Self-adaptive cutter system for brake disc machining

Abstract

The invention discloses a self-adaptive cutter system for brake disc machining. The self-adaptive cutter system comprises a cutter handle, a cutter disc, a cutting blade, a suspension sleeve, an electromagnet and a control system. The permanent magnet is embedded in the circular truncated cone section of the cutter handle, the suspension sleeve is circumferentially fixed to the cutter head through the flat key, the flat key is pasted with the strain gauge to detect cutting force in real time, and the electromagnet and the permanent magnet are oppositely arranged in the radial direction to form magnetic suspension supporting. And the control system adjusts the current of the electromagnet according to the strain signal, dynamically adjusts the radial rigidity and the suspension position of the cutterhead, and realizes axial-radial decoupling support in combination with the thrust bearing. In a preferable embodiment, the cutting blade realizes micron-order cutting depth adjustment through a piezoelectric ceramic driving gasket, the service life of the cutter is prolonged due to the alternative opening design of a cutter head mounting boss, and the problem of winding of a rotating lead is solved by a conductive slip ring assembly. Working conditions such as sand holes and hardness sudden change can be responded in real time, broadband vibration is restrained, the machining precision is improved, the service life of the cutter is prolonged, and the method is suitable for high-precision brake disc machining.

Description

Technical Field

[0001] The present invention relates to the technical field of mechanical processing tools, and in particular to an adaptive tool system for processing brake discs, which solves the problems of processing chatter and insufficient precision caused by casting defects such as sand holes and uneven hardness. Background Art

[0002] As a core component of the vehicle braking system, brake discs often have defects such as pinholes and shrinkage during the production process due to limitations of the casting process. These defective areas will cause significant differences in local material hardness due to uneven distribution of casting stress. For example, the Brinell hardness of the area around the pinhole may fluctuate significantly, which in turn causes a sudden change in the cutting resistance borne by the tool during processing. Traditional machining tools generally adopt a rigid structure design, which lacks the ability to perceive and adaptively adjust the real-time changes in the hardness of the workpiece material. When encountering such hardness differences, machining chatter is very likely to occur. Specifically, the vibration amplitude of the tool increases, which not only causes the tool cutting edge to break due to periodic impact loads, but also worsens the surface roughness of the brake disc, making it difficult to meet high-precision machining requirements.

[0003] When it comes to adjusting machining parameters, traditional cutting tools rely on mechanical structures to adjust the blade position, such as by fine-tuning the blade's radial extension with bolts. However, this type of mechanical adjustment suffers from significant response lag, typically requiring more than 10 seconds to complete an effective adjustment. This makes it impossible to track the high-frequency hardness variations in the sand hole area, which can reach frequencies exceeding 100 Hz. This makes it difficult for the tool to dynamically match the workpiece material properties during machining, further exacerbating fluctuations in machining quality and tool wear.

[0004] Conventional passive vibration reduction methods, such as damping blocks, can only attenuate vibrations of specific frequencies. However, vibrations caused by defects such as pinholes and shrinkage in brake disc castings have broadband characteristics, ranging from 10 to 500 Hz. Traditional passive vibration reduction methods are unable to effectively suppress the complex vibration components within this frequency range, resulting in limited vibration control during machining and making it difficult to meet the stringent vibration suppression requirements of high-precision machining. Summary of the Invention

[0005] In order to solve the above-mentioned technical problem or one of the technical problems existing in the prior art, the present invention provides an adaptive tool system for brake disc machining, and the specific technical solution is: An adaptive tool system for brake disc machining, comprising a tool holder, at least one tool disc fixed on the tool holder, and at least one cutting blade fixed on the tool disc. Different from the prior art, The tool handle includes, from bottom to top, a Morse cone section, a stop section, a frustum section with a smaller diameter than the stop section, and a thread section with a smaller diameter than the frustum section. Eight embedding grooves are evenly arranged along the circumference of the frustum section, and a permanent magnet is embedded in each embedding groove. The same poles of all permanent magnets are oriented toward the axis of the tool handle. The cutter disc is annular and has at least one internal keyway; Also includes The suspension sleeve, with a length equal to the combined thickness of all the cutter discs, is mounted on the outside of the cone section of the toolholder and inserted into the cutter disc. The outer wall of the suspension sleeve is provided with flat keys that correspond one-to-one with the inner keyways of the cutter discs. The flat keys and the inner keyways cooperate to achieve circumferential fixation of the suspension sleeve and the cutter disc. A strain gauge for detecting cutting force is adhered to one side of one of the flat keys. The inner wall of the suspension sleeve is evenly distributed with eight T-slots along the circumference. 8 electromagnets are respectively embedded in 8 T-slots and arranged radially opposite to the permanent magnets on the frustum segment; Two pressure plates are respectively mounted on the conical section of the tool handle and abut against the upper and lower sides of the suspension sleeve and the tool disc; Two thrust bearings are respectively mounted on the outside of the two pressure plates; The large nut is screwed to the threaded section to fix the tool handle, suspension sleeve, tool disc, pressure plate and thrust bearing into one; The control system is electrically connected to the strain gauge to receive the strain signal and is electrically connected to the electromagnet to control the current size and direction of the electromagnet.

[0006] Furthermore, the cutting blade is fixed in the blade mounting groove of the cutter disc by a blade screw and a spring washer, and a piezoelectric ceramic drive gasket is arranged between the cutting blade and the cutter disc; the thickness direction of the piezoelectric ceramic drive gasket is consistent with the cutting depth adjustment direction, and its upper and lower surfaces are tightly fitted with the bottom surface of the cutting blade and the bottom surface of the mounting groove of the cutter disc respectively; the stiffness of the piezoelectric ceramic drive gasket is greater than the elastic coefficient of the spring washer; the electrode lead of the piezoelectric ceramic drive gasket is electrically connected to the control system.

[0007] Furthermore, the periphery of the cutter disc extends outward to form 12 mounting bosses, and each of the mounting bosses is provided with a blade mounting groove; the blade mounting grooves are respectively opened on the upper end face or the lower end face of the cutter disc, and are alternately arranged along the circumference of the cutter disc according to the opening direction, that is, the first blade mounting groove is opened on the upper end face, the second is opened on the lower end face, the third is opened on the upper end face, the fourth is opened on the lower end face, and so on; when the cutting blade on one side of the cutter disc needs to be replaced due to wear, the cutter disc can be flipped so that the blade mounting groove opened on the other side faces the processing surface, and the cutting blade on that side can be switched to continue using.

[0008] Furthermore, a vertical hole is provided at the inner corner of each blade mounting groove along the radial direction of the cutter disc, and the vertical hole also serves as a blade avoidance groove; a transverse hole is provided on each mounting boss along the axial direction of the cutter disc, and the transverse hole is connected with the corresponding vertical hole; an arc-shaped groove with the center of the cutter disc as the center of the circle is provided on the upper and lower end surfaces of the mounting boss, and the bottom of the arc-shaped groove is connected with the axial opening of the transverse hole; the vertical hole, transverse hole and arc-shaped groove together constitute an electrode lead channel, which is used to arrange the electrode lead of the piezoelectric ceramic drive gasket.

[0009] Furthermore, an axial center through hole is provided at the center axis of the tool handle, which passes through the upper and lower ends thereof and serves as a main lead-in channel; an annular groove is provided on the upper end surface of the truncated cone section of the tool handle, and 8 radial guide holes are evenly distributed on the bottom wall of the annular groove along the circumference; the stator part of the conductive slip ring assembly is fixedly installed in the annular groove, and its input end is electrically connected to the control system through a wire; the rotor part of the conductive slip ring assembly rotates synchronously with the suspension sleeve or the cutter head, and its output end is provided with a radial lead-in hole connected to the axial center through hole; the piezoelectric The electrode leads of the ceramic drive gasket are led out through the arc grooves, horizontal holes and vertical holes of the cutter disc, and then merge into the radial lead holes of the rotor of the conductive slip ring assembly through the circumferential lead grooves of the suspension sleeve; the electrode leads of the eight electromagnets respectively pass through the corresponding radial guide holes and the T-slots of the frustum segment, and are connected to the brush group of the stator of the conductive slip ring assembly through the axial center through hole; through the stator-rotor conductive ring structure of the conductive slip ring assembly, a tangle-free connection of the electrode leads between the cutter disc, the suspension sleeve and the tool handle is achieved, ensuring stable transmission of signals and electrical energy during the cutting process.

[0010] Furthermore, the cutter disc is provided with two inner keyways, and the angle between the center points of the two inner keyways and the center of the cutter disc is 120°; adjacent cutter discs are assembled with the flat keys of the suspension sleeve through different inner keyways, so that the cutting blades on each cutter disc are staggered in the circumferential direction.

[0011] The present invention also discloses a control method for an adaptive tool system for brake disc machining, comprising the following steps: S1. Real-time detection of cutting force: The strain gauge on the side of the flat key is used to collect the strain signal generated by the cutter disc during the cutting of the brake disc in real time. The strain signal reflects the shear strain change of the flat key caused by the cutting force; S2. Signal Processing and Control Command Generation: The control system receives the strain signal, amplifies it, and filters it. Using a preset threshold comparison algorithm or machine learning model, it determines whether the current cutting process is experiencing abnormal conditions such as sand holes or sudden hardness changes. If an abnormal condition is detected, it generates a current regulation command for the corresponding electromagnet based on the strain signal amplitude and rate of change. The command includes current magnitude and direction parameters. S3. Dynamic Magnetic Suspension Force Adjustment: The control system outputs a drive current to the corresponding electromagnet according to the current adjustment command, causing the electromagnet to form a radially coupled magnetic field with the permanent magnet on the frustum. By adjusting the current in the electromagnet to change the magnetic field strength or by switching the current direction to change the magnetic polarity, the radial support stiffness and suspension position of the cutterhead are adjusted in real time to compensate for vibration or displacement caused by sudden changes in cutting force. S4. Coordinated control of axial stiffness: The thrust bearing and pressure plate are used to maintain the axial positioning of the cutter disc. The radial magnetic levitation force of the electromagnet and permanent magnet is combined to form an axially-radially decoupled adaptive support system to ensure the rigidity and stability of the tool system during the brake disc machining process.

[0012] Furthermore, during the dynamic magnetic levitation force adjustment process described in step S3, the control system uses a PID (Proportional-Integral-Differential) control algorithm to adjust the driving current of the electromagnet in real time, specifically including: Establish radial displacement deviation ,in is the target value of the cutter head radial position, is the real-time radial displacement calculated from the strain gauge signal; Calculate PID control output current ,in is the proportionality coefficient, is the integration coefficient, is the differential coefficient; The PID algorithm is used to dynamically adjust the current of the electromagnet so that the radial suspension position error of the cutter disc is controlled within 0.1 μm, and the cutting vibration in the frequency range of 0-10 kHz is suppressed.

[0013] Furthermore, between steps S2 and S3, the following steps are further included: S2.5. Dynamic Adjustment of Cutting Depth: The control system calculates the required blade cutting depth adjustment based on the abnormal operating condition detected in step S2 and a preset cutting depth-voltage mapping model. The voltage mapping model is calculated using the formula: Δh = k·U, where Δh is the cutting depth adjustment, k is the voltage-deformation coefficient of the piezoelectric ceramic drive pad, and U is the drive voltage. The control system applies a corresponding driving voltage to the piezoelectric ceramic drive gasket, utilizing its inverse piezoelectric effect to generate micron-level deformation in the thickness direction, with the deformation amount Δh not exceeding 50 μm; and achieves real-time adjustment of the extension length of the cutting blade through elastic compensation of the spring washer, wherein the elastic coefficient of the spring washer is less than the stiffness of the piezoelectric ceramic drive gasket; When a hard spot such as a sand hole is detected, the control system controls the piezoelectric ceramic drive gasket to contract, reducing the cutting depth by 0.01 to 0.05 mm; when a soft area or pit is detected, it controls its extension to increase the cutting depth by 0.005 to 0.02 mm to match the real-time cutting conditions.

[0014] Furthermore, during the dynamic adjustment of the cutting depth described in step S2.5, the control system uses a fuzzy logic algorithm to process multi-source signals and generate a driving voltage, specifically including: Define shear strain rate ,in is the shear strain of the flat key, t is time; stress signal The stress is collected by the built-in stress sensor of the piezoelectric ceramic drive gasket; and As the input variable of the fuzzy logic algorithm, the output variable is the driving voltage U ; Establish a fuzzy rule base: When a sand hole hard point condition is detected, >0.5% / ms and When the pressure is higher than 100MPa, a negative voltage is output to shrink the gasket; when the soft area is detected, <-0.3% / ms and When the pressure is less than 50MPa, the forward voltage is output to make the gasket extend; the accurate voltage value is obtained by defuzzification using the center of gravity method. U , the deformation error of the piezoelectric ceramic drive gasket is controlled within ±2%, achieving a fast response of cutting depth adjustment with a delay time of less than 200μs.

[0015] The beneficial technical effects of the present invention compared to the prior art are as follows: 1. Dynamic cutting force perception and active vibration suppression Real-time sensing capability: The shear strain signal caused by cutting force is collected in real time through the strain gauge on the suspended sleeve flat key, which can accurately capture the sudden change of cutting force under working conditions such as sand holes and hardness mutation, solving the problem that traditional rigid tools cannot sense material unevenness in real time.

[0016] Active Magnetic Levitation Adjustment: The control system dynamically adjusts the electromagnet's current magnitude and direction based on the strain signal. Through the radially coupled magnetic field between the electromagnet and the permanent magnet, the radial support stiffness and suspension position of the cutterhead are adjusted in real time. Compared to traditional passive vibration reduction methods, this effectively suppresses broadband vibration, reducing vibration amplitude by over 60%, thereby preventing tool chipping and deterioration of surface roughness.

[0017] 2. Adaptive support system and improved processing stability Axial-Radial Decoupling Control: Utilizing a thrust bearing and pressure plate to maintain the cutterhead's axial position, combined with the radial magnetic levitation force of electromagnets and permanent magnets, this system forms an adaptive support system with independent axial and radial adjustments. Compared to traditional single-rigid connection structures, this system optimizes both axial and radial dynamic stiffness, adapting to multi-directional changes in cutting force caused by brake disc casting defects and improving overall machining system stability.

[0018] Magnetic levitation non-contact support: The electromagnet and permanent magnet achieve cutter head suspension through magnetic field coupling, reducing the friction loss of traditional mechanical contact support, lowering the cutter head rotation resistance, and avoiding the reduction of machining accuracy due to mechanical wear, thereby extending the service life of the tool system.

[0019] 3. High-frequency response and adaptability to multiple working conditions Fast dynamic adjustment: The response time of the electromagnet drive current is less than 1ms, which can track the frequency of hardness changes in the sand hole area in real time. Compared with traditional mechanical adjustment methods, the response speed is increased by more than 1000 times, ensuring that the tool always cuts with the optimal parameters and reducing fluctuations in processing quality caused by adjustment lag.

[0020] Multi-condition robustness: Through preset control algorithms, the system can automatically identify different working conditions such as sand holes, hard spots, and soft areas, and dynamically switch magnetic levitation force parameters, so that the tool can still maintain a cutting depth error of ≤±0.01mm when the material hardness fluctuates, and the processed surface roughness is stable at Ra≤1.6μm, meeting high-precision processing requirements.

[0021] 4. Compact structure and engineering applicability Integrated design: Permanent magnets, electromagnets, sensors, and control systems are integrated into the toolholder-suspension sleeve-cutting disc structure, eliminating the need for additional external equipment. The system is compatible with existing machine tool interfaces, making engineering modifications easy and directly applicable to CNC lathes, grinders, and other equipment.

[0022] Maintenance-free feature: Magnetic levitation support has no mechanical contact parts, reducing the lubrication requirements of traditional sliding bearings. The maintenance cycle is extended to more than three times that of traditional structures, reducing downtime maintenance costs in industrial production.

[0023] In summary, the present invention systematically solves the core problems faced by traditional tools in brake disc processing, such as vibration sensitivity, response lag, and poor adaptability to multiple working conditions, through the "perception-decision-execution" closed-loop control and magnetic levitation adaptive support technology, significantly improving processing accuracy, tool life, and production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 It is a structural schematic diagram of the present invention.

[0025] Figure 2 yes Figure 1 Component separation diagram.

[0026] Figure 3 It is a structural schematic diagram of the suspension sleeve of the present invention.

[0027] Figure 4 It is a schematic structural diagram of a cutter head and a cutting blade of the present invention.

[0028] Figure 5 yes Figure 4 A partial enlarged view of .

[0029] Figure 6 It is a structural schematic diagram of the knife handle of the present invention. DETAILED DESCRIPTION

[0030] The present invention will be further described below with reference to the accompanying drawings.

[0031] like Figure 1-6 The adaptive tool system for brake disc machining shown in the figure includes a tool holder 1, four tool discs 2 fixed to the tool holder 1, and 12 cutting blades 3 fixed to each tool disc 2. The tool holder includes, from bottom to top, a Morse taper section 11, a stop section 12, a frustum section 13 with a smaller diameter than the stop section 12, and a threaded section 14 with a smaller diameter than the frustum section 13. Eight grooves 15 are evenly arranged along the circumference of the frustum section 13. A permanent magnet 16 is embedded in each groove 15, and the like poles of all permanent magnets 16 are oriented toward the axis of the tool holder. The tool disc 2 is annular and has at least one internal keyway 21. It also includes The suspension sleeve 4, whose length is equal to the sum of the thicknesses of all the cutter discs 2, is mounted outside the conical section 13 of the tool handle 1 and inserted into the cutter disc 2. The outer wall of the suspension sleeve 4 is provided with flat keys 41 corresponding one-to-one with the inner key slots 21 of the cutter disc 2. The flat keys 41 cooperate with the inner key slots 21 to achieve circumferential fixation of the suspension sleeve 4 to the cutter disc 2. A strain gauge 42 for detecting cutting force is adhered to one side of one of the flat keys 41. The inner wall of the suspension sleeve 4 is provided with eight T-slots 43 evenly distributed along the circumference. Eight electromagnets 5 are respectively embedded in eight T-slots 43 and arranged radially opposite to the permanent magnets 16 on the frustum section 13; Two pressure plates 6 are respectively mounted on the truncated cone section 13 of the tool handle 1 and abut against the upper and lower sides of the suspension sleeve 4 and the tool disc 2; Two thrust bearings 7 are respectively sleeved on the outer sides of the two pressure plates 6; The large nut 8 is screwed to the threaded section 14 to fix the tool handle 1, suspension sleeve 4, tool disc 2, pressure plate 6 and thrust bearing 7 into one body; The control system is electrically connected to the strain gauge 42 to receive the strain signal, and is electrically connected to the electromagnet 5 to control the current size and direction of the electromagnet 5.

[0032] This embodiment integrates the mechanical structure and the electronic control system to form a closed-loop adaptive system of "cutting force sensing - magnetic suspension adjustment - multi-directional stiffness control". The specific principles are as follows: The toolholder and supporting structure utilize a segmented design. The Morse taper section 11 can be directly mounted on the machine tool spindle, utilizing a standard tapered surface fit to ensure installation precision and rigidity. The diameter difference between the stop section 12 and the frustum section 13 provides an axial positioning reference for the suspension sleeve 4 and thrust bearing 7. The threaded section 14, via a large nut 8, axially compresses all components, ensuring structural stability during high-speed rotation. Eight permanent magnets 16 (with like poles facing inward) evenly distributed around the frustum section 13 generate a radial magnetic field, providing the fundamental magnetic field source for subsequent magnetic levitation force adjustment. This uniform distribution ensures a symmetrical initial magnetic attraction around the circumference of the cutterhead 2.

[0033] Coupling transmission between the suspension sleeve and the cutterhead: The length of the suspension sleeve 4 matches the combined thickness of the four cutterheads 2. The outer cylindrical key 41 circumferentially mates with the cutterhead's internal keyway 21, ensuring synchronous rotation of the cutterhead with the suspension sleeve while allowing for slight axial float of the cutterhead via the thrust bearing 7. Strain gauges 42 on the side of the key 41 directly sense shear deformation caused by cutting forces. When the cutting blade 3 encounters a hard spot such as a sand hole, the sudden change in cutting force causes shear strain on the key. The strain gauge converts the mechanical deformation into a change in resistance, which is then converted into an electrical signal by the circuit and transmitted to the control system, enabling real-time monitoring of abnormal operating conditions (response time <1ms).

[0034] Dynamic magnetic levitation force adjustment mechanism: Eight electromagnets 5 embedded in T-slots 43 on the inner wall of the levitation sleeve are radially opposed to the permanent magnets 16 on the conical segment, forming a coupled magnetic circuit consisting of a "permanent magnet bias magnetic field + electromagnet control magnetic field." During normal machining, a constant current flows through the electromagnets to maintain basic levitation force, maintaining a radial levitation gap of 20-50μm between the cutterhead 2 and the conical segment 13. If the control system detects an abnormal strain gauge signal (such as a sudden increase in cutting force caused by a sand hole), it immediately adjusts the current magnitude or direction of the corresponding electromagnets. Increasing the current strengthens the magnetic field attraction, increasing radial support stiffness (from 20N / μm to 50N / μm), and suppressing tool vibration. Switching the current direction changes the magnetic polarity, generating a repulsive force to compensate for sudden impact loads, enabling active adjustment of the cutterhead's radial position (with an adjustment accuracy of ±0.1μm).

[0035] Axial rigidity and overall stability design: The upper and lower pressure plates 6 cooperate with the thrust bearing 7 to form a rigid axial positioning in the cutterhead 2. The pressure plate 6 transmits the axial load of the suspension sleeve 4 and cutterhead 2 to the thrust bearing 7. The latter provides low-resistance axial support (friction coefficient <0.001) through rolling friction in the raceway, while preventing axial movement (positioning accuracy ≤5μm). This decoupling design of axial rigid support and radial magnetic suspension support enables the system to independently adjust the stiffness characteristics in two directions: the axial direction relies on the mechanical structure to ensure positioning accuracy, while the radial direction uses the magnetic suspension force to dynamically adapt to sudden changes in cutting force. The two work together to control the machining vibration amplitude to within 10μm, significantly improving the vibration amplitude of traditional rigid connection structures (typically >50μm).

[0036] Control system and closed-loop regulation: The control system collects the voltage signal from the strain gauge 42 in real time. After amplification and filtering, it uses a preset threshold comparison algorithm or machine learning model to determine the operating condition type (e.g., sand holes, soft areas). To address high-frequency vibrations caused by sand holes and hard particles, the system completes the following operations within 200μs: ① Calculates the required magnetic levitation force increment based on the strain signal amplitude; ② Outputs a pulse current to the corresponding electromagnet 5 to rapidly adjust the magnetic field strength; ③ Verifies the adjustment effect through strain gauge feedback signals, forming a "detection-control-feedback" closed loop. This ensures that the cutterhead's radial stiffness is reconstructed within 1ms, effectively suppressing broadband vibrations within the 10-500Hz frequency band and keeping cutting depth fluctuations within ±0.01mm, meeting the brake disc surface roughness requirement of Ra ≤ 1.6μm.

[0037] This embodiment achieves non-contact support through magnetic coupling between permanent magnets and electromagnets. Combined with the real-time sensing of strain gauges and the rapid response of the control system, it breaks through the limitations of traditional rigid tool connections and provides an engineering solution for high-precision machining of workpieces with casting defects that combines dynamic stiffness adjustment and multi-directional vibration suppression capabilities.

[0038] In another preferred embodiment, the cutting blade 3 is fixed in the blade mounting groove 23 of the cutter disc 2 by a blade screw 31 and a spring washer 32, and a piezoelectric ceramic drive gasket 9 is arranged between the cutting blade 3 and the cutter disc 2; the thickness direction of the piezoelectric ceramic drive gasket 9 is consistent with the cutting depth adjustment direction, and its upper and lower surfaces are tightly fitted with the bottom surface of the cutting blade 3 and the bottom surface of the mounting groove of the cutter disc 2 respectively; the stiffness of the piezoelectric ceramic drive gasket 9 is greater than the elastic coefficient of the spring washer 32; the electrode lead of the piezoelectric ceramic drive gasket 9 is electrically connected to the control system.

[0039] Working principle of piezoelectric ceramic drive gasket 9: Inverse piezoelectric effect: Piezoelectric ceramic materials undergo minute deformation (elongation or contraction) along their thickness when exposed to an electric field. When the control system applies voltage to the piezoelectric ceramic drive pad 9, this thickness change is directly transmitted to the cutting blade 3, pushing it along the cutting depth (perpendicular to the workpiece surface), enabling active adjustment of the cutting depth.

[0040] Closed-loop control logic: The strain gauge 42 monitors the cutting force in real time and feeds it back to the control system. The system calculates the required voltage value based on preset processing parameters (such as target cutting depth and allowable error range), drives the piezoelectric ceramic to produce corresponding deformation, and forms a "detection-calculation-execution" closed-loop control to ensure the dynamic stability of processing accuracy.

[0041] Adjustment without mechanical wear: Compared with traditional mechanical adjustment mechanisms (such as screw nuts), piezoelectric ceramic drives do not require mechanical contact, have a fast response speed (nanosecond level), and are free of wear issues, making them suitable for high-frequency, high-precision real-time adjustment scenarios.

[0042] Beneficial effects: Dynamic cutting depth adjustment: Through the inverse piezoelectric effect of the piezoelectric ceramic drive gasket 9, the extension of the cutting blade 3 can be fine-tuned in real time to achieve micron-level precision cutting depth control to meet the precision requirements of different processing stages (such as switching from roughing to finishing).

[0043] Adaptive wear compensation: When the cutting blade 3 wears and causes processing size deviation, the control system can automatically adjust the voltage of the piezoelectric ceramic according to the feedback signal (such as the cutting force change detected by the strain gauge 42) to compensate for the wear, avoid frequent shutdowns for tool setting, and improve processing efficiency.

[0044] Reduce mechanical stress impact: The stiffness of piezoelectric ceramics is greater than that of spring washers 32, which can suppress the tiny vibration of the blade during the cutting process. At the same time, by quickly responding to dynamic cutting forces, it reduces the impact load between the tool and the workpiece and extends the tool life.

[0045] In another preferred embodiment, the circumference of the cutterhead 2 extends outward to form twelve mounting bosses 22, each of which is provided with a blade mounting slot 23. The blade mounting slots 23 open either on the upper or lower end surface of the cutterhead 2 and are arranged alternately along the circumference of the cutterhead 2, i.e., the first blade mounting slot 23 opens on the upper end surface, the second on the lower end surface, the third on the upper end surface, the fourth on the lower end surface, and so on. When the cutting blade 3 on one side of the cutterhead 2 needs to be replaced due to wear, the cutterhead 2 can be flipped so that the blade mounting slot 23 on the other side faces the machining surface, allowing the cutting blade 3 on that side to continue in use. This doubles tool life: With cutting blades 3 on both sides of the cutterhead 2, if one side wears, simply flip the cutterhead to activate the blade on the other side, reducing blade replacement frequency and tool costs. Fast switching reduces downtime: Mechanical flipping eliminates the need for blade removal, enabling switching between cutting surfaces. This is particularly suitable for high-volume continuous machining, improving equipment utilization. Balanced distribution of cutting force: The blades open alternately along the circumference, so that the cutting forces of the blades on both sides are balanced when the cutter head rotates, reducing the eccentric load of the spindle, reducing vibration, and improving the surface finish of the machined surface.

[0046] In another preferred embodiment, a vertical hole 24 is provided at the inner corner of each blade mounting slot 23 along the radial direction of the cutter disc 2, and the vertical hole 24 also serves as a blade avoidance slot. A transverse hole 25 is provided on each mounting boss 22 along the axial direction of the cutter disc 2, and the transverse hole 25 is connected to the corresponding vertical hole 24. An arcuate groove 26 centered on the center of the cutter disc 2 is provided on both the upper and lower end surfaces of the mounting boss 2, and the bottom of the arcuate groove 26 is connected to the axial opening of the transverse hole 25. The vertical hole 24, transverse hole 25, and arcuate groove 26 together constitute an electrode lead channel for arranging the electrode leads of the piezoelectric ceramic drive gasket 9. The lead layout is compact and reliable: the vertical hole 24, transverse hole 25, and arcuate groove 26 form an independent lead channel, which prevents interference between the electrode leads and the moving parts of the cutting blade 3 and the cutter disc 2, ensuring stable signal transmission. Resistant to cutting fluid and debris interference: Enclosed channels prevent cutting fluid and metal debris from entering the lead area, preventing short circuits and signal attenuation, making it suitable for harsh machining environments. Maintenance-friendly: Wires are centrally routed through pre-set channels, eliminating the need for rewiring when replacing blades or cutterheads, simplifying maintenance and improving production efficiency.

[0047] In another preferred embodiment, an axial center through hole is provided at the center axis of the tool handle 1, which passes through the upper and lower ends thereof and serves as a main lead-in channel; an annular groove is provided on the upper end surface of the truncated cone section of the tool handle 1, and 8 radial guide holes are evenly distributed along the circumference on the bottom wall of the annular groove; the stator part of the conductive slip ring assembly is fixedly installed in the annular groove, and its input end is electrically connected to the control system through a wire; the rotor part of the conductive slip ring assembly rotates synchronously with the suspension sleeve 4 or the cutter head 2, and its output end is provided with a radial lead-in hole connected to the axial center through hole; the pressure The electrode leads of the electro-ceramic drive gasket 9 are routed through the arcuate slots, horizontal holes, and vertical holes of the cutterhead 2, then flow through the circumferential lead slots of the suspension sleeve 4 into the radial lead holes of the conductive slip ring assembly's rotor. The electrode leads of the eight electromagnets 5 are routed through corresponding radial guide holes, corresponding one-to-one with the T-slots of the truncated cone segment, and connected to the brush assembly of the conductive slip ring assembly's stator via the axial center through-hole. The stator-rotor conductive ring structure of the conductive slip ring assembly enables a tangle-free connection of the electrode leads between the cutterhead 2, suspension sleeve 4, and toolholder 1, ensuring stable transmission of signals and electrical energy during cutting. The tangle-free connection between rotating and fixed components: The stator-rotor structure of the conductive slip ring assembly eliminates the need for electrode leads (such as the piezoelectric ceramic and electromagnet wires) to follow the high-speed rotation of the cutterhead 2 and suspension sleeve 4, completely eliminating the problem of traditional lead wire breakage caused by entanglement during rotation. Stable Signal and Power Transmission: The conductive slip rings utilize high-precision brushes for contact with the conductive rings, resulting in low contact resistance and wear resistance. This ensures reliable transmission of high-frequency control signals (such as real-time voltage adjustment for piezoelectric ceramics) and high currents (such as electromagnet excitation), preventing machining anomalies caused by poor contact. Integrated Wire Management: The center through-hole of the toolholder serves as the primary wire channel. Radial guide holes and annular countersunk grooves combine to centralize dispersed electrode wires to the conductive slip rings, simplifying the toolholder's internal structure and improving system reliability.

[0048] In another preferred embodiment, the cutterhead 2 is provided with two internal keyways 21, with the centerline of the two keyways 21 forming an angle of 120° relative to the center of the cutterhead 2. Adjacent cutterheads 2 are assembled using different internal keyways 21 to mate with the flat keys 41 of the suspension sleeve 4, resulting in a staggered distribution of the cutting blades 3 on each cutterhead 2 in the circumferential direction. This circumferentially evens out cutting forces: The blades of adjacent cutterheads are staggered in position (e.g., with a phase difference of 120°) via the internal keyways. This prevents sudden changes in cutting forces caused by multiple blades simultaneously engaging the workpiece and reduces peak spindle load. Cutting vibration (chatter) is suppressed: The staggered blade distribution disperses periodic impacts during cutting, altering the natural frequency of the vibration system and reducing the risk of resonance. This is particularly suitable for machining materials with large cutting depths and high hardness. Improved surface quality: The uniform distribution of cutting forces reduces chatter marks on the workpiece surface, improves dimensional accuracy and surface finish, and reduces the cost of subsequent polishing processes.

[0049] A control method for an adaptive tool system for brake disc machining according to embodiment 1 includes the following steps: S1. Real-time detection of cutting force: The strain signal generated by the cutter head 2 during the cutting of the brake disc is collected in real time by the strain gauge 42 on the side of the flat key 41. The strain signal reflects the shear strain change caused by the cutting force on the flat key 41; S2. Signal Processing and Control Command Generation: The control system receives the strain signal, amplifies it, and filters it. Using a preset threshold comparison algorithm or machine learning model, it determines whether the current cutting process is experiencing abnormal conditions such as sand holes or sudden hardness changes. If an abnormal condition is detected, a current regulation instruction for the corresponding electromagnet 5 is generated based on the strain signal amplitude and rate of change. The instruction includes current magnitude and direction parameters. S3. Dynamic Magnetic Suspension Force Adjustment: The control system outputs a drive current to the corresponding electromagnet 5 according to the current adjustment command, causing the electromagnet 5 to form a radially coupled magnetic field with the permanent magnet 16 on the frustum segment 13. By adjusting the current in the electromagnet 5 to change the magnetic field strength or by switching the current direction to change the magnetic polarity, the radial support stiffness and suspension position of the cutterhead 2 are adjusted in real time to compensate for vibration or displacement caused by sudden changes in cutting force. S4. Coordinated control of axial stiffness: The thrust bearing 7 and pressure plate 6 are used to maintain the axial positioning of the cutter disc 2. The radial magnetic levitation force of the electromagnet 5 and the permanent magnet 16 are combined to form an axially-radially decoupled adaptive support system to ensure the rigidity and stability of the tool system during the brake disc machining process.

[0050] Full-process dynamic perception and active control By collecting cutting force signals in real time through strain gauges (response time <1ms), real-time monitoring of casting defects such as sand holes and hardness mutations can be achieved for the first time, solving the vibration problem caused by "blind cutting" of traditional tools.

[0051] The coordinated control of magnetic levitation force regulation and axial stiffness forms a decoupling system: radially, the support stiffness is dynamically adjusted (adjustment range 20-50N / μm) through the electromagnet-permanent magnet coupling magnetic field, suppressing 10-500Hz wide-band vibration; axially, the thrust bearing is rigidly positioned (accuracy ≤5μm) to avoid system instability caused by multi-directional load coupling, reducing the machining vibration amplitude by more than 60%.

[0052] Multi-condition robustness and machining accuracy assurance The threshold comparison algorithm / machine learning model can automatically identify abnormal working conditions, output repulsive force compensation for sand holes and hard spots (sudden increase in cutting force), and enhance suction to stabilize the cutter disc in soft areas (sudden decrease in cutting force), ensuring that the cutting depth error is ≤±0.01mm and the surface roughness is stable at Ra≤1.6μm.

[0053] The electromagnet current response time is less than 1ms, far exceeding the traditional mechanical adjustment method (which requires more than 10 seconds). It can track high-frequency defects with hardness change frequencies up to 100Hz, avoiding fluctuations in processing quality caused by adjustment lag.

[0054] In another preferred embodiment, during the dynamic magnetic levitation force adjustment process described in step S3, the control system uses a PID (Proportional-Integral-Differential) control algorithm to adjust the driving current of the electromagnet 5 in real time, specifically including: Establish radial displacement deviation ,in is the target value of the radial position of cutter head 2, is the real-time radial displacement calculated from the signal of the strain gauge 42; Calculate PID control output current ,in is the proportionality coefficient, is the integration coefficient, is the differential coefficient; The current of the electromagnet 5 is dynamically adjusted by the PID algorithm, so that the radial suspension position error of the cutter head 2 is controlled within 0.1 μm, and the cutting vibration in the frequency range of 0-10 kHz is suppressed.

[0055] High-precision displacement control and vibration suppression: The proportional (P) stage rapidly responds to radial displacement deviations, adjusting the magnetic field in real time to offset cutting force disturbances, and keeping dynamic stiffness adjustment delays within 50μs. The integral (I) stage eliminates static errors, ensuring the radial position error of the cutterhead remains stable within 0.1μm during long-term operation (compared to >5μm with traditional open-loop control). The differential (D) stage predicts vibration trends and suppresses high-frequency vibrations below 10kHz (such as in high-dynamic scenarios like grinding), preventing damage from resonance between the tool and the workpiece. System stability and interference resistance are enhanced through PID parameter tuning (e.g., Kp=20, Ki=5, and Kd=0.5), which increases the damping ratio of the magnetic suspension support system to the critical damping state. This results in a step response overshoot of less than 5%, significantly outperforming traditional PD control and meeting the stringent "zero vibration" requirements of high-precision machining.

[0056] In another preferred embodiment, the method further includes between steps S2 and S3: S2.5. Dynamic Adjustment of Cutting Depth: The control system calculates the required blade cutting depth adjustment based on the abnormal operating condition detected in step S2 and a preset cutting depth-voltage mapping model. The voltage mapping model is calculated using the formula: Δh = k·U, where Δh is the cutting depth adjustment, k is the voltage-deformation coefficient of the piezoelectric ceramic drive pad 9, and U is the drive voltage. The control system applies a corresponding driving voltage to the piezoelectric ceramic drive gasket 9, utilizing its inverse piezoelectric effect to generate micron-level deformation in the thickness direction, with the deformation Δh not exceeding 50 μm. The extension length of the cutting blade 3 is adjusted in real time through elastic compensation of the spring washer 32, wherein the elastic coefficient of the spring washer 32 is less than the stiffness of the piezoelectric ceramic drive gasket 9. When a hard spot such as a sand hole is detected, the control system controls the piezoelectric ceramic drive gasket 9 to contract, reducing the cutting depth by 0.01 to 0.05 mm; when a soft area or a pit is detected, it controls its extension, increasing the cutting depth by 0.005 to 0.02 mm to match the real-time cutting conditions.

[0057] Micron-level precision real-time compensation The piezoelectric ceramic drive gasket uses the inverse piezoelectric effect (deformation variable Δh=k・U, k=0.5μm / V) to achieve cutting depth adjustment with a resolution of 0.1μm. For example, applying a voltage of 10V can stretch it by 5μm, accurately matching the differentiated needs of sand hole hard points (reducing 0.01-0.05mm) and soft areas (increasing 0.005-0.02mm).

[0058] Spring washer elastic compensation mechanism Ensure that the blade only produces pure translational motion (tilt angle < 0.01°), avoiding surface plowing defects caused by changes in blade posture. Compared with the rigid connection solution, the surface roughness Ra value is reduced from 3.2μm to below 1.2μm.

[0059] Improved tool life and machining efficiency In hard point scenarios, the cutting depth is actively reduced (for example, by 0.03mm), reducing the peak cutting force by 30% and the probability of tool chipping from 15% in traditional solutions to less than 2%. The cutting depth is automatically increased in soft areas (for example, by 0.01mm), shortening the processing time of a single workpiece by 10%-15% while ensuring surface quality. This is particularly suitable for optimizing the efficiency of large-scale brake disc production lines.

[0060] In another preferred embodiment, during the dynamic adjustment of the cutting depth described in step S2.5, the control system uses a fuzzy logic algorithm to process multi-source signals and generate a driving voltage, specifically including: Define shear strain rate ,in is the shear strain of the flat key 41, t is time; stress signal The stress is collected by the built-in stress sensor of the piezoelectric ceramic drive pad 9; and As the input variable of the fuzzy logic algorithm, the output variable is the driving voltage U ; Establish a fuzzy rule base: When a sand hole hard point condition is detected, >0.5% / ms and When the pressure is higher than 100MPa, a negative voltage is output to shrink the gasket; when the soft area is detected, <-0.3% / ms and When the pressure is less than 50MPa, the forward voltage is output to make the gasket extend; the accurate voltage value is obtained by defuzzification using the center of gravity method. U , the deformation error of the piezoelectric ceramic driving gasket 9 is controlled within ±2%, achieving a fast response of the cutting depth adjustment with a delay time of less than 200μs.

[0061] Intelligent decision-making for nonlinear working conditions Multi-source signal fusion (shear strain rate +Gasket stress ) Resolve the ambiguity of single strain gauge detection: For example, when >0.5% / ms and When the pressure is greater than 100MPa (hard point feature), the output voltage is -50V to shrink the gasket; when <-0.3% / ms and When the pressure is less than 50MPa (soft area characteristics), the output voltage is +30V, which avoids the misjudgment problem of the traditional threshold algorithm (the misjudgment rate is reduced from 20% to less than 5%).

[0062] Fast response and enhanced robustness The center of gravity method for defuzzification enables precise calculation of voltage values ​​(error ±2%). Combined with the nanosecond response characteristics of piezoelectric ceramics, the entire adjustment process delay is less than 200μs, and sudden changes in operating conditions above 1000Hz (such as high-frequency defects during high-speed cutting) can be tracked. The fuzzy rule base covers the Brinell hardness fluctuation range of ±50HB. Compared with traditional linear control, the processing qualification rate under extreme working conditions (such as continuous sand hole intervals <1mm) is improved from 70% to over 95%.

[0063] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. An adaptive tool system for machining a brake disc, comprising a tool holder (1), at least one tool disc (2) fixed to the tool holder (1), and at least one cutting blade (3) fixed to the tool disc (2), characterized in that: The tool handle comprises, from bottom to top, a Morse cone section (11), a stop section (12), a frustum section (13) with a diameter smaller than that of the stop section (12), and a thread section (14) with a diameter smaller than that of the frustum section (13); eight embedded grooves (15) are evenly arranged along the circumference of the frustum section (13); a permanent magnet (16) is embedded in each embedded groove (15); and the same-named magnetic poles of all the permanent magnets (16) are oriented toward the axis of the tool handle; The cutter disc (2) is annular and has at least one inner keyway (21); Also includes A suspension sleeve (4) having a length equal to the sum of the thicknesses of all the cutter discs (2) is sleeved on the outside of the truncated cone section (13) of the cutter handle (1) and inserted into the cutter disc (2); a flat key (41) corresponding to the inner key groove (21) of the cutter disc (2) is provided on the outer wall of the suspension sleeve (4); the flat key (41) cooperates with the inner key groove (21) to achieve circumferential fixation of the suspension sleeve (4) and the cutter disc (2); a strain gauge (42) for detecting cutting force is adhered to one side of one of the flat keys (41); and eight T-shaped slots (43) are evenly provided on the inner wall of the suspension sleeve (4) along the circumference. Eight electromagnets (5) are respectively embedded in the eight T-slots (43) and are arranged radially opposite to the permanent magnets (16) on the frustum section (13); Two pressure plates (6) are respectively mounted on the truncated cone section (13) of the tool handle (1) and abut against the upper and lower sides of the suspension sleeve (4) and the tool disc (2); Two thrust bearings (7) are respectively sleeved on the outer sides of the two pressure plates (6); The large nut (8) is screwed to the threaded section (14) to fix the tool handle (1), the suspension sleeve (4), the tool disc (2), the pressure plate (6) and the thrust bearing (7) into one body; The control system is electrically connected to the strain gauge (42) to receive the strain signal, and is electrically connected to the electromagnet (5) to control the magnitude and direction of the current of the electromagnet (5).

2. The adaptive tool system for brake disc machining according to claim 1, characterized in that: The cutting blade (3) is fixed in the blade mounting groove (23) of the cutter disc (2) by a blade screw (31) and a spring washer (32), and a piezoelectric ceramic drive gasket (9) is arranged between the cutting blade (3) and the cutter disc (2); the thickness direction of the piezoelectric ceramic drive gasket (9) is consistent with the cutting depth adjustment direction, and its upper and lower surfaces are tightly fitted with the bottom surface of the cutting blade (3) and the bottom surface of the mounting groove of the cutter disc (2), respectively; the stiffness of the piezoelectric ceramic drive gasket (9) is greater than the elastic coefficient of the spring washer (32); and the electrode lead of the piezoelectric ceramic drive gasket (9) is electrically connected to the control system.

3. The adaptive tool system for brake disc machining according to claim 1, characterized in that: The periphery of the cutter disc (2) extends outward to form 12 mounting bosses (22), and each mounting boss (22) is provided with a blade mounting groove (23); the blade mounting grooves (23) are respectively opened at the upper end face or the lower end face of the cutter disc (2), and are alternately arranged along the circumference of the cutter disc (2) according to the opening direction, that is, the first blade mounting groove (23) is opened at the upper end face, the second is opened at the lower end face, the third is opened at the upper end face, the fourth is opened at the lower end face, and so on; when the cutting blade (3) on one side of the cutter disc (2) needs to be replaced due to wear, the cutter disc (2) can be turned over so that the blade mounting groove (23) opened on the other side faces the processing surface, and the cutting blade (3) on that side is switched to continue to be used.

4. The adaptive tool system for brake disc machining according to claim 1, characterized in that: A vertical hole (24) is provided at the inner corner of each blade mounting groove (23) along the radial direction of the cutter disc (2), and the vertical hole (24) also serves as a blade avoidance groove; a transverse hole (25) is provided on each mounting boss (22) along the axial direction of the cutter disc (2), and the transverse hole (25) is connected to the corresponding vertical hole (24); an arc groove (26) with the center of the cutter disc (2) as the center of the circle is provided on the upper and lower end surfaces of the mounting boss (22), and the bottom of the arc groove (26) is connected to the axial opening of the transverse hole (25); the vertical hole (24), the transverse hole (25) and the arc groove (26) together constitute an electrode lead channel for arranging the electrode lead of the piezoelectric ceramic drive gasket (9).

5. The adaptive tool system for brake disc machining according to claim 4, characterized in that: The center axis of the tool handle (1) is provided with an axial center through hole that passes through the upper and lower ends thereof, serving as a main lead-in channel; the upper end surface of the truncated cone section of the tool handle (1) is provided with an annular recessed groove, and the bottom wall of the annular recessed groove is provided with 8 radial guide holes evenly distributed along the circumference; the stator part of the conductive slip ring assembly is fixedly installed in the annular recessed groove, and its input end is electrically connected to the control system through a wire; the rotor part of the conductive slip ring assembly rotates synchronously with the suspension sleeve (4) or the tool disc (2), and its output end is provided with a radial lead-in hole that is connected to the axial center through hole; the piezoelectric ceramic drive gasket ( The electrode leads of the electromagnets (9) are led out through the arc groove, the horizontal hole and the vertical hole of the cutter head (2), and then flow into the radial lead holes of the rotor of the conductive slip ring assembly through the circumferential lead groove of the suspension sleeve (4); the electrode leads of the eight electromagnets (5) respectively pass through the corresponding radial guide holes and the T-slots of the truncated cone section, and are connected to the brush group of the stator of the conductive slip ring assembly through the axial center through hole; through the stator-rotor conductive ring structure of the conductive slip ring assembly, the electrode leads between the cutter head (2), the suspension sleeve (4) and the tool handle (1) are connected without entanglement, thereby ensuring the stable transmission of signals and electric energy during the cutting process.

6. The adaptive tool system for brake disc machining according to claim 1, characterized in that: The cutter disc (2) is provided with two inner keyways (21), and the angle between the center lines of the two inner keyways (21) and the center of the cutter disc (2) is 120°; adjacent cutter discs (2) are assembled with the flat keys (41) of the suspension sleeve (4) through different inner keyways (21), so that the cutting blades (3) on each cutter disc (2) are staggered in the circumferential direction.

7. The control method of the adaptive tool system for brake disc machining according to claim 1, characterized in that: The following steps are involved: S1. Real-time detection of cutting force: The strain signal generated by the cutter head (2) during the cutting of the brake disc is collected in real time through the strain gauge (42) on the side of the flat key (41), wherein the strain signal reflects the shear strain change of the flat key (41) caused by the cutting force; S2. Signal processing and control instruction generation: The control system receives the strain signal and performs amplification and filtering processing, and determines whether the current cutting encounters an abnormal working condition of sand holes or hardness mutation through a preset threshold comparison algorithm or machine learning model; if an abnormal working condition is detected, a current adjustment instruction for the corresponding electromagnet (5) is generated according to the amplitude and change rate of the strain signal, and the instruction includes current magnitude and direction parameters; S3. Dynamic magnetic levitation force adjustment: The control system outputs a driving current to the corresponding electromagnet (5) according to the current adjustment instruction, so that the electromagnet (5) and the permanent magnet (16) on the frustum segment (13) form a radial coupling magnetic field; by adjusting the current magnitude of the electromagnet (5) to change the magnetic field strength, or by switching the current direction to change the magnetic pole polarity, the radial support stiffness and suspension position of the cutter head (2) are adjusted in real time to compensate for the vibration or offset caused by the sudden change of the cutting force; S4. Coordinated control of axial stiffness: The thrust bearing (7) and the pressure plate (6) are used to maintain the axial positioning of the cutter disc (2), and the radial magnetic suspension force of the electromagnet (5) and the permanent magnet (16) are combined to form an axial-radial decoupled adaptive support system to ensure the rigidity and stability of the tool system during the brake disc machining process.

8. The control method of the adaptive tool system for brake disc machining according to claim 7, characterized in that: During the dynamic magnetic levitation force adjustment process described in step S3, the control system uses a PID proportional-integral-differential control algorithm to adjust the driving current of the electromagnet (5) in real time, specifically including: Establish radial displacement deviation ,in is the target value of the radial position of the cutter head (2), is the real-time radial displacement calculated by the signal of the strain gauge (42); Calculate PID control output current ,in is the proportionality coefficient, is the integration coefficient, is the differential coefficient; The current of the electromagnet (5) is dynamically adjusted by the PID algorithm, so that the radial suspension position error of the cutter disc (2) is controlled within 0.1 μm, and the cutting vibration in the frequency range of 0-10 kHz is suppressed.

9. The control method of the adaptive tool system for brake disc machining according to claim 7, characterized in that: Also included between steps S2 and S3: S2.

5. Dynamic adjustment of cutting depth: The control system calculates the required blade cutting depth adjustment amount based on the abnormal working condition detected in step S2 and in combination with a preset cutting depth-voltage mapping model; the calculation formula of the voltage mapping model is: Δh=k·U, where Δh is the cutting depth adjustment amount, k is the voltage-deformation coefficient of the piezoelectric ceramic drive pad (9), and U is the drive voltage; The control system applies a corresponding driving voltage to the piezoelectric ceramic drive gasket (9), utilizing its inverse piezoelectric effect to generate micron-level deformation in the thickness direction, with the deformation amount Δh not exceeding 50 μm; and the real-time adjustment of the extension length of the cutting blade (3) is achieved through the elastic compensation of the spring washer (32), wherein the elastic coefficient of the spring washer (32) is less than the stiffness of the piezoelectric ceramic drive gasket (9); When a hard spot such as a sand hole is detected, the control system controls the piezoelectric ceramic drive pad (9) to contract, thereby reducing the cutting depth by 0.01 to 0.05 mm; and when a soft area or a pit is detected, the control system controls the piezoelectric ceramic drive pad (9) to extend, thereby increasing the cutting depth by 0.005 to 0.02 mm to match the real-time cutting conditions.

10. The control method of the adaptive tool system for brake disc machining according to claim 7, characterized in that: During the dynamic adjustment of the cutting depth described in step S2.5, the control system uses a fuzzy logic algorithm to process multi-source signals and generate a driving voltage, specifically including: Define shear strain rate ,in is the shear strain of the flat key (41), t is time; stress signal The stress is collected by the built-in stress sensor of the piezoelectric ceramic drive pad (9); and As the input variable of the fuzzy logic algorithm, the output variable is the driving voltage U ; Establish a fuzzy rule base: When a sand hole hard point condition is detected, >0.5% / ms and When the pressure is higher than 100MPa, a negative voltage is output to shrink the gasket; when the soft area is detected, <-0.3% / ms and When the pressure is less than 50MPa, the forward voltage is output to make the gasket extend; the accurate voltage value is obtained by defuzzification using the center of gravity method. U , the deformation error of the piezoelectric ceramic driving gasket (9) is controlled within ±2%, and a fast response of the cutting depth adjustment is achieved, with a delay time of less than 200 μs.

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