and increasing tooling costs. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention proposes a milling method based on the reciprocating motion of a milling cutter. By dynamically adjusting the axial position of the milling cutter during the milling of a 2D contour, the wear of the milling cutter can be effectively reduced, and its service life can be extended. While extending the milling cutter's service life, the machining accuracy and surface quality are not affected. It can also simplify the drawbacks of operators manually adjusting the length tool compensation and simplify the tedious programming steps for process engineers.

[0005] The technical solution of this invention is as follows:

[0006] The first aspect of the present invention provides a milling method based on the reciprocating movement 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 to 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-mill 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 to complete the milling.

[0012] Further, the maximum cutting depth L1 of the milling cutter is the maximum axial depth of the milling cutter without interference with the part;

[0013] The finishing part L2 of the milling cutter is an interval 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, with a length equal to the wall thickness dimension of the part plus a set distance R3;

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

[0015] Further, 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, 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 wall thickness of the part and R3 is a set distance.

[0016] Further, 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 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, and when R4 < R1, the milling cutter performs finish machining of the part contour at the -R4 position.

[0019] In a second aspect of the present invention, an electronic device is provided, 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] In a third aspect of the present invention, a computer-readable storage medium is provided. 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 the dynamic axial adjustment technology with the wear control of the milling cutter, 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 the wear of the milling cutter, and improving the processing efficiency.

[0023] (2) Intelligent adjustment based on condition monitoring: By monitoring the state of the milling cutter and the 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) The traditional processing method of manually modifying the tool compensation for layer-by-layer cutting is cancelled. The method of programming personnel manually inserting the axial position points of the milling cutter is eliminated, simplifying the working steps of the programming personnel and improving the work efficiency; it also avoids the processing hidden dangers brought by the operator manually modifying the tool compensation; it avoids 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 not uniform. If the milling cutter with a cutting edge shorter than the maximum cutting depth is replaced, the original manual adjustment program will not be suitable for the use of the current milling cutter. The problem of reprogramming the program is avoided by using a parameterized program.

[0026] (5) Through the vibration statistics of the adaptive system, it can be analyzed that when the reciprocating movement of the tool axis is milling the through-feature of thin-walled parts (such as lace, through hole), the vibration amplitude of the spindle tool can be effectively reduced. Since the reduction of the tool vibration amplitude can effectively improve the tool service life. Attached Figure Description

[0027] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0028] Figure 1 This is a flowchart 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 This is a schematic diagram of the milling cutter cutting part in an embodiment of the present invention. Detailed Implementation

[0031] The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

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

[0033] Step 1: Based on the workpiece material and machining requirements, set the initial cutting parameters, including cutting speed, feed rate, and width of cut;

[0034] Step 2: Based on the interference between the milling cutter and the workpiece, determine the maximum cutting depth L1 of the current milling cutter, and divide the milling cutter into finishing section L2 and roughing section L3 within the maximum cutting depth L1 range to minimize milling cutter wear and maximize the accuracy of the workpiece. 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 workpiece.

[0036] The fine machining part L2 of the milling cutter is an interval with a length equal to the part wall thickness dimension plus a set distance R3 along the axial direction of the milling cutter from the vertex position within 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 fine 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 fine 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 and the upper surface of the lace of the part are on 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 -(R2 + R3) position, 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, and uses its rough machining part L3 to rough-machine the part. At the same time, the cutting parameters are adjusted in real time using adaptive software;

[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 adaptive software is as follows: Through sensors installed on the CNC machining center, the vibration and cutting force of the milling cutter are monitored in real time to evaluate the current machining vibration state and wear degree of the milling cutter. 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 their lifespan 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 lifespan: Through dynamic axial adjustment, the lifespan 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 where machining once is qualified, improving the machining efficiency by 67%;

[0054] Reduction of milling cutter chipping rate: Through dynamic adjustment, the corner chipping rate 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, including: a processor, a memory, and a bus. The memory stores machine-readable instructions executable by the processor. When the electronic device is running, the processor communicates with the memory via the bus. When the machine-readable instructions are executed by the processor, the steps of the milling method based on the reciprocating motion of a milling cutter are performed.

[0057] This embodiment also provides a computer-readable storage medium storing a computer program that, when executed by a processor, performs the steps of a milling method based on the reciprocating motion of a milling cutter as described above.

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 rate, 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 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, the lower edge of the milling cutter is negative when it is below the upper surface of the lace, and it is 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 wall thickness of the part and R3 is a set distance; 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; The specific axial reciprocating motion is as follows: 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; Set the cutting parameters for finishing, and continue to perform milling finishing on the part using the finishing part L2 according to the cutting parameters for finishing to complete the milling; During the milling process, use the finishing part L2 to perform finishing on the part. Specifically, when R4 >= R1, make the milling cutter perform finishing on the part contour at the position of -R1, and when R4 < R1, make the milling cutter perform finishing on the part contour at the position of -R4.

2. The milling method based on the 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 dimension 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 from the position set at a distance R3 from the bottom of the milling cutter to the lower edge of the finishing part L2; 3. The milling method based on the reciprocating motion of a milling cutter according to claim 1, characterized in that, The specific method of using the adaptive software to adjust the cutting parameters in real time 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 rate of the milling cutter according to the vibration and cutting force of the milling cutter.

4. 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 motion of a milling cutter according to any one of claims 1 - 3 are executed.

5. A computer-readable storage medium, characterized in that, The computer-readable storage medium stores a computer program that, when executed by a processor, performs the steps of a milling method based on the reciprocating motion of a milling cutter as described in any one of claims 1-3.

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