Method for achieving five-axis directional machining through three-axis programming

Abstract

The invention provides a method for realizing five-axis directional machining by using three-axis programming, which relates to the technical field of numerical control machining and comprises the following steps of: firmly clamping a workpiece on a five-axis machine tool worktable, setting an initial workpiece coordinate system in a machine tool numerical control system, and measuring and setting an original point offset; determining the spatial orientation of a target machining surface on the to-be-machined workpiece, and calculating the rotation angle of a machine tool rotating shaft required for enabling the direction of a machine tool spindle to be consistent with the normal direction of the target machining surface; the rotating shaft of the five-axis machine tool is controlled to move to the rotating angle obtained through calculation in S2; according to the method, the complex five-axis directional machining problem is simplified into the single three-axis linkage machining problem perpendicular to the target machining face by accurately calculating and locking the two rotating shafts A and C of the five-axis machine tool to specific angles in advance, in a workpiece coordinate system, the normal direction of the target machining face is regarded as the new Z-axis direction for programming, and the machining precision is improved. A programmer only needs to master conventional three-axis programming knowledge and technology.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of numerical control machining, in particular to a method for realizing five-axis directional machining by three-axis programming. BACKGROUND

[0002] In the field of mechanical manufacturing, five-axis machining technology is often used to process parts with complex inclined surfaces and inclined holes, and is particularly suitable for directional machining scenes such as drilling, milling and boring that require the tool axis to be perpendicular to inclined surfaces at different angles. At present, such directional machining usually relies on the following technical means: Professional five-axis CAM software is used for programming, and special five-axis post-processing is generated to generate numerical control codes. This method not only requires programmers to have interdisciplinary knowledge of CAM software operation, five-axis machining technology and machine tool structure, but also has high cost of custom development of special post-processing, which puts great economic pressure on small and medium-sized enterprises; Some numerical control system manufacturers provide inclined surface machining function packages, but this function usually needs to be purchased at an additional cost, further increasing the process cost of enterprises; The above status leads to the problem that small and medium-sized manufacturing enterprises face high technical threshold and high cost when applying five-axis directional machining technology, and even leads to the problem that some enterprises have five-axis machines but idle the five-axis function due to programming and post-processing restrictions, resulting in low equipment utilization. Therefore, the present application proposes a method for realizing five-axis directional machining by three-axis programming to solve the problems in the prior art. SUMMARY

[0003] To solve the above problems, the present application proposes a method for realizing five-axis directional machining by three-axis programming, which simplifies the complex five-axis directional machining problem to a single three-axis linkage machining problem perpendicular to the target machining surface by pre-accurately calculating and locking the two rotary axes A and C of the five-axis machine tool to a specific angle.

[0004] To achieve the purpose of the present application, the present application realizes the following technical scheme: a method for realizing five-axis directional machining by three-axis programming, comprising the following steps: S1: firmly clamping the workpiece on the workbench of the five-axis machine tool, setting the initial workpiece coordinate system in the machine tool numerical control system, and measuring and setting the origin offset; S2: determining the spatial orientation of the target machining surface on the workpiece to be machined, and calculating the rotation angle of the rotary axis of the machine tool required to make the machine tool spindle direction consistent with the normal direction of the target machining surface; S3: control the rotary axis of the five-axis machine tool to move to the rotation angle calculated in S2, and lock the rotary axis; S4: Establish a virtual three-axis machining coordinate system and control the Z-axis direction of the virtual three-axis machining coordinate system to be consistent with the direction of the rotation axis after locking in S3; S5: Compile a three-axis machining program based on a virtual three-axis machining coordinate system, and perform post-processing on the three-axis machining program; S6: With the rotary axis locked, perform tool setting in the virtual three-axis machining coordinate system, execute the three-axis machining program, and complete the orientation machining of the target machining surface; S7: After processing is completed, release the lock on the rotating shaft and reset the rotating shaft as needed.

[0005] A further improvement is made in S1, where an initial workpiece coordinate system is set in the machine tool CNC system, the origin of the coordinate system is set at the intersection of the center of the disk and the end face or a reference point that is easy to align, the Z-axis is perpendicular to the end face of the disk, and the origin offset is measured and set.

[0006] Further improvements are made in the following: In S2, the rotation axes are A-axis and C-axis. When the target machining surface is radially inclined around the disk, the rotation angle of the A-axis is equal to the inclination angle of the target machining surface. The rotation angle of the C-axis is determined according to whether there are circumferential requirements in the direction of the inclined hole. When the spatial orientation of the target machining surface is complex, the combined angles of A and C are calculated to ensure that the spindle +Z direction is parallel to the normal direction of the target machining surface after rotation.

[0007] A further improvement is that, in S3, the A-axis and C-axis are precisely rotated to the calculated angle using a rotary axis motion command; and the current position of the rotary axis is firmly locked by the CNC system function M code or G code lock axis command.

[0008] A further improvement is that, in step S4, the method for establishing the virtual three-axis machining coordinate system is any one of the following: In the CNC system of a five-axis machine tool, a new local coordinate system is established, the origin of the local coordinate system is set at the target machining position, and the Z-axis direction of the local coordinate system is aligned with the locked machine tool spindle direction. In the initial workpiece coordinate system, spatial transformation calculations are performed on the coordinates of all tool path points to ensure that the calculated coordinates guarantee that the tool tip moves in a direction perpendicular to the target machining surface.

[0009] A further improvement is made in S5, where the target machining surface is regarded as a horizontal plane when the three-axis machining program is compiled. The programming is based on the three-axis machining logic. The programming tool is manual programming or a three-axis CAM software module. The programming content includes defining the tool, setting the safety height, setting the feed rate and spindle speed, and writing the tool path.

[0010] A further improvement is that, in S5, during post-processing, a three-axis post-processor is used to process the program into a standard G-code program that can be executed by the machine tool.

[0011] A further improvement is that in S6, the tool setting operation uses a tool setter or edge finder to precisely set the tool tip on the Z0 plane of the coordinate system origin.

[0012] A further improvement is made in S6, where a three-axis machining program is loaded, the program is started to execute machining, and the machine tool is controlled to perform linear interpolation motion or fixed cycle on the X, Y, and Z axes.

[0013] A further improvement is that in step S7, the rotation axis is reset to a safe position, which includes 0° on axis A and 0° on axis C.

[0014] The beneficial effects of this invention are as follows: 1. This invention simplifies the complex five-axis orientation machining problem into a single three-axis linkage machining problem that is perpendicular to the target machining surface by pre-calculating and locking the two rotary axes A and C of a five-axis machine tool to a specific angle. In the workpiece coordinate system, the normal direction of the target machining surface is regarded as the new "Z-axis" direction for programming. Programmers only need to master conventional three-axis programming knowledge and techniques, and can generate effective machining programs using a general-purpose, low-cost three-axis post-processor.

[0015] 2. This invention does not require expensive five-axis CAM software licenses, custom development of dedicated five-axis post-processors, or paid inclined surface machining function packages from CNC system manufacturers, which greatly reduces the technical threshold and overall cost for small and medium-sized enterprises to apply five-axis orientation machining.

[0016] 3. This invention simplifies the complex "five-axis programming - five-axis post-processing - five-axis linkage machining" process chain into "angle calculation - rotary axis locking - three-axis programming - three-axis post-processing - three-axis linkage machining", which significantly improves the efficiency and reliability of process preparation. This allows small and medium-sized enterprises equipped with A / C dual-swivel head five-axis machine tools to more conveniently use the equipment to perform directional machining tasks such as drilling, milling, and boring, without having to idle the five-axis function due to programming and post-processing costs. Attached Figure Description

[0017] Figure 1 This is a flowchart of the present invention; Figure 2 This is a schematic diagram of Embodiment 2 of the present invention. Detailed Implementation

[0018] To enhance understanding of the present invention, the present invention will be further described in detail below with reference to embodiments. These embodiments are only used to explain the present invention and do not constitute a limitation on the scope of protection of the present invention. Example 1

[0019] according to Figure 1 As shown, this embodiment proposes a method for implementing five-axis orientation machining using three-axis programming, including the following steps: S1: Securely clamp the workpiece on the five-axis machine tool worktable, set the initial workpiece coordinate system in the machine tool CNC system, measure and set the origin offset; set the initial workpiece coordinate system in the machine tool CNC system, set the origin of the coordinate system at the intersection of the center of the disk and the end face or a reference point that is easy to align, make the Z-axis perpendicular to the end face of the disk, measure and set the origin offset.

[0020] S2: Determine the spatial orientation of the target machining surface on the workpiece to be machined, and calculate the rotation angle of the machine tool's rotary axes required to align the machine tool spindle direction with the normal direction of the target machining surface. The rotary axes are the A-axis and the C-axis. When the target machining surface is radially inclined around the disk, the rotation angle of the A-axis is equal to the inclination angle of the target machining surface. The rotation angle of the C-axis is determined based on whether there are circumferential requirements for the inclined hole direction. When the spatial orientation of the target machining surface is complex, the combined angles of A and C are calculated to ensure that the spindle +Z direction is parallel to the normal direction of the target machining surface after rotation.

[0021] S3: Control the rotary axis of the five-axis machine tool to move to the rotation angle calculated in S2 and lock the rotary axis; use the rotary axis motion command to precisely rotate the A-axis and C-axis to the calculated angle; use the CNC system function M code or G code lock axis command to firmly lock the current position of the rotary axis.

[0022] S4: Establish a virtual three-axis machining coordinate system, and control the Z-axis direction of the virtual three-axis machining coordinate system to be consistent with the direction of the rotation axis locked in S3; the method for establishing the virtual three-axis machining coordinate system can be any of the following: In the CNC system of a five-axis machine tool, a new local coordinate system is established, the origin of the local coordinate system is set at the target machining position, and the Z-axis direction of the local coordinate system is aligned with the locked machine tool spindle direction. In the initial workpiece coordinate system, spatial transformation calculations are performed on the coordinates of all tool path points to ensure that the calculated coordinates guarantee that the tool tip moves in a direction perpendicular to the target machining surface.

[0023] S5: Compile a three-axis machining program based on a virtual three-axis machining coordinate system and perform post-processing on the three-axis machining program; when compiling the three-axis machining program, the target machining surface is regarded as a horizontal plane, and programming is performed based on the three-axis machining logic. The programming tools are manual programming or three-axis CAM software modules. The programming content includes defining the tool, setting the safety height, setting the feed rate and spindle speed, and writing the tool path; during post-processing, a three-axis post-processor is used to process the program into a standard G-code program that can be executed by the machine tool.

[0024] S6: With the rotary axis locked, perform tool setting in the virtual three-axis machining coordinate system, execute the three-axis machining program, and complete the orientation machining of the target machining surface; the tool setting operation uses a tool setter or edge finder to accurately set the tool tip point on the Z0 surface of the coordinate system origin; load the three-axis machining program, start the program to execute machining, and control the machine tool to perform linear interpolation motion or fixed cycle on the X, Y, and Z axes.

[0025] S7: After machining is completed, release the lock on the rotating axis and reset the rotating axis as needed; reset the rotating axis to a safe position, including 0° on axis A and 0° on axis C. Example 2

[0026] according to Figure 1 , 2 As shown, this embodiment proposes a method for achieving five-axis orientation machining using three-axis programming. Figure 2 Taking the machining of a 42° angled hole in a 1000mm diameter disc as an example: S1: Workpiece clamping and initial coordinate system setting: Securely clamp the disc workpiece onto the worktable of the five-axis machine tool.

[0027] Set the initial workpiece coordinate system (e.g., G54) in the machine tool CNC system. The origin of the coordinate system is usually set at the intersection of the disk center and the end face (or an easily alignable reference point), with the Z-axis perpendicular to the disk end face (i.e., the default horizontal plane). Measure and set the origin offset.

[0028] S2: Calculate the normal and rotation angle of the target machining surface: Determine the spatial orientation of the inclined plane containing the 42° inclined hole to be machined. Analyze the orientation of this inclined plane relative to the initial workpiece coordinate system.

[0029] Core calculations: Calculate the A-axis and C-axis rotation angles required to make the machine tool spindle (tool axis) precisely perpendicular to the 42° inclined plane.

[0030] In this example, assume the 42° ramp is inclined radially (e.g., along the X-axis) of the disk. Then: A-axis rotation angle = 42° (to rotate the main axis 42° around the X-axis from the state of being perpendicular to the initial end face to be perpendicular to the inclined plane).

[0031] C-axis rotation angle = 0° (if the inclined plane does not require adjustment around the Z-axis. If the inclined hole direction has circumferential requirements, the C-axis needs to be rotated by the corresponding angle, for example, to align the spindle with the radial line where the hole center is located).

[0032] (Note: If the orientation of the inclined plane is more complex, it is necessary to calculate the combined angles of A and C. The principle is the same: ensure that the principal axis +Z direction is parallel to the direction of the normal to the inclined plane after rotation.) S3: Machine tool rotary axis positioning and locking: In a CNC machine tool system, rotary axis motion commands (such as G0, A42.0, C0.0) are used to precisely rotate the A-axis of the machine tool to 42° and the C-axis to 0° (or the calculated angle).

[0033] Locking the rotary axes: The A and C axes are securely locked in their current positions using CNC system functions (such as M-code or G-code lock axis commands; the specific command depends on the machine tool system, such as SINUMERIK's M70 / M71, FANUC's G53.1, or a specific PLC lock axis signal), preventing accidental movement during subsequent three-axis machining. At this point, the machine tool spindle direction is fixed perpendicular to the 42° inclined plane.

[0034] S4: Establish a virtual three-axis machining coordinate system: Core concept shift: Treat the currently locked main axis direction (perpendicular to the 42° inclined plane) as the new "+Z axis" direction.

[0035] Set the machining coordinate system: Method 1 (Recommended - Local Coordinate System): Create a new local coordinate system in the CNC system (e.g., G54.1P1, G55, G56, etc.). Translate the origin of this coordinate system (G52X_Y_Z_) or use coordinate system rotation / translation commands (such as G68.2 / G53.1+G52, or system-specific spatial rotation functions) to set it at the target machining position point for the 42° inclined hole (e.g., the hole center's position in the initial coordinate system). Most importantly, ensure that the current locked spindle direction in this newly created coordinate system is the +Z direction of this coordinate system. This means that when programming in this new coordinate system, the tool axis direction will be +Z.

[0036] Method 2 (Manual Offset Calculation - Suitable for Simple Scenarios): This method does not create a new coordinate system, but when programming in the initial coordinate system (G54), the coordinates of all toolpath points must be calculated using spatial transformation based on the rotation of the A and C axes. This ensures that the toolpath point coordinates in the initial coordinate system guarantee that the tool tip moves in a direction perpendicular to the inclined plane. This method is computationally complex, error-prone, and not recommended.

[0037] S5: Three-axis programming and post-processing: Programmers perform programming within the new coordinate system (virtual three-axis environment) established in step 4.

[0038] Programming thinking: Treat the 42° inclined plane as a "horizontal plane". The programming content is entirely based on three-axis logic. Define the cutting tools (drills, milling cutters, etc.).

[0039] Set a safe height (in the +Z direction of the new coordinate system, ensure it is higher than the inclined plane).

[0040] Set cutting parameters such as feed rate and spindle speed.

[0041] Write the toolpath: Quickly locate to the safe point -> Lower the tool to the machining surface (new coordinate system Z0 surface) -> Execute the drilling cycle (such as G81 / G83) or milling path (such as G01) -> Lift the tool to the safe height.

[0042] Key advantage: This programming step can be completed using standard three-axis CAM software modules or by manually writing G-code.

[0043] Use a general-purpose, machine tool-integrated, or free / low-cost three-axis post-processor to process the above program into a standard G-code program executable by the machine tool. No five-axis post-processor is required.

[0044] S6: Tool setting and machining execution: With the machine tool locked at A42°C0°, perform tool setting in the new coordinate system (virtual three-axis coordinate system) set in step 4. Use a tool setter or edge finder to precisely set the tool tip on the Z0 plane (i.e., the 42° inclined plane) of the origin (i.e., the target machining point) of the new coordinate system.

[0045] Load the three-axis machining program generated in step 5.

[0046] The program is started to execute the machining. The machine tool will strictly perform linear interpolation motion (G01) or fixed cycle (G81, etc.) on the X, Y, and Z axes. Since the A and C axes are locked, the tool axis direction is always perpendicular to the 42° inclined plane, thereby achieving precise directional machining (drilling, milling, etc.).

[0047] S7: Processing Completed and Reset: Once processing is complete, the program ends.

[0048] Release the A and C axes lock (using the corresponding M or G codes).

[0049] Move the rotating shaft back to a safe position (e.g., A0, C0) as needed.

[0050] This method of achieving five-axis orientation machining using three-axis programming simplifies the complex five-axis orientation machining problem into a single, three-axis linkage machining problem perpendicular to the target machining surface by pre-calculating and locking the two rotary axes (A-axis and C-axis) of a five-axis machine tool to a specific angle. In the workpiece coordinate system, the normal direction of the target machining surface is regarded as the new "Z-axis" direction for programming. Programmers only need to master conventional three-axis programming knowledge and techniques, and can generate effective machining programs using a general-purpose, low-cost three-axis post-processor. Furthermore, this invention does not rely on expensive five-axis CAM software licenses, custom development of dedicated five-axis post-processors, or paid inclined surface machining function packages from CNC system manufacturers, significantly reducing the technical threshold and overall cost for small and medium-sized enterprises to apply five-axis orientation machining. Meanwhile, this invention simplifies the complex "five-axis programming - five-axis post-processing - five-axis linkage machining" process chain into "angle calculation - rotary axis locking - three-axis programming - three-axis post-processing - three-axis linkage machining", significantly improving process preparation efficiency and reliability. This enables small and medium-sized enterprises equipped with A / C dual-swivel head five-axis machine tools to more conveniently utilize the equipment for directional machining tasks such as drilling, milling, and boring, without having to idle the five-axis function due to programming and post-processing costs.

[0051] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of the present invention is defined by the appended claims and their equivalents.

Claims

1. A method for achieving five-axis orientation machining using three-axis programming, characterized in that, Includes the following steps: S1: Securely clamp the workpiece onto the five-axis machine tool worktable, set the initial workpiece coordinate system in the machine tool CNC system, and measure and set the origin offset; S2: Determine the spatial orientation of the target machining surface on the workpiece to be machined, and calculate the rotation angle of the machine tool spindle required to make the direction of the machine tool spindle consistent with the normal direction of the target machining surface; S3: Control the rotation axis of the five-axis machine tool to move to the rotation angle calculated by S2, and lock the rotation axis; S4: Establish a virtual three-axis machining coordinate system and control the Z-axis direction of the virtual three-axis machining coordinate system to be consistent with the direction of the rotation axis after locking in S3; S5: Compile a three-axis machining program based on a virtual three-axis machining coordinate system, and perform post-processing on the three-axis machining program; S6: With the rotary axis locked, perform tool setting in the virtual three-axis machining coordinate system, execute the three-axis machining program, and complete the orientation machining of the target machining surface; S7: After processing is completed, release the lock on the rotating shaft and reset the rotating shaft as needed.

2. The method for achieving five-axis orientation machining using three-axis programming according to claim 1, characterized in that: In step S1, an initial workpiece coordinate system is set in the machine tool CNC system. The origin of the coordinate system is set at the intersection of the center of the disk and the end face or at a reference point that is easy to align. The Z-axis is perpendicular to the end face of the disk. The origin offset is measured and set.

3. The method for implementing five-axis orientation machining using three-axis programming according to claim 1, characterized in that: In S2, the rotation axes are A-axis and C-axis. When the target machining surface is radially inclined around the disk, the rotation angle of the A-axis is equal to the inclination angle of the target machining surface. The rotation angle of the C-axis is determined according to whether there are circumferential requirements in the direction of the inclined hole. When the spatial orientation of the target machining surface is complex, the combined angles of A and C are calculated to ensure that the spindle +Z direction is parallel to the normal direction of the target machining surface after rotation.

4. A method for implementing five-axis orientation machining using three-axis programming according to claim 3, characterized in that: In step S3, the A-axis and C-axis are precisely rotated to the calculated angle using rotation axis motion commands; the current position of the rotation axis is securely locked using CNC system function M-code or G-code lock axis commands.

5. A method for implementing five-axis orientation machining using three-axis programming according to claim 1, characterized in that: In step S4, the method for establishing the virtual three-axis machining coordinate system is any one of the following: In the CNC system of a five-axis machine tool, a new local coordinate system is established, the origin of the local coordinate system is set at the target machining position, and the Z-axis direction of the local coordinate system is aligned with the locked machine tool spindle direction. In the initial workpiece coordinate system, spatial transformation calculations are performed on the coordinates of all tool path points to ensure that the calculated coordinates guarantee that the tool tip moves in a direction perpendicular to the target machining surface.

6. The method for implementing five-axis orientation machining using three-axis programming according to claim 1, characterized in that: In S5, when compiling a three-axis machining program, the target machining surface is regarded as a horizontal plane. Programming is performed based on the three-axis machining logic. The programming tool is manual programming or a three-axis CAM software module. The programming content includes defining the tool, setting the safety height, setting the feed rate and spindle speed, and writing the tool path.

7. A method for implementing five-axis orientation machining using three-axis programming according to claim 6, characterized in that: In S5, during post-processing, a three-axis post-processor is used to process the program into a standard G-code program that can be executed by the machine tool.

8. A method for implementing five-axis orientation machining using three-axis programming according to claim 1, characterized in that: In step S6, the tool setting operation uses a tool setting device or an edge finder to precisely set the tool tip on the Z0 plane of the coordinate system origin.

9. A method for implementing five-axis orientation machining using three-axis programming according to claim 8, characterized in that: In step S6, a three-axis machining program is loaded, the program is started to execute machining, and the machine tool is controlled to perform linear interpolation motion or fixed cycle on the X, Y, and Z axes.

10. A method for implementing five-axis orientation machining using three-axis programming according to claim 3, characterized in that: In step S7, the rotating axis is reset to a safe position, which includes 0° on axis A and 0° on axis C.

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