Integrated machining process for metal products

Abstract

The invention belongs to the technical field of metal processing, and particularly relates to an integrated processing technology of a metal product, which comprises the following steps: S1, sequentially performing rough machining, semi-finish machining and finish machining on a metal blank to obtain a required geometrical shape; and S2, in any stage of the machining process or in a set period, a laser scanning device is used for conducting non-contact scanning on the surface of a currently-used or to-be-detected tool, and tool surface appearance information is obtained. The laser scanning device is integrated in the machining system, the scanning time sequence is controlled through the numerical control system, and automatic switching between machining and detection is achieved. On-line detection of the surface state of the cutter can be completed without manually disassembling the cutter or stopping a machine tool, so that the non-machining time is greatly reduced, and the equipment utilization rate is improved.

Description

Technical Field

[0001] This invention belongs to the field of metal processing technology, and specifically relates to an integrated processing technology for metal products. Background Technology

[0002] In traditional metalworking processes, workpieces typically undergo multiple stages, including roughing, semi-finishing, and finishing, to gradually achieve the desired geometry and surface accuracy. Existing machining processes largely rely on machine tool parameters and human experience for control. Although modern CNC technology has made significant progress in machining automation, real-time detection and intelligent control of tool status remain key factors affecting machining quality and production efficiency.

[0003] In existing technologies, the detection of tool wear or damage mostly employs the following methods: (1) Offline inspection method: The tool is manually inspected in the machining gap using an optical microscope, profilometer or 3D scanner. This method has high inspection accuracy, but it requires manual disassembly of the tool, which is not only time-consuming, but also interrupts the machining process and affects the production cycle.

[0004] (2) Indirect monitoring method: The tool wear condition is inferred by monitoring spindle power, cutting force, vibration signal or acoustic emission signal. This method has simple equipment, but the detection results are greatly affected by the processing material, process parameters and noise interference, making it difficult to achieve quantitative analysis.

[0005] (3) Image recognition method: Using an industrial camera to capture images of the tool surface and perform image analysis to determine the wear state. This method is significantly affected by lighting conditions, surface reflection and cleanliness, and has poor detection stability.

[0006] The aforementioned methods all suffer from problems such as detection lag, insufficient accuracy, or low automation, making it difficult to meet the demands of modern manufacturing for online inspection, intelligent compensation, and life prediction. Especially in multi-axis machining, high-speed cutting, and unmanned production scenarios, if tool damage cannot be identified and addressed in a timely manner, it can easily lead to workpiece scrap, equipment damage, or production interruption, severely impacting production efficiency and processing quality.

[0007] Therefore, there is an urgent need for an integrated metal processing technology that can realize online detection, automatic identification and adaptive control of tool surface condition during the machining process, so as to improve tool utilization efficiency, ensure machining accuracy and realize intelligent manufacturing. Summary of the Invention

[0008] To address the problems mentioned in the background section, this invention provides an integrated processing technology for metal products.

[0009] To achieve the above objectives, the present invention provides the following technical solution: an integrated processing technology for metal products, comprising the following steps: S1: The metal blank is sequentially roughed, semi-finished and finished to obtain the desired geometric shape; S2: At any stage of the machining process or within a set period, a laser scanning device is used to perform a non-contact scan on the surface of the tool currently in use or to be inspected to obtain tool surface morphology information. S3: Compare the 3D point cloud data of the tool obtained by laser scanning with the initial reference model of the tool or the model of the previous detection to generate tool damage characteristic parameters; S4: Based on the comparison results, determine whether there is wear, chipping, cracks or edge defects on the tool surface, and compare the obtained damage characteristic parameters with the preset threshold. S5: When the detection result shows that the tool damage exceeds the preset limit, the system will automatically perform tool replacement, machining parameter compensation or alarm prompt; S6: Record the three-dimensional morphology data, damage characteristic parameters, processing parameters and tool usage time obtained from each laser inspection into the tool management system for subsequent life prediction and process optimization.

[0010] Preferably, the laser scanning device is fixedly installed at the tool detection position or near the automatic tool changer in the machine tool workspace, and the scanning sequence is controlled by the CNC system to realize automatic switching between processing and detection.

[0011] Preferably, the laser scanning device includes a laser emitting module, a reflected light acquisition module, and a data processing module; The laser emitting module emits a focused laser beam to illuminate the cutting edge area of ​​the tool, and the reflected light acquisition module receives the reflected signal and generates three-dimensional point cloud data.

[0012] Preferably, the data processing module calculates parameters such as the change in the cutting edge radius, the deviation in the cutting edge height, the notch depth, the crack length, and the surface roughness by comparing the point cloud model, so as to quantitatively assess the degree of damage to the tool surface.

[0013] Preferably, when any parameter in the detection result exceeds a preset threshold, the system triggers the control logic to perform one or a combination of the following operations: A1: Automatically pauses processing and prompts for tool replacement; A2: Automatically activate the standby tool to continue processing; A3: Automatically adjusts feed rate, spindle speed, or depth of cut to compensate for tool wear; A4: Upload the detection information to the tool life database.

[0014] Preferably, the laser scanning resolution is 1 µm to 10 µm, and the scanning cycle is less than 10 seconds, which can realize online rapid detection without affecting the processing cycle.

[0015] Preferably, the tool morphology comparison uses shape reconstruction algorithms or optical surface deviation analysis algorithms, which can automatically identify the crack boundaries and wear distribution on the tool surface.

[0016] Preferably, the machining system interacts with the CNC machine tool control system via a communication interface.

[0017] Preferably, this process is applicable to turning, milling, boring or drilling processes of materials such as steel, aluminum, titanium alloys, stainless steel and cemented carbide.

[0018] Preferably, the tool inspection data, after statistical analysis, can be used to establish a tool life prediction model.

[0019] Compared with existing technologies, the advantages of this invention are: This invention integrates a laser scanning device into the machining system, and controls the scanning sequence through a CNC system to achieve automatic switching between machining and inspection. Online inspection of the tool surface condition can be completed without manual tool disassembly or machine tool shutdown, significantly reducing non-machining time and improving equipment utilization. Attached Figure Description

[0020] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used in conjunction with embodiments of the invention to explain the invention and do not constitute a limitation thereof. In the drawings: Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is an exploded view of the invention; Figure 3 This is a schematic diagram of the connection structure between the monitoring unit and the clamping unit in this invention; Figure 4 This is an exploded view of the monitoring unit and the clamping unit in this invention; Figure 5 This is a schematic diagram of the connection structure of the cleaning component in this invention; Figure 6 This is a schematic diagram of a partial connection structure of the cleaning component in this invention; Figure 7 This is a schematic diagram of the connection structure of the clamping unit in this invention; Figure 8 This is a schematic diagram of the connection structure of the monitoring unit in this invention; Figure 9 This is a schematic diagram of a partial connection structure of the processing components in this invention.

[0021] Explanation of reference numerals in the attached figures: 1-Rack, 2-Monitoring unit, 201-First frame, 202-First drive module, 203-Base plate, 204-Telescopic cylinder, 205-Laser scanning device, 3-Clamping unit, 4-Processing component, 401-Drive motor, 402-Fourth drive module, 403-Second frame, 404-Third drive module, 5-Cleaning component, 501-Air pump, 502-First branch pipe, 503-First one-way valve, 504-Annular pipe, 505-Nozzle, 506-Second branch pipe, 507-Second one-way valve, 508-Limit rod, 509-Sliding sleeve, 510-Solenoid valve, 511-Cylinder, 512-Piston rod, 513-Sliding rod, 514-Spring, 515-Protrusion. Detailed Implementation

[0022] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0023] This invention provides an integrated machining process for metal products, applicable to turning, milling, boring, or drilling of materials such as steel, aluminum, titanium alloys, stainless steel, and cemented carbide. This process integrates a laser scanning detection device and an intelligent parameter compensation control module into the machine tool system to achieve online monitoring of the tool surface condition, damage feature identification, adaptive parameter compensation, and online regrinding during machining, thereby significantly improving machining accuracy, tool life, and production automation. Specifically, it includes the following steps: The metal blank is subjected to roughing, semi-finishing and finishing in sequence to obtain the basic geometric shape and dimensional accuracy of the target part.

[0024] This step is performed using a CNC lathe, machining center, or composite machine tool. After each stage is completed, the tool inspection process can be automatically invoked to ensure the continuous stability of subsequent machining accuracy.

[0025] At any stage of the machining process or within a set inspection cycle, the laser scanning device 205 performs a non-contact scan on the surface of the currently used or to-be-inspected tool to obtain the three-dimensional morphological information of the tool cutting edge area.

[0026] The laser scanning device 205 includes: Laser emitting module: emits a focused laser beam to illuminate the cutting edge of the tool; Reflected light acquisition module: Receives reflected signals and generates 3D point cloud data; Data processing module: performs filtering, modeling, and comparative analysis on point cloud data, and outputs damage characteristic parameters.

[0027] Preferably, the spatial resolution of the laser scan is 1 µm to 10 µm, and the single scan cycle is less than 10 seconds.

[0028] The laser scanning device 205 can be installed near the machine tool tool detection position or the automatic tool changer. The scanning sequence is controlled by the CNC system to realize automatic switching between machining, inspection and repair without affecting the normal machining cycle.

[0029] The data processing module compares the 3D point cloud data of the tool obtained by laser scanning with the initial reference model of the tool or the previous detection model, and uses shape reconstruction algorithm or optical surface deviation analysis algorithm to extract parameters including but not limited to: the change in cutting edge radius, the deviation in cutting edge height, the notch depth, the crack length and the change in surface roughness.

[0030] Based on the comparison results, it is determined whether there is wear, chipping, cracks or edge defects on the tool surface, and the calculated damage characteristic parameters are compared with preset thresholds to quantitatively assess the degree of tool damage.

[0031] When any parameter in the test result exceeds the limit, the system automatically triggers one or a combination of the following logical operations: A1: Automatically pauses processing and prompts the operator to change the tool; A2: Automatically activate the standby tool to continue processing; A3: Automatically adjusts machining parameters, including feed rate, spindle speed, depth of cut, etc., to achieve macroscopic compensation; A4: Perform fine parameter compensation. Based on the spatial distribution characteristics of tool damage, the system can use the tool coordinate system compensation module to correct the tool center point offset of the wear area at a specific angle or position, thereby achieving micro-scale compensation in the spatial dimension and maintaining the machining contour accuracy. A5: The system can call up the online regrinding device. For specific types of tools (such as solid carbide end mills), the system can control the integrated laser micro-regrinding module or micro-grinding device to perform local repair on the tool cutting edge, thereby achieving on-machine regeneration and life extension of the tool.

[0032] This control logic is achieved through the coordinated operation of the machine tool CNC system, the detection module, and the online grinding module, thus forming a closed-loop adaptive machining system.

[0033] The system automatically stores the 3D morphology data, damage characteristic parameters, regrinding records, and machining parameters obtained from each inspection into the tool management database for tool life prediction and process optimization. Through statistical analysis of historical data, tool wear prediction models and machining accuracy maintenance models can be established, enabling intelligent maintenance and self-learning optimization of the system.

[0034] To further enhance the intuitiveness of operation and maintenance, this invention can be expanded with an augmented reality (AR) interactive interface. Operators or maintenance engineers wearing AR glasses can view the process in real time within the virtual interface. The tool's 3D model and the highlighted wear area; Numerical distribution of each damage characteristic parameter; System automatic decision-making logic and execution records; Recommended maintenance or refurbishment action path.

[0035] This interface is synchronized in real time with the machine tool's CNC system and testing module, forming a closed loop of data visualization, which significantly improves the intelligence of the equipment and the level of human-machine collaboration.

[0036] Compared with existing technologies, this process has the following advantages: it achieves integrated linkage of machining, inspection, regrinding and compensation; the laser scanning has high resolution and short inspection cycle, without affecting the production cycle; it can monitor, quantitatively evaluate and automatically repair tool wear in real time; it supports fine parameter compensation and AR visualization diagnosis based on spatial wear model; it can significantly extend tool life, reduce production costs and improve the system's intelligence level.

[0037] like Figures 1 to 9 As shown, the device for integrated processing of metal products provided by the present invention includes a cabinet 1, a monitoring unit 2, a clamping unit 3, a processing component 4, and a cleaning component 5.

[0038] The monitoring unit 2, clamping unit 3, and processing component 4 are all located inside the cabinet 1, and the cleaning component 5 is mounted on the processing component 4. Through the coordinated action of these components, an integrated operation process can be achieved, including automatic workpiece clamping, processing, tool detection, and cleaning.

[0039] Monitoring unit 2 is mainly used for non-contact scanning and detection of the surface of the machining tool, and includes: The first frame 201, the first drive module 202, the base plate 203, the telescopic cylinder 204, and the laser scanning device 205.

[0040] The first drive module 202 is installed on the first frame 201 and can drive the base plate 203 to move precisely in a set direction. The telescopic cylinder 204 is fixedly installed on the base plate 203, and its output end is connected to the laser scanning device 205 to control the telescopic movement of the laser scanning device. The laser scanning device 205 is used to emit a laser beam to the surface of the tool and collect the reflected light signal, thereby generating three-dimensional point cloud data of the tool surface.

[0041] Preferably, the laser scanning device 205 includes a laser emitting module, a reflected light acquisition module, and a data processing module. This device can detect the tool at any stage of the processing or within a preset period, achieving real-time monitoring of the tool's status.

[0042] Clamping unit 3 is used to fix and clamp the workpiece to ensure its positioning accuracy and stability during processing. This unit can be pneumatically, hydraulically, or electrically driven to achieve clamping and releasing actions, thus adapting to metal blanks of different specifications and shapes.

[0043] The processing component 4 is used to perform cutting processing on the workpiece, and includes: a second frame 403, a third drive module 404, a fourth drive module 402, and a drive motor 401.

[0044] The third drive module 404 is fixedly mounted on the second frame 403 and is used to drive the fourth drive module 402 to move along the first direction (such as the X-axis). The fourth drive module 402 is used to drive the drive motor 401 to move along a second direction (such as the Y-axis), and this direction is perpendicular to the moving direction of the third drive module 404. The output end of the drive motor 401 is equipped with a cutting head for cutting, milling, drilling or boring operations on the workpiece.

[0045] With the cooperation of the bidirectional drive module, the tool can move in multiple dimensions in space, thereby meeting the needs of complex curved surfaces or high-precision machining.

[0046] Cleaning component 5 is used to clean the tool surface during machining gaps or before inspection to remove adhering chips or coolant, ensuring the accuracy of laser inspection. This component includes: Air pump 501, first branch pipe 502, first one-way valve 503, annular pipe 504, multiple nozzles 505, second branch pipe 506, second one-way valve 507, limit rod 508, sliding sleeve 509, solenoid valve 510, cylinder 511, piston rod 512, slide rod 513, spring 514 and protrusion 515.

[0047] The air pump 501 is connected in sequence to the second branch pipe 506, the second one-way valve 507 and the cylinder 511 at the air inlet end, and in sequence to the first branch pipe 502, the first one-way valve 503, the annular pipe 504 and multiple nozzles 505 at the air outlet end. The annular tube 504 and multiple nozzles 505 are installed on the outside of the cutter head, so that the cutter head is located at the center of the annular tube 504 to achieve 360° uniform spraying. A solenoid valve 510 is provided on the cylinder 511 to control the air pressure balance; The piston rod 512 is slidably connected to the cylinder 511, and its end is fixedly connected to the slide rod 513; The slide rod 513 is slidably engaged with the protrusion 515, and the spring 514 is sleeved on the slide rod 513 and connected to the protrusion 515 and the two ends of the piston rod 512 respectively. The limiting rod 508 is fixed on the drive motor 401, and its outer wall is provided with a sliding sleeve 509. The sliding sleeve 509 is connected to the annular tube 504 through a connecting rod and is used to guide the synchronous movement of the annular tube.

[0048] When it is necessary to clean the surface of the tool, the air pump 501 is started, and air enters the cylinder 511 through the second branch pipe 506 and the second one-way valve 507. At this time, the piston rod 512 is pushed inward by the air pressure, compressing the internal space of the cylinder 511 and forming a negative pressure zone.

[0049] At the same time, air is delivered to the annular pipe 504 through the first branch pipe 502 and the first one-way valve 503, and is evenly sprayed out through multiple nozzles 505 to clean the surface of the tool with airflow from all directions.

[0050] During the advance of the piston rod 512, it drives the slide rod 513 and the slide sleeve 509 to move closer to the drive motor 401, thereby driving the annular tube 504 to move closer to the cutter in sync, achieving a dynamic cleaning effect.

[0051] After cleaning is completed, turn off the air pump 501 and open the solenoid valve 510 to balance the air pressure inside and outside the cylinder 511. At this time, the spring 514 releases its restoring force, pushing the piston rod 512 and slide rod 513 to automatically reset, preparing for the next cleaning operation.

[0052] Compared with the prior art, the equipment of the present invention has the following significant advantages: it integrates a laser detection and cleaning system to achieve fully automatic linkage of processing, detection and maintenance; it achieves high-precision spatial positioning and multi-directional cutting of the tool through a dual-drive module; the cleaning component adopts a ring-shaped blowing and pneumatic reset structure, which has high cleaning efficiency and stable structure; and it has a high degree of automation, which can ensure the accuracy of tool detection and extend the tool service life.

[0053] Finally, it should be noted that the above descriptions are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An integrated processing technology for metal products, characterized in that, Includes the following steps: S1: The metal blank is sequentially roughed, semi-finished and finished to obtain the desired geometric shape; S2: At any stage of the machining process or within a set period, the surface of the currently used or to be inspected tool is non-contactly scanned using a laser scanning device (205) to obtain tool surface morphology information. S3: Compare the 3D point cloud data of the tool obtained by laser scanning with the initial reference model of the tool or the model of the previous detection to generate tool damage characteristic parameters; S4: Based on the comparison results, determine whether there is wear, chipping, cracks or edge defects on the tool surface, and compare the obtained damage characteristic parameters with the preset threshold. S5: When the detection result shows that the tool damage exceeds the preset limit, the system will automatically perform tool replacement, machining parameter compensation or alarm prompt; S6: Record the three-dimensional morphology data, damage characteristic parameters, processing parameters and tool usage time obtained from each laser inspection into the tool management system for subsequent life prediction and process optimization.

2. The integrated processing technology for metal products according to claim 1, characterized in that, The laser scanning device (205) is fixedly installed at the tool detection position or near the automatic tool changer in the machine tool workspace. The scanning sequence is controlled by the CNC system to realize the automatic switching between processing and detection.

3. The integrated processing technology for metal products according to claim 1 or 2, characterized in that, The laser scanning device (205) includes a laser emitting module, a reflected light acquisition module, and a data processing module; The laser emitting module emits a focused laser beam to illuminate the cutting edge area of ​​the tool, and the reflected light acquisition module receives the reflected signal and generates three-dimensional point cloud data.

4. The integrated processing technology for metal articles according to any of the preceding claims, characterized in that, The data processing module calculates parameters such as the change in cutting edge radius, the deviation in cutting edge height, the notch depth, the crack length, and the surface roughness by comparing the point cloud model, so as to quantitatively assess the degree of damage to the tool surface.

5. The integrated processing technology for metal articles according to any of the preceding claims, characterized in that, When any parameter in the detection result exceeds a preset threshold, the system triggers the control logic to perform one or a combination of the following operations: A1: Automatically pauses processing and prompts for tool replacement; A2: Automatically activate the standby tool to continue processing; A3: Automatically adjusts feed rate, spindle speed, or depth of cut to compensate for tool wear; A4: Upload the detection information to the tool life database.

6. The integrated processing technology for metal articles according to any of the preceding claims, characterized in that, The laser scanning resolution is 1 µm to 10 µm, and the scanning cycle is less than 10 seconds, enabling rapid online inspection without affecting the processing cycle.

7. The integrated processing technology for metal articles according to any of the preceding claims, characterized in that, Tool morphology comparison uses shape reconstruction algorithms or optical surface deviation analysis algorithms to automatically identify tool surface crack boundaries and wear distribution.

8. The integrated processing technology for metal articles according to any of the preceding claims, characterized in that, The machining system interacts with the CNC machine tool control system via a communication interface.

9. The integrated processing technology for metal articles according to any of the preceding claims, characterized in that, This process is applicable to turning, milling, boring, or drilling of materials such as steel, aluminum, titanium alloys, stainless steel, and cemented carbide.

10. The integrated processing technology for metal articles according to any of the preceding claims, characterized in that, Tool inspection data, after statistical analysis, can be used to establish a tool life prediction model.

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