An adaptive tool system for brake disc machining

Abstract

The application discloses a self-adaptive tool system for brake disc machining, comprising a tool holder, a tool disc, a cutting blade, a suspension sleeve, an electromagnet and a control system. The permanent magnet is embedded in the tool holder round table section, the suspension sleeve is fixed in the circumferential direction with the tool disc through a flat key, the flat key pastes a strain gauge to detect the cutting force in real time, and the electromagnet and the permanent magnet are radially opposite to form a magnetic suspension support. The control system adjusts the current of the electromagnet according to the strain signal, dynamically adjusts the radial stiffness and the suspension position of the tool disc, and realizes axial-radial decoupling support in combination with the thrust bearing. In the preferred embodiment, the cutting blade realizes micron-level cutting depth adjustment through the piezoelectric ceramic driving gasket, the tool disc mounting boss alternating opening design improves the tool life, and the conductive slip ring assembly solves the winding problem of the rotating lead wire. The application can respond to the working conditions such as sand hole and hardness mutation in real time, suppress wideband vibration, improve machining precision and tool life, and is suitable for high-precision brake disc machining.

Description

Technical Field

[0001] This invention relates to the field of machining tool technology, specifically to an adaptive tool system for brake disc machining, which solves the problems of machining chatter and insufficient precision caused by casting defects such as sand holes and uneven hardness. Background Technology

[0002] As a core component of the vehicle braking system, brake discs often suffer from defects such as sand holes and shrinkage cavities during the casting process due to limitations in the casting technology. These defective areas, due to uneven distribution of casting stress, lead to significant differences in local material hardness. For example, the Brinell hardness around a sand hole may fluctuate considerably, causing abrupt changes in the cutting resistance experienced by the tool during machining. Traditional machining tools generally employ a rigid structure design, lacking the ability to sense and adaptively adjust to real-time changes in workpiece material hardness. When encountering such hardness differences, they are highly susceptible to machining chatter. Specifically, this manifests as increased tool vibration amplitude, which not only causes chipping and damage to the cutting edge due to cyclic impact loads but also deteriorates the surface roughness of the brake disc, making it difficult to meet high-precision machining requirements.

[0003] In terms of machining parameter adjustment, traditional cutting tools rely on mechanical structures to adjust the insert position, such as by fine-tuning the radial extension of the insert with bolts. However, this type of mechanical adjustment has a significant response lag problem. The time required to complete an effective adjustment usually exceeds 10 seconds, making it impossible to track the high-frequency hardness changes (up to 100Hz) in the sand hole area in a timely manner. This makes it difficult for the cutting tool to dynamically match the workpiece material properties during machining, further exacerbating machining quality fluctuations and tool wear.

[0004] In terms of vibration suppression technology, conventional passive vibration reduction methods such as damping blocks can only attenuate vibrations at specific frequencies. However, the vibrations caused by defects such as sand holes and shrinkage cavities in brake disc castings have wide frequency characteristics, covering a frequency range of 10-500Hz. Traditional passive vibration reduction methods cannot effectively suppress the complex vibration components in this frequency band, resulting in limited vibration control during the machining process and failing to meet the stringent vibration suppression requirements of high-precision machining. Summary of the Invention

[0005] To address the aforementioned technical problems or one of the technical problems existing in the prior art, the present invention provides an adaptive tooling system for brake disc machining, the specific technical solution of which is:

[0006] An adaptive tooling system for machining brake discs includes a tool holder, at least one tool disc fixed to the tool holder, and at least one cutting insert fixed to the tool disc. Unlike existing technologies,

[0007] The tool holder, from bottom to top, includes a Morse taper section, a stop section, a frustum section with a diameter smaller than that of the stop section, and a threaded section with a diameter smaller than that of the frustum section. The frustum section has eight slots evenly distributed around its circumference, and each slot contains one permanent magnet. The same magnetic poles of all permanent magnets face the axis of the tool holder.

[0008] The cutter head is annular and has at least one internal keyway;

[0009] Also includes

[0010] The suspension sleeve, with a length equal to the sum of the thicknesses of all the cutter heads, is fitted outside the frustum section of the tool holder and inserted into the cutter head; the outer wall of the suspension sleeve is provided with flat keys that correspond one-to-one with the inner keyways of the cutter head, and the flat keys and the inner keyways cooperate to achieve circumferential fixation of the suspension sleeve and the cutter head; a strain gauge for detecting cutting force is attached to one side of one of the flat keys; eight T-slots are evenly opened circumferentially on the inner wall of the suspension sleeve.

[0011] Eight electromagnets are respectively embedded in eight T-slots and are radially opposite to the permanent magnets on the frustum section;

[0012] Two pressure plates are respectively fitted onto the frustum section of the tool holder and abut against the upper and lower sides of the suspension sleeve and the tool disc;

[0013] Two thrust bearings are respectively fitted onto the outer sides of the two pressure plates;

[0014] The large nut is screwed into the threaded section, which fixes the tool holder, suspension sleeve, tool disc, pressure plate and thrust bearing into one unit;

[0015] The control system is electrically connected to the strain gauge to receive strain signals and electrically connected to the electromagnet to control the magnitude and direction of the current in the electromagnet.

[0016] Furthermore, the cutting blade is fixed in the blade mounting groove of the cutter head by blade screws and spring washers, and a piezoelectric ceramic drive pad is placed between the cutting blade and the cutter head; the thickness direction of the piezoelectric ceramic drive pad is consistent with the cutting depth adjustment direction, and its upper and lower surfaces are in close contact with the bottom surface of the cutting blade and the bottom surface of the mounting groove of the cutter head, respectively; the stiffness of the piezoelectric ceramic drive pad is greater than the elastic coefficient of the spring washer; the electrode lead of the piezoelectric ceramic drive pad is electrically connected to the control system.

[0017] Furthermore, the periphery of the cutter head extends outward to form 12 mounting bosses, each of which has a blade mounting groove. The blade mounting grooves open onto the upper or lower end face of the cutter head, and are alternately arranged along the circumference of the cutter head in the direction of their openings. That is, the first blade mounting groove opens onto the upper end face, the second opens onto the lower end face, the third opens onto the upper end face, the fourth opens onto the lower end face, and so on. When the cutting blade on one side of the cutter head needs to be replaced due to wear, the cutter head can be flipped so that the blade mounting groove on the other side faces the machining surface, and the cutting blade on that side can be switched to continue to be used.

[0018] Furthermore, each of the blade mounting slots has a vertical hole at its inner corner along the radial direction of the cutter head, which also serves as a blade clearance slot; each mounting boss has a horizontal hole along the axial direction of the cutter head, which is connected to the corresponding vertical hole; both the upper and lower end faces of the mounting boss have arc-shaped grooves centered on the center of the cutter head, and the bottom of the arc-shaped grooves is connected to the axial opening of the horizontal hole; the vertical hole, the horizontal hole, and the arc-shaped groove together form an electrode lead channel for arranging the electrode leads of the piezoelectric ceramic drive pad.

[0019] Furthermore, an axial central through hole is provided at the central axis of the tool holder, passing through both its upper and lower ends, serving as the main lead wire channel; an annular groove is provided on the upper end face of the frustum section of the tool holder, and eight radial guide holes are evenly distributed circumferentially 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 via a wire; the rotor part of the conductive slip ring assembly rotates synchronously with the suspension sleeve or the tool disc, and its output end has a radial lead wire hole communicating with the axial central through hole; the piezoelectric... The electrode leads of the ceramic drive pad are led out through the arc groove, horizontal hole and vertical hole of the cutter head, and then converge into the radial lead hole of the rotor of the conductive slip ring assembly through the circumferential lead groove of the suspension sleeve. The electrode leads of the eight electromagnets pass through the corresponding radial guide holes and T-slots of the frustum section, and are connected to the brush group of the stator of the conductive slip ring assembly through the axial central through hole. Through the stator-rotor conductive ring structure of the conductive slip ring assembly, the electrode leads between the cutter head and the suspension sleeve and the tool holder are connected without entanglement, ensuring stable transmission of signals and electrical energy during the cutting process.

[0020] Furthermore, the cutter head is provided with two internal keyways, and the angle between the line connecting the centers of the two internal keyways and the center of the cutter head is 120°; adjacent cutter heads are assembled with the parallel key of the suspension sleeve through different internal keyways, so that the cutting blades on each cutter head are staggered in the circumferential direction.

[0021] This invention also discloses a control method for an adaptive tooling system for brake disc machining, comprising the following steps:

[0022] S1. Real-time detection of cutting force: The strain signal generated by the cutter head during the cutting of the brake disc is collected in real time by the strain gauge on the side of the flat key. The strain signal reflects the change of shear strain of the flat key caused by the cutting force.

[0023] S2. Signal processing and control command generation: The control system receives the strain signal and amplifies and filters it. Through a preset threshold comparison algorithm or machine learning model, it determines whether the current cutting encounters abnormal conditions such as sand holes or sudden changes in hardness. If an abnormal condition is detected, the control system generates a current adjustment command for the corresponding electromagnet based on the amplitude and rate of change of the strain signal. The command includes current magnitude and direction parameters.

[0024] S3. Dynamic magnetic levitation force adjustment: The control system outputs a driving current to the corresponding electromagnet according to the current adjustment command, so that the electromagnet and the permanent magnet on the frustum section form a radially coupled magnetic field; by adjusting the magnitude of the current of the electromagnet to change the magnetic field strength, or by switching the current direction to change the magnetic polarity, the radial support stiffness and levitation position of the cutter head are adjusted in real time to compensate for the vibration or offset caused by the sudden change in cutting force.

[0025] S4. Axial stiffness coordinated control: The thrust bearing and pressure plate are used to maintain the axial positioning of the cutter head. Combined with the radial magnetic levitation force of the electromagnet and the permanent magnet, an axial-radial decoupled adaptive support system is formed to ensure the rigidity and stability of the tool system during the machining of the brake disc.

[0026] Furthermore, in the dynamic magnetic levitation force adjustment process described in step S3, the control system employs a PID (Proportional-Integral-Derivative) control algorithm to adjust the driving current of the electromagnet in real time, specifically including:

[0027] Establish radial displacement deviation ,in The target value for the radial position of the cutter head. This is the real-time radial displacement calculated using strain gauge signals;

[0028] Calculate the output current of the PID control ,in This is the proportionality coefficient. The integral coefficient is... These are the differential coefficients;

[0029] The PID algorithm dynamically adjusts the current of the electromagnet, keeping the radial suspension position error of the cutter head within 0.1μm and suppressing cutting vibrations in the frequency range of 0-10kHz.

[0030] Furthermore, the process between steps S2 and S3 also includes:

[0031] S2.5. Dynamic adjustment of cutting depth: The control system calculates the required cutting depth adjustment amount of the cutting tool based on the abnormal working conditions detected in step S2 and in combination with the 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, and U is the drive voltage;

[0032] The control system applies a corresponding driving voltage to the piezoelectric ceramic driving pad, which generates micron-level deformation in the thickness direction using its inverse piezoelectric effect, with the deformation Δh not exceeding 50μm; the cutting blade extension length is adjusted in real time through the elastic compensation of the spring washer, wherein the elastic coefficient of the spring washer is less than the stiffness of the piezoelectric ceramic driving pad.

[0033] When a hard point such as a sand hole is detected, the control system controls the piezoelectric ceramic drive pad to shrink, reducing the cutting depth by 0.01 to 0.05 mm; when a soft area or 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.

[0034] Furthermore, in the dynamic adjustment of 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:

[0035] Define shear strain rate ,in For the shear strain of the flat key. t For time; stress signal The stress is collected by a stress sensor built into the piezoelectric ceramic driven pad; and The input variable for the fuzzy logic algorithm is the driving voltage. U ;

[0036] Establish a fuzzy rule base: When a sand hole hard point condition is detected, i.e. >0.5% / ms and When the pressure is >100MPa, the output negative voltage causes the pad to shrink; when a soft area is detected, i.e. <-0.3% / ms and When the pressure is less than 50 MPa, the output positive voltage causes the pad to elongate; the accurate voltage value is obtained by defuzzification using the centroid method. U The deformation error of the piezoelectric ceramic drive pad is controlled within ±2%, achieving a fast response for cutting depth adjustment with a delay time of less than 200μs.

[0037] The beneficial technical effects of this invention compared to the prior art are as follows:

[0038] 1. Dynamic cutting force sensing and active vibration suppression

[0039] Real-time sensing capability: By collecting shear strain signals caused by cutting force in real time through strain gauges on the suspended sleeve key, it can accurately capture sudden changes in cutting force under working conditions such as sand holes and sudden changes in hardness, solving the problem that traditional rigid tools cannot sense material inhomogeneity in real time.

[0040] Active magnetic levitation adjustment: The control system dynamically adjusts the magnitude and direction of the electromagnet current based on the strain signal. Through the radial coupling magnetic field between the electromagnet and the permanent magnet, the radial support stiffness and levitation position of the cutter head are adjusted in real time. Compared with traditional passive vibration reduction methods, it can effectively suppress broadband vibration, reduce the vibration amplitude by more than 60%, and avoid tool chipping and surface roughness deterioration.

[0041] 2. Adaptive support system and improved machining stability

[0042] Axial-radial decoupling control: A thrust bearing and pressure plate maintain the axial positioning of the cutter head, while the radial magnetic levitation force of the electromagnet and permanent magnet forms an independently adjustable adaptive support system for both axial and radial directions. Compared to traditional single rigid connection structures, this system can optimize axial rigidity and radial dynamic stiffness separately, adapting to multi-directional abrupt changes in cutting force caused by casting defects in the brake disc, and improving the overall stability of the machining system.

[0043] Magnetic levitation non-contact support: Electromagnets and permanent magnets achieve tool head levitation through magnetic field coupling, reducing frictional losses of traditional mechanical contact supports, reducing the rotational resistance of the tool head, and avoiding the decrease in machining accuracy due to mechanical wear, thus extending the service life of the tool system.

[0044] 3. High-frequency response and adaptability to multiple operating conditions

[0045] Rapid dynamic adjustment: The response time of the electromagnet driving current is <1ms, which can track the frequency of hardness change in the sand hole area in real time. Compared with the traditional mechanical adjustment method, the response speed is increased by more than 1000 times, ensuring that the tool always cuts with the optimal parameters and reducing the fluctuation of machining quality caused by adjustment lag.

[0046] Multi-condition robustness: Through a preset control algorithm, the system can automatically identify different working conditions such as sand holes, hard points, and soft areas, and dynamically switch magnetic levitation force parameters, so that the cutting depth error can still be ≤±0.01mm when the material hardness fluctuates, and the surface roughness of the machined surface can be kept stable at Ra≤1.6μm, meeting the requirements of high-precision machining.

[0047] 4. Structural compactness and engineering applicability

[0048] Integrated design: The permanent magnet, electromagnet, sensor and control system are integrated into the tool holder-suspending sleeve-tool disc structure, which does not require additional external equipment, is compatible with existing machine tool interfaces, has low engineering modification difficulty, and can be directly applied to CNC lathes, grinding machines and other equipment.

[0049] Maintenance-free characteristics: Magnetic levitation supports have no mechanical contact parts, reducing the lubrication requirements of traditional sliding bearings and extending the maintenance cycle to more than 3 times that of traditional structures, thus reducing downtime maintenance costs in industrial production.

[0050] In summary, this invention systematically solves the core problems faced by traditional cutting tools in brake disc machining, such as chatter sensitivity, response lag, and poor adaptability to multiple working conditions, through "perception-decision-execution" closed-loop control and magnetic levitation adaptive support technology, significantly improving machining accuracy, tool life, and production efficiency. Attached Figure Description

[0051] Figure 1 This is a schematic diagram of the structure of the present invention.

[0052] Figure 2 yes Figure 1 Partial diagram.

[0053] Figure 3 This is a schematic diagram of the suspension sleeve of the present invention.

[0054] Figure 4 This is a schematic diagram of the structure of one of the cutter heads and cutting blades of the present invention.

[0055] Figure 5 yes Figure 4 A magnified view of a portion of the image.

[0056] Figure 6 This is a schematic diagram of the structure of the knife handle of the present invention. Detailed Implementation

[0057] The present invention will be further described below with reference to the accompanying drawings.

[0058] like Figure 1-6 An adaptive tooling system for machining brake discs is shown, comprising a tool holder 1, four tool discs 2 fixed to the tool holder 1, and twelve cutting inserts 3 fixed to each tool disc 2. The tool holder, from bottom to top, includes a Morse taper section 11, a stop section 12, a frustum section 13 with a diameter smaller than the stop section 12, and a threaded section 14 with a diameter smaller than the frustum section 13. The frustum section 13 has eight circumferentially evenly spaced slots 15, each slot 15 containing one permanent magnet 16, with all corresponding magnetic poles of the permanent magnets 16 facing the tool holder axis. The tool discs 2 are annular and have at least one internal keyway 21. The system also includes...

[0059] The suspension sleeve 4, with a length equal to the sum of the thicknesses of all the cutter heads 2, is fitted outside the frustum section 13 of the tool holder 1 and inserted into the cutter head 2; the outer wall of the suspension sleeve 4 is provided with flat keys 41 that correspond one-to-one with the inner keyways 21 of the cutter head 2, and the flat keys 41 cooperate with the inner keyways 21 to achieve circumferential fixation of the suspension sleeve 4 and the cutter head 2; a strain gauge 42 for detecting cutting force is attached to one side of one of the flat keys 41; eight T-slots 43 are evenly opened circumferentially on the inner wall of the suspension sleeve 4.

[0060] Eight electromagnets 5 are respectively embedded in eight T-slots 43 and are radially opposite to the permanent magnets 16 on the frustum section 13;

[0061] Two pressure plates 6 are respectively fitted onto the frustum section 13 of the tool holder 1 and abut against the upper and lower sides of the suspension sleeve 4 and the tool disc 2;

[0062] Two thrust bearings 7 are respectively fitted onto the outer sides of the two pressure plates 6;

[0063] The large nut 8 is screwed to the threaded section 14, which fixes the tool holder 1, the suspension sleeve 4, the tool disc 2, the pressure plate 6 and the thrust bearing 7 into one unit;

[0064] The control system is electrically connected to strain gauge 42 to receive strain signals and electrically connected to electromagnet 5 to control the magnitude and direction of the current in electromagnet 5.

[0065] This embodiment integrates mechanical structure and electronic control system to form a closed-loop adaptive system of "cutting force sensing - magnetic levitation adjustment - multi-directional stiffness control". The specific principle is as follows:

[0066] Tool holder and base support structure: The tool holder adopts a segmented design. The Morse taper section 11 can be directly installed on the machine tool spindle, and the standard tapered surface fit ensures installation accuracy and rigidity. The stop section 12 and the frustum section 13 form a diameter difference, providing an axial positioning reference for the suspension sleeve 4 and the thrust bearing 7. The threaded section 14 uses a large nut 8 to axially press all components together, ensuring structural stability during high-speed rotation. The eight permanent magnets 16 (with the same magnetic poles facing inward) evenly distributed around the circumference of the frustum section 13 form a radial magnetic field, providing a basic magnetic field source for subsequent magnetic levitation force adjustment. Their uniform distribution enables the tool disc 2 to obtain a symmetrical initial magnetic attraction force in the circumferential direction.

[0067] The coupling transmission between the suspension sleeve and the cutter head: the length of the suspension sleeve 4 matches the total thickness of the four cutter heads 2, and the outer flat key 41 circumferentially engages with the keyway 21 inside the cutter head, ensuring that the cutter head rotates synchronously with the suspension sleeve, while allowing the cutter head to float slightly in the axial direction through the thrust bearing 7. The strain gauge 42 on the side of the flat key 41 directly senses the shear deformation caused by the cutting force—when the cutting insert 3 encounters a sand hole hard point, the sudden change in cutting force causes the flat key to generate shear strain. The strain gauge converts the mechanical deformation into a change in resistance value, which is then converted into an electrical signal by the circuit and transmitted to the control system to realize real-time monitoring of abnormal working conditions (response time < 1ms).

[0068] Magnetic levitation force dynamic adjustment mechanism: Eight electromagnets 5 embedded in the T-slot 43 on the inner wall of the levitation sleeve are radially opposed to the permanent magnet 16 of the frustum section, forming a coupled magnetic circuit of "permanent magnet bias magnetic field + electromagnet control magnetic field". During normal machining, a constant current is supplied to the electromagnets to maintain the basic levitation force, keeping the cutter head 2 and the frustum section 13 in a radial levitation gap of 20-50μm. When the control system detects an abnormal strain gauge signal (such as a sudden increase in cutting force caused by sand holes), it immediately adjusts the magnitude or direction of the current of the corresponding electromagnet: increasing the current can enhance the magnetic attraction force, increase the radial support stiffness (from 20N / μm to 50N / μm), and suppress tool vibration; switching the current direction can change the magnetic polarity, generating a repulsive force to compensate for sudden impact loads, and realize the active adjustment of the radial position of the cutter head (adjustment accuracy ±0.1μm).

[0069] Axial stiffness and overall stability design: The upper and lower pressure plates 6, in conjunction with the thrust bearing 7, form a rigid positioning in the axial direction of the cutter head 2. The pressure plate 6 transmits the axial load of the suspension sleeve 4 and the cutter head 2 to the thrust bearing 7, which achieves low-resistance axial support (friction coefficient < 0.001) through raceway rolling friction, while avoiding axial movement (positioning accuracy ≤ 5 μm). This decoupled design of axial rigid support and radial magnetic levitation support allows the system to independently adjust the stiffness characteristics in two directions: axial positioning accuracy is ensured by the mechanical structure, while radial dynamic adaptation to sudden changes in cutting force is achieved through magnetic levitation force. The synergistic effect of the two controls the machining vibration amplitude to within 10 μm, which is significantly better than the traditional rigid connection structure (vibration amplitude is usually > 50 μm).

[0070] Control System and Closed-Loop Adjustment: The control system acquires the voltage signal from strain gauge 42 in real time. After amplification and filtering, the system determines the working condition type (such as sand holes or soft areas) through a preset threshold comparison algorithm or machine learning model. For high-frequency vibrations caused by hard sand holes, 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 quickly 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 radial stiffness of the cutter head is reconstructed within 1ms, effectively suppressing broadband vibrations in the 10-500Hz frequency range, controlling the cutting depth fluctuation within ±0.01mm, and meeting the machining requirement of a brake disc surface roughness Ra≤1.6μm.

[0071] This embodiment achieves non-contact support through the magnetic coupling of permanent magnets and electromagnets. Combined with the real-time sensing and rapid response of strain gauges and control systems, it breaks through the limitations of traditional rigid tool connections and provides an engineering solution for high-precision machining of defective casting workpieces that combines dynamic stiffness adjustment and multi-directional vibration suppression capabilities.

[0072] In another preferred embodiment, the cutting blade 3 is fixed in the blade mounting groove 23 of the cutter head 2 by a blade screw 31 and a spring washer 32. A piezoelectric ceramic drive pad 9 is placed between the cutting blade 3 and the cutter head 2. The thickness direction of the piezoelectric ceramic drive pad 9 is consistent with the cutting depth adjustment direction, and its upper and lower surfaces are in close contact with the bottom surface of the cutting blade 3 and the bottom surface of the mounting groove of the cutter head 2, respectively. The stiffness of the piezoelectric ceramic drive pad 9 is greater than the elastic coefficient of the spring washer 32. The electrode lead of the piezoelectric ceramic drive pad 9 is electrically connected to the control system.

[0073] Working principle of piezoelectric ceramic drive pad 9:

[0074] Inverse piezoelectric effect: Piezoelectric ceramic materials undergo minute deformations (elongation or shortening) along their thickness direction under the influence of an electric field. When the control system applies voltage to the piezoelectric ceramic drive pad 9, its thickness change is directly transmitted to the cutting blade 3, pushing the blade to move along the cutting depth direction (perpendicular to the machined surface), thus achieving active adjustment of the cutting depth.

[0075] 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 the preset processing parameters (such as the target cutting depth and allowable error range), drives the piezoelectric ceramic to produce corresponding deformation, forming a closed-loop control of "detection-calculation-execution" to ensure the dynamic stability of processing accuracy.

[0076] No mechanical wear adjustment: Compared with traditional mechanical adjustment mechanisms (such as lead screws and nuts), piezoelectric ceramic drives do not require mechanical contact, have a fast response speed (nanosecond level), and have no wear issues, making them suitable for high-frequency, high-precision real-time adjustment scenarios.

[0077] Beneficial effects:

[0078] Dynamic cutting depth adjustment: By driving the piezoelectric ceramic shim 9 with the inverse piezoelectric effect, the extension of the cutting blade 3 can be finely adjusted in real time to achieve micron-level precision cutting depth control, adapting to the precision requirements of different machining stages (such as the switch from roughing to finishing).

[0079] Adaptive wear compensation: When the wear of the cutting tool 3 causes deviation in machining dimensions, the control system can automatically adjust the voltage of the piezoelectric ceramic according to the feedback signal (such as the change in cutting force detected by the strain gauge 42) to compensate for the wear, avoid frequent machine stops for tool setting, and improve machining efficiency.

[0080] Reduce mechanical stress impact: The stiffness of piezoelectric ceramics is greater than that of spring washers by 32, which can suppress the small vibration of the cutting tool during the cutting process. At the same time, by responding quickly to dynamic cutting forces, it reduces the impact load between the tool and the workpiece and extends the tool life.

[0081] In another preferred embodiment, the periphery of the cutter head 2 extends outward to form 12 mounting bosses 22, each of which has a blade mounting groove 23. The blade mounting grooves 23 open onto either the upper or lower end face of the cutter head 2, and are alternately arranged along the circumference of the cutter head 2 in the direction of their openings. Specifically, the first blade mounting groove 23 opens onto the upper end face, the second onto the lower end face, the third onto the upper end face, the fourth onto the lower end face, and so on. When a cutting blade 3 on one side of the cutter head 2 needs to be replaced due to wear, the cutter head 2 can be flipped so that the blade mounting groove 23 on the other side faces the machining surface, allowing the cutting blade 3 on that side to continue to be used. Tool life is doubled: Cutting blades 3 are provided on both sides of the cutter head 2. After wear on one side, simply flipping the cutter head allows the blade on the other side to be used, reducing the frequency of blade replacement and lowering tool costs. Quick switching reduces downtime: No blade disassembly is required; the cutting surface is switched through mechanical flipping, making it particularly suitable for high-volume continuous processing scenarios and improving equipment utilization. Balanced cutting force distribution: The cutting blades open alternately in the circumferential direction, so that the cutting forces of the two blades on both sides are balanced when the cutter head rotates, reducing the spindle eccentric load, reducing vibration, and improving the surface finish of the machined surface.

[0082] In another preferred embodiment, each blade mounting slot 23 has a vertical hole 24 radially formed at its inner corner along the cutter head 2, which also serves as a blade clearance slot; each mounting boss 22 has a horizontal hole 25 axially formed along the cutter head 2, which communicates with the corresponding vertical hole 24; both the upper and lower end faces of the mounting boss 22 have arc-shaped grooves 26 centered on the center of the cutter head 2, and the bottom of the arc-shaped grooves 26 communicates with the axial opening of the horizontal hole 25; the vertical hole 24, the horizontal hole 25, and the arc-shaped groove 26 together form an electrode lead channel for arranging the electrode leads of the piezoelectric ceramic drive pad 9. The lead layout is compact and reliable: the vertical hole 24, the horizontal hole 25, and the arc-shaped groove 26 form independent lead channels, avoiding interference between the electrode leads and the moving parts of the cutting blade 3 and the cutter head 2, and ensuring signal transmission stability. Anti-interference from cutting fluid and metal shavings: The enclosed channel prevents cutting fluid and metal shavings from entering the lead wire area, avoiding short circuits or signal attenuation, making it suitable for harsh machining environments. Convenience of maintenance: Lead wires are centrally routed through preset channels, eliminating the need for rewiring when changing cutting tools or tool heads, simplifying maintenance processes and improving production efficiency.

[0083] In another preferred embodiment, an axial central through hole is provided at the central axis of the tool holder 1, passing through its upper and lower ends, serving as the main lead wire channel; an annular groove is provided on the upper end face of the frustum section of the tool holder 1, and eight radial guide holes are evenly distributed circumferentially 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 tool disc 2, and its output end is provided with a radial lead wire hole communicating with the axial central through hole; the pressure The electrode leads of the electro-ceramic drive pad 9 are led out through the arc-shaped groove, horizontal hole, and vertical hole of the cutter head 2, and then converge into the radial lead hole 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 pass through the corresponding radial guide holes and the T-slots of the frustum section, and are connected to the brush group of the stator of the conductive slip ring assembly through the axial central through hole. Through the stator-rotor conductive ring structure of the conductive slip ring assembly, the electrode leads between the cutter head 2 and the suspension sleeve 4 and the tool holder 1 are connected without entanglement, ensuring stable transmission of signals and electrical energy during the cutting process. Unentangled connection between rotating and stationary parts: Through the stator-rotor structure, the conductive slip ring assembly ensures that the electrode leads (such as the wires of piezoelectric ceramics and electromagnets) do not need to move when the cutter head 2 and the suspension sleeve 4 rotate at high speed, completely solving the problem of breakage caused by rotational entanglement of traditional leads. Stable signal and power transmission: The conductive slip ring uses a high-precision brush for contact with the conductive ring, resulting in low contact resistance and wear resistance. This ensures reliable transmission of high-frequency control signals (such as real-time voltage adjustment of piezoelectric ceramics) and high currents (such as electromagnet excitation), avoiding machining abnormalities caused by poor contact. Integrated lead management: The central through-hole of the tool holder serves as the main lead channel, while radial guide holes and annular grooves work together to concentrate the dispersed electrode leads to the conductive slip ring, simplifying the internal structure of the tool holder and improving system reliability.

[0084] In another preferred embodiment, the cutter head 2 is provided with two internal keyways 21, and the line connecting the centers of the two internal keyways 21 forms an angle of 120° with respect to the center of the cutter head 2. Adjacent cutter heads 2 are assembled with the flat key 41 of the suspension sleeve 4 through different internal keyways 21, so that the cutting blades 3 on each cutter head 2 are staggered in the circumferential direction. Circumferential uniformity of cutting force: The blades of adjacent cutter heads are staggered by the internal keyways with a 120° angle, so that the cutting blades of each cutter head are staggered in the circumferential direction (e.g., a phase difference of 120°), avoiding sudden changes in cutting force caused by multiple blades cutting into the workpiece simultaneously, and reducing the peak spindle load. Suppression of cutting vibration (chatter): The staggered distribution of blades can disperse the periodic impacts during the cutting process, change the natural frequency of the vibration system, and reduce the risk of resonance, especially suitable for machining scenarios with large depths of cut and high hardness materials. Improved surface quality: The uniform distribution of cutting force can reduce surface chatter marks on the workpiece, improve dimensional accuracy and surface finish, and reduce the cost of subsequent polishing processes.

[0085] Example 1 describes a control method for an adaptive tooling system used in brake disc machining, comprising the following steps:

[0086] 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 change of shear strain of the flat key 41 caused by the cutting force.

[0087] S2. Signal processing and control command generation: The control system receives the strain signal and amplifies and filters it. Through a preset threshold comparison algorithm or machine learning model, it determines whether the current cutting encounters abnormal conditions such as sand holes or sudden changes in hardness. If an abnormal condition is detected, the control system generates a current adjustment command for the corresponding electromagnet 5 based on the amplitude and rate of change of the strain signal. The command includes current magnitude and direction parameters.

[0088] S3. Dynamic magnetic levitation force adjustment: The control system outputs a driving current to the corresponding electromagnet 5 according to the current adjustment command, so that the electromagnet 5 and the permanent magnet 16 on the frustum section 13 form a radially coupled magnetic field; by adjusting the magnitude of the current of 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 levitation position of the cutter head 2 are adjusted in real time to compensate for the vibration or displacement caused by the sudden change of cutting force.

[0089] S4. Axial stiffness coordinated control: The thrust bearing 7 and pressure plate 6 are used to maintain the axial positioning of the cutter head 2. Combined with the radial magnetic levitation force of the electromagnet 5 and the permanent magnet 16, an axial-radial decoupled adaptive support system is formed to ensure the rigidity and stability of the tool system during the machining of the brake disc.

[0090] Full-process dynamic perception and active control

[0091] By acquiring cutting force signals in real time using strain gauges (response time < 1ms), it is the first time to achieve real-time monitoring of casting defects such as sand holes and sudden changes in hardness, solving the chatter problem caused by the "blind cutting" of traditional tools.

[0092] The magnetic levitation force adjustment and axial stiffness coordinated control form a decoupled system: the radial support stiffness is dynamically adjusted by the electromagnetic-permanent magnet coupling magnetic field (adjustment range 20-50N / μm), suppressing 10-500Hz wideband vibration; the axial position is rigidly positioned by the thrust bearing (accuracy ≤5μm), avoiding system instability caused by multi-directional load coupling, and reducing the processing vibration amplitude by more than 60%.

[0093] Multi-condition robustness and machining accuracy assurance

[0094] The threshold comparison algorithm / machine learning model can automatically identify abnormal working conditions, output repulsive force compensation for hard sand holes (sudden increase in cutting force), and enhance suction to stabilize the tool head for 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.

[0095] The electromagnet's current response time is less than 1ms, far exceeding that of traditional mechanical adjustment methods (which require more than 10 seconds). It can track high-frequency defects with hardness changes up to 100Hz, avoiding fluctuations in processing quality caused by adjustment lag.

[0096] In another preferred embodiment, during the dynamic magnetic levitation force adjustment process described in step S3, the control system employs a PID (Proportional-Integral-Derivative) control algorithm to adjust the driving current of the electromagnet 5 in real time, specifically including:

[0097] Establish radial displacement deviation ,in The target value for the radial position of cutterhead 2. This is the real-time radial displacement calculated using the signal from strain gauge 42;

[0098] Calculate the output current of the PID control ,in This is the proportionality coefficient. The integral coefficient is... These are the differential coefficients;

[0099] The current of the electromagnet 5 is dynamically adjusted by the PID algorithm to keep the radial suspension position error of the cutter head 2 within 0.1μm and suppress cutting vibration in the frequency range of 0-10kHz.

[0100] The high-precision displacement control and vibration suppression proportional (P) stage rapidly responds to radial displacement deviations, adjusts the magnetic field force in real time to counteract cutting force disturbances, and controls the dynamic stiffness adjustment delay to within 50μs; the integral (I) stage eliminates steady-state error, ensuring that the radial position error of the tool head remains stable within 0.1μm during long-term operation (traditional open-loop control error > 5μm); the derivative (D) stage predicts vibration trends and suppresses high-frequency vibrations below 10kHz (such as in high-dynamic scenarios like grinding wheels), avoiding resonance damage between the tool and the workpiece. System stability and anti-interference capability are improved through PID parameter tuning (e.g., Kp=20, Ki=5), Kd=0.5, raising the damping ratio of the magnetic levitation support system to the critical damping state, with a step response overshoot of <5%, significantly better than traditional PD control, suitable for the stringent "zero vibration" requirements of high-precision machining.

[0101] In another preferred embodiment, the method further includes the following step between S2 and S3:

[0102] S2.5. Dynamic adjustment of cutting depth: The control system calculates the required cutting depth adjustment amount of the cutting tool based on the abnormal working conditions detected in step S2 and the 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.

[0103] The control system applies a corresponding driving voltage to the piezoelectric ceramic driving pad 9, which generates micron-level deformation in the thickness direction using its inverse piezoelectric effect, with the deformation Δh not exceeding 50μm; the cutting blade 3 extension length is adjusted in real time 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 driving pad 9.

[0104] When a hard spot with pinholes is detected, the control system controls the piezoelectric ceramic drive pad 9 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, increasing the cutting depth by 0.005 to 0.02 mm to match the real-time cutting conditions.

[0105] Real-time compensation with micron-level accuracy

[0106] Piezoelectric ceramic drive pads utilize the inverse piezoelectric effect (deformation Δh=k・U, k=0.5μm / V) to achieve cutting depth adjustment with a resolution of 0.1μm. For example, applying a 10V voltage can elongate the pad by 5μm, precisely matching the differentiated needs of hard sand holes (reducing by 0.01-0.05mm) and soft areas (increasing by 0.005-0.02mm).

[0107] Spring washer elastic compensation mechanism By ensuring that the blade only produces pure translational motion (tilt angle < 0.01°), surface plowing defects caused by changes in blade posture are avoided. Compared with the rigid connection scheme, the surface roughness Ra value is reduced from 3.2μm to below 1.2μm.

[0108] Improved tool life and machining efficiency

[0109] In hard-point scenarios, actively reducing the depth of cut (e.g., by 0.03mm) reduces the peak cutting force by 30%, and the probability of tool chipping drops from 15% in traditional solutions to below 2%. In soft-point areas, automatically increasing the depth of cut (e.g., by 0.01mm) shortens the processing time per workpiece by 10%-15% while ensuring surface quality, making it particularly suitable for efficiency optimization in high-volume brake disc production lines.

[0110] 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:

[0111] Define shear strain rate ,in The shear strain of the flat key 41. t For time; stress signal The stress is collected by the built-in stress sensor of the piezoelectric ceramic driven gasket 9; and The input variable for the fuzzy logic algorithm is the driving voltage. U ;

[0112] Establish a fuzzy rule base: When a sand hole hard point condition is detected, i.e. >0.5% / ms and When the pressure is >100MPa, the output negative voltage causes the pad to shrink; when a soft area is detected, i.e. <-0.3% / ms and When the pressure is less than 50 MPa, the output positive voltage causes the pad to elongate; the accurate voltage value is obtained by defuzzification using the centroid method. U The deformation error of the piezoelectric ceramic drive pad 9 is controlled within ±2%, achieving a fast response for cutting depth adjustment with a delay time of less than 200μs.

[0113] Intelligent decision-making for nonlinear operating conditions

[0114] Multi-source signal fusion (shear strain rate) +Gasket stress Solving the ambiguity of single strain gauge testing: for example, when >0.5% / ms and When the pressure is >100MPa (hard point characteristic), the output voltage of -50V causes the pad to shrink; when <-0.3% / ms and When the pressure is less than 50MPa (soft region characteristics), the output voltage is extended by +30V, avoiding the misjudgment problem of traditional threshold algorithm (the misjudgment rate is reduced from 20% to less than 5%).

[0115] Rapid response and enhanced robustness

[0116] The centroid method for fuzzy resolution enables accurate calculation of voltage values ​​(error ±2%). Combined with the nanosecond-level response characteristics of piezoelectric ceramics, the entire adjustment process delay is <200μs, which can track sudden changes in working conditions above 1000Hz (such as high-frequency defects during high-speed cutting). The fuzzy rule library covers the range of Brinell hardness fluctuations within ±50HB. Compared with traditional linear control, the processing pass rate under extreme working conditions (such as continuous sand hole interval <1mm) is increased from 70% to over 95%.

[0117] The above description is merely 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 within the protection scope of the present invention.

Claims

1. An adaptive tooling system for machining brake discs, comprising a tool holder (1), at least one tool disc (2) fixed to the tool holder (1), and at least one cutting insert (3) fixed to the tool disc (2), characterized in that, The tool holder, from bottom to top, includes 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). The frustum section (13) has eight slots (15) evenly distributed around its circumference. Each slot (15) contains one permanent magnet (16), and the same magnetic poles of all permanent magnets (16) face the axis of the tool holder. The cutter head (2) is annular and has at least one internal keyway (21). Also includes The suspension sleeve (4), whose length is equal to the sum of the thicknesses of all the cutter heads (2), is fitted outside the frustum section (13) of the tool holder (1) and inserted into the cutter head (2); the outer wall of the suspension sleeve (4) is provided with a flat key (41) that corresponds one-to-one with the inner keyway (21) of the cutter head (2). The flat key (41) and the inner keyway (21) cooperate to achieve circumferential fixation of the suspension sleeve (4) and the cutter head (2); a strain gauge (42) for detecting cutting force is attached to one side of one of the flat keys (41); eight T-slots (43) are evenly opened along the circumference of the inner wall of the suspension sleeve (4). Eight electromagnets (5) are respectively embedded in eight T-slots (43) and are radially opposite to the permanent magnets (16) on the frustum section (13); Two pressure plates (6) are respectively fitted onto the frustum section (13) of the tool holder (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 fitted on the outside of two pressure plates (6); The large nut (8) is screwed to the threaded section (14) to fix the tool holder (1), suspension sleeve (4), tool disc (2), pressure plate (6) and thrust bearing (7) into one unit; The control system is electrically connected to the strain gauge (42) to receive strain signals and electrically connected to the electromagnet (5) to control the magnitude and direction of the current of the electromagnet (5); The cutting blade (3) is fixed in the blade mounting groove (23) of the cutter head (2) by a blade screw (31) and a spring washer (32). A piezoelectric ceramic drive pad (9) is placed between the cutting blade (3) and the cutter head (2). The thickness direction of the piezoelectric ceramic drive pad (9) is consistent with the cutting depth adjustment direction. Its upper and lower surfaces are in close contact with the bottom surface of the cutting blade (3) and the bottom surface of the mounting groove of the cutter head (2), respectively. The stiffness of the piezoelectric ceramic drive pad (9) is greater than the elastic coefficient of the spring washer (32). The electrode lead of the piezoelectric ceramic drive pad (9) is electrically connected to the control system.

2. The adaptive tooling system for brake disc machining according to claim 1, characterized in that, The periphery of the cutter head (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 on the upper end face or the lower end face of the cutter head (2), and are alternately arranged in the opening direction along the circumference of the cutter head (2). That is, the first blade mounting groove (23) 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 (3) on one side of the cutter head (2) needs to be replaced due to wear, the cutter head (2) can be flipped so that the blade mounting groove (23) on the other side faces the machining surface, and the cutting blade (3) on that side can be switched to continue to be used.

3. The adaptive tooling system for brake disc machining according to claim 2, characterized in that, Each blade mounting slot (23) has a vertical hole (24) at its inner corner along the radial direction of the cutter head (2), and the vertical hole (24) also serves as a blade clearance slot; each mounting boss (22) has a horizontal hole (25) along the axial direction of the cutter head (2), and the horizontal hole (25) is connected to the corresponding vertical hole (24); both the upper and lower end faces of the mounting boss (22) have arc-shaped grooves (26) with the center of the cutter head (2) as the center, and the bottom of the arc-shaped groove (26) is connected to the axial opening of the horizontal hole (25); the vertical hole (24), the horizontal hole (25) and the arc-shaped groove (26) together form an electrode lead channel for arranging the electrode leads of the piezoelectric ceramic drive pad (9).

4. The adaptive tooling system for brake disc machining according to claim 3, characterized in that, The tool holder (1) has an axial central through hole at its central axis, which serves as the main lead wire channel; the upper end face of the frustum section of the tool holder (1) has an annular groove, and the bottom wall of the annular groove has 8 radial guide holes evenly distributed around its 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 (4) or the tool disc (2), and its output end has a radial lead wire hole communicating with the axial central through hole; the piezoelectric ceramic drive pad ( The electrode leads of 9) are led out through the arc groove, horizontal hole and vertical hole of the cutter head (2), and then enter the radial lead hole 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) pass through the corresponding radial guide holes and the T-shaped grooves of the frustum section, and are connected to the brush group of the stator of the conductive slip ring assembly through the axial central through hole; through the stator-rotor conductive ring structure of the conductive slip ring assembly, the electrode leads between the cutter head (2) and the suspension sleeve (4) and the tool holder (1) are connected without entanglement, ensuring the stable transmission of signal and electrical energy during the cutting process.

5. The adaptive tooling system for brake disc machining according to claim 1, characterized in that, The cutter head (2) is provided with two internal keyways (21), and the angle between the line connecting the centers of the two internal keyways (21) and the center of the cutter head (2) is 120°. Adjacent cutter heads (2) are assembled with the flat key (41) of the suspension sleeve (4) through different internal keyways (21), so that the cutting blades (3) on each cutter head (2) are staggered in the circumferential direction.

6. The control method for an adaptive tooling system for brake disc machining according to claim 1, characterized in that, 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 change of shear strain of the flat key (41) caused by the cutting force. S2. Signal processing and control command generation: The control system receives the strain signal and amplifies and filters it. Through a preset threshold comparison algorithm or machine learning model, it determines whether the current cutting encounters abnormal conditions such as sand holes or sudden changes in hardness. If an abnormal condition is detected, the control system generates a current adjustment command for the corresponding electromagnet (5) based on the amplitude and rate of change of the strain signal. The command includes the current magnitude and direction parameters. S3. Dynamic magnetic levitation force adjustment: The control system outputs driving current to the corresponding electromagnet (5) according to the current adjustment command, so that the electromagnet (5) and the permanent magnet (16) on the frustum section (13) form a radially coupled 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 polarity, the radial support stiffness and levitation position of the cutter head (2) are adjusted in real time to compensate for the vibration or offset caused by the sudden change in cutting force; S4. Axial stiffness coordination control: The thrust bearing (7) and pressure plate (6) are used to maintain the axial positioning of the cutter head (2), and the radial magnetic levitation force of the electromagnet (5) and permanent magnet (16) is 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.

7. The control method for an adaptive tooling system for brake disc machining according to claim 6, characterized in that, In the dynamic magnetic levitation force adjustment process described in step S3, the control system uses a PID (Proportional-Integral-Derivative) control algorithm to adjust the driving current of the electromagnet (5) in real time, specifically including: Establish radial displacement deviation ,in The target value for the radial position of the cutter head (2) is... The real-time radial displacement is calculated using the signal from the strain gauge (42); Calculate the output current of the PID control ,in This is the proportionality coefficient. The integral coefficient is... These are the differential coefficients; By dynamically adjusting the current of the electromagnet (5) using the PID algorithm, the radial suspension position error of the cutter head (2) is controlled within 0.1μm, thus suppressing cutting vibration in the frequency range of 0-10kHz.

8. The control method for an adaptive tooling system for brake disc machining according to claim 6, characterized in that, Between steps S2 and S3, the following is also included: S2.

5. Dynamic adjustment of cutting depth: The control system calculates the required cutting depth adjustment amount of the blade based on the abnormal working conditions detected in step S2 and the 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 pad (9) to generate micron-level deformation in the thickness direction using its inverse piezoelectric effect, with the deformation Δh not exceeding 50μm; through the elastic compensation of the spring washer (32), the extension length of the cutting blade (3) is adjusted in real time, wherein the elastic coefficient of the spring washer (32) is less than the stiffness of the piezoelectric ceramic drive pad (9); When a hard spot is detected, the control system controls the piezoelectric ceramic drive pad (9) to shrink, reducing the cutting depth by 0.01 to 0.05 mm; when a soft area or 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.

9. The control method for an adaptive tooling system for brake disc machining according to claim 8, characterized in that, In the dynamic adjustment of 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 For the shear strain of the flat key (41), t For time; stress signal is from The stress sensor built into the piezoelectric ceramic drive pad (9) collects data; and The input variable for the fuzzy logic algorithm is the driving voltage. U ; Establish a fuzzy rule base: When a sand hole hard point condition is detected, i.e. >0.5% / ms and When the pressure is >100MPa, the output negative voltage causes the pad to shrink; when a soft area is detected, i.e. <-0.3% / ms and When the pressure is less than 50 MPa, the output positive voltage causes the pad to elongate; the accurate voltage value is obtained by defuzzification using the centroid method. U The deformation error of the piezoelectric ceramic drive pad (9) is controlled within ±2%, and the cutting depth adjustment is fast and the delay time is less than 200μs.

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