An integrated processing of a metal product

Abstract

The present application belongs to the technical field of metal processing, and is especially a kind of integrated processing technology of metal products, comprising the following steps: S1: sequentially performing rough machining, semi-finishing and finishing on a metal blank to obtain a required geometric shape; S2: using a laser scanning device to non-contact scan the surface of a currently used or to-be-detected tool at any stage or in a set period of the machining process to obtain tool surface topography information.The present application integrates a laser scanning device in a machining system, controls the scanning timing through a numerical control system, and realizes automatic switching of machining and detection.Online detection of the tool surface state can be completed without manual disassembly of the tool or stoppage of the machine tool, greatly reducing non-machining time and improving equipment utilization.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of metal processing, and particularly relates to an integrated processing technology for metal products. BACKGROUND

[0002] In the traditional metal processing process, the workpiece usually needs to go through multiple stages such as rough machining, semi-finishing machining and finishing machining to gradually obtain the required geometric shape and surface precision. The existing processing technology is mostly controlled by machine tool processing parameters and manual experience. Although modern numerical control technology has made significant progress in processing automation, real-time detection and intelligent control of tool state are still key factors affecting processing quality and production efficiency.

[0003] In the prior art, the detection of tool wear or damage is mostly in the following ways:

[0004] (1) Offline detection method: manual detection of the tool in the processing gap through an optical microscope, a profilometer or a three-dimensional scanner. This method has high detection accuracy, but it needs to manually disassemble the tool, which not only takes a long time, but also interrupts the processing process and affects the production rhythm.

[0005] (2) Indirect monitoring method: the tool wear state is inferred by monitoring the spindle power, cutting force, vibration signal or acoustic emission signal. This method is simple in equipment, but the detection result is greatly affected by the processing material, process parameters and noise interference, and it is difficult to realize quantitative analysis.

[0006] (3) Image recognition method: the tool surface image is collected by an industrial camera and analyzed to determine the wear state. This method is obviously affected by light conditions, surface reflection and cleanliness, and has poor detection stability.

[0007] Since the above methods all have problems such as detection lag, insufficient accuracy or low automation, they are difficult to meet the needs of online detection, intelligent compensation and life prediction in modern manufacturing. Especially in multi-axis composite machining, high-speed cutting and unmanned production scenarios, if the tool damage cannot be identified and handled in time, it is easy to cause workpiece scrap, equipment damage or production interruption, which seriously affects production efficiency and processing quality.

[0008] Therefore, there is an urgent need for an integrated processing technology for metal products that can realize online detection, automatic identification and adaptive control of tool surface state during processing, in order to improve tool utilization efficiency, ensure processing precision and realize intelligent manufacturing. SUMMARY

[0009] To solve the problems raised in the background art, the present application provides an integrated processing technology for metal products.

[0010] To achieve the above object, the present application provides the following technical scheme: an integrated processing technology of metal products, comprising the following steps:

[0011] S1: sequentially performing rough machining, semi-finishing and finishing on the metal blank to obtain the required geometric shape;

[0012] S2: using a laser scanning device to non-contact scan the surface of the currently used or to-be-detected tool at any stage or set period of the processing process, and obtaining tool surface topography information;

[0013] S3: comparing the three-dimensional point cloud data of the tool obtained by laser scanning with the initial reference model of the tool or the model detected last time, and generating tool damage characteristic parameters;

[0014] S4: judging whether the tool surface has wear, chipping, crack or edge defect according to the comparison result, and comparing the obtained damage characteristic parameters with the preset threshold value;

[0015] S5: when the detection result shows that the tool damage exceeds the preset limit value, the system automatically executes tool replacement, processing parameter compensation or alarm prompt;

[0016] S6: recording the three-dimensional topography data, damage characteristic parameters, processing parameters and tool use time obtained by each laser detection to the tool management system, for subsequent life prediction and process optimization.

[0017] Preferably, the laser scanning device is fixedly installed near the tool detection position of the machine tool working space or the automatic tool changer, and the scanning timing is controlled through the numerical control system to realize automatic switching of processing and detection.

[0018] Preferably, the laser scanning device comprises a laser emission module, a reflected light collection module and a data processing module.

[0019] The laser emission module emits a focused laser beam to irradiate the tool edge region, and the reflected light collection module receives the reflected signal and generates three-dimensional point cloud data.

[0020] Preferably, the data processing module calculates the tool edge radius variation, edge height deviation, notch depth, crack length and surface roughness and other parameters by comparing the point cloud model, so as to quantitatively evaluate the damage degree of the tool surface.

[0021] Preferably, when any parameter in the detection result exceeds the preset threshold value, the system triggers the control logic to execute one or a combination of the following operations:

[0022] A1: automatically pause processing and prompt to replace the tool;

[0023] A2: automatically enable the standby tool to continue processing;

[0024] A3: automatically adjusting the feed speed, spindle speed or cutting depth to compensate for tool wear;

[0025] A4: uploading the detection information to a tool life database.

[0026] Preferably, the resolution of the laser scanning is 1 µm to 10 µm, and the scanning period is less than 10 seconds, so that online rapid detection can be achieved without affecting the processing rhythm.

[0027] Preferably, the tool morphology comparison adopts a shape reconstruction algorithm or an optical surface deviation analysis algorithm, which can automatically identify the tool surface crack boundary and wear distribution.

[0028] Preferably, the machining system interacts with the numerical control machine tool control system through a communication interface.

[0029] Preferably, the process is suitable for turning, milling, boring or drilling processes of steel, aluminum, titanium alloy, stainless steel and hard alloy materials.

[0030] Preferably, the tool detection data can be used to establish a tool life prediction model after statistical analysis.

[0031] Compared with the prior art, the beneficial effects of the present application are: the present application integrates a laser scanning device in the machining system, controls the scanning timing through the numerical control system, and realizes automatic switching of machining and detection. Without manual disassembly of the tool or stopping of the machine tool, online detection of the tool surface state can be completed, non-processing time is greatly reduced, and equipment utilization is improved. BRIEF DESCRIPTION OF DRAWINGS

[0032] The accompanying drawings are included to provide a further understanding of the present application, and constitute a part of the specification, illustrate the present application together with the embodiments thereof, and explain the present application, but do not limit the present application. In the drawings:

[0033] Figure 1 is a schematic diagram of the overall structure of the present application;

[0034] Figure 2 is an exploded view of the present application;

[0035] Figure 3 is a schematic diagram of the connection structure of the monitoring unit and the clamping unit in the present application;

[0036] Figure 4 is an exploded view of the monitoring unit and the clamping unit in the present application;

[0037] Figure 5 is a schematic diagram of the connection structure of the cleaning assembly in the present application;

[0038] Figure 6A schematic view of a local connection structure of the cleaning assembly in the application;

[0039] Figure 7 A schematic view of a connection structure of the clamping unit in the application;

[0040] Figure 8 A schematic view of a connection structure of the monitoring unit in the application;

[0041] Figure 9 A schematic view of a local connection structure of the machining assembly in the application.

[0042] Explanation of reference signs:

[0043] 1-cabinet, 2-monitoring unit, 201-first frame body, 202-first driving module, 203-bottom plate, 204-telescopic air cylinder, 205-laser scanning device, 3-clamping unit, 4-machining assembly, 401-driving motor, 402-fourth driving module, 403-second frame body, 404-third driving module, 5-cleaning assembly, 501-air pump, 502-first branch pipe, 503-first check valve, 504-annular pipe, 505-nozzle, 506-second branch pipe, 507-second check valve, 508-limiting rod, 509-sliding sleeve, 510-solenoid valve, 511-cylinder, 512-piston rod, 513-sliding rod, 514-spring, 515-protruding block. DETAILED DESCRIPTION

[0044] The technical solutions in the embodiments of the application will be clearly and completely described below with reference to the drawings in the embodiments of the application. Obviously, the described embodiments are only part of the embodiments of the application, rather than all the embodiments of the application. Based on the embodiments in the application, all other embodiments obtained by a person of ordinary skill in the art without creative work fall within the protection scope of the application.

[0045] The application provides an integrated machining process for metal products, which is suitable for turning, milling, boring or drilling machining processes of materials such as steel, aluminum, titanium alloy, stainless steel and hard alloy. The process realizes online monitoring of a tool surface state, damage feature identification, parameter self-adaptive compensation and online grinding treatment in the machining process by integrating a laser scanning detection device and an intelligent parameter compensation control module in a machine tool system, thereby significantly improving machining precision, tool service life and production automation level, and specifically includes the following steps:

[0046] The metal blank is sequentially subjected to rough machining, semi-finish machining and finish machining to obtain the basic geometric shape and dimensional accuracy of the target part.

[0047] This step is performed by a CNC lathe, machining center or compound machine tool, and after each stage is completed, the tool detection process can be automatically called to ensure the continuous stability of the subsequent machining precision.

[0048] At any stage of the machining process or at a set detection period, the laser scanning device 205 is used to non-contact scan the surface of the currently used or to-be-detected tool, and obtain the three-dimensional topographic information of the tool edge region.

[0049] The laser scanning device 205 comprises:

[0050] A laser emission module: emits a focused laser beam to irradiate the tool edge;

[0051] A reflected light collection module: receives the reflected signal and generates three-dimensional point cloud data;

[0052] A data processing module: filters, models and compares the point cloud data, and outputs the damage characteristic parameters.

[0053] Preferably, the spatial resolution of laser scanning is 1-10 μm, and the single scanning period is less than 10 seconds.

[0054] The laser scanning device 205 can be installed near the tool detection position of the machine tool or the automatic tool changer, and the scanning timing is controlled by the numerical control system to realize the automatic switching of machining-detection-repair without affecting the normal machining rhythm.

[0055] The data processing module compares the three-dimensional point cloud data of the tool obtained by laser scanning with the initial reference model or the last detection model of the tool, adopts a shape reconstruction algorithm or an optical surface deviation analysis algorithm, and extracts parameters including but not limited to the following: change in edge radius, edge height deviation, notch depth, crack length and surface roughness change value.

[0056] According to the comparison result, it is judged whether the tool surface has wear, edge collapse, crack or edge defect, and the calculated damage characteristic parameters are compared with the preset threshold value to quantitatively evaluate the damage degree of the tool.

[0057] When any parameter in the detection result exceeds the limit value, the system automatically triggers one or a combination of the following logical operations:

[0058] A1: automatically pause machining and prompt the operator to replace the tool;

[0059] A2: automatically enable the standby tool to continue machining;

[0060] A3: automatically adjust the machining parameters, including feed speed, spindle speed, cutting depth, etc., to realize macro compensation;

[0061] 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.

[0062] 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.

[0063] 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.

[0064] 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.

[0065] 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.

[0066] The tool's 3D model and the highlighted wear area;

[0067] Numerical distribution of each damage characteristic parameter;

[0068] System automatic decision-making logic and execution records;

[0069] Recommended maintenance or refurbishment action path.

[0070] 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.

[0071] 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.

[0072] 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.

[0073] The monitoring unit 2, the clamping unit 3 and the machining assembly 4 are arranged in the interior of the cabinet 1, and the cleaning assembly 5 is arranged on the machining assembly 4. Through the cooperation of the above-mentioned assemblies, the automatic clamping, machining, tool detection and cleaning of the workpiece can be realized.

[0074] The monitoring unit 2 is mainly used for non-contact scanning detection of the surface of the machining tool, and comprises:

[0075] The first frame body 201, the first driving module 202, the bottom plate 203, the telescopic cylinder 204 and the laser scanning device 205.

[0076] The first driving module 202 is installed on the first frame body 201 and can drive the bottom plate 203 to move accurately along a set direction;

[0077] The telescopic cylinder 204 is fixedly installed on the bottom plate 203, and the output end thereof is connected with the laser scanning device 205, for controlling the telescopic movement of the laser scanning device;

[0078] The laser scanning device 205 is used for emitting a laser beam to the surface of the tool and collecting a reflected light signal, so as to generate three-dimensional point cloud data of the surface of the tool.

[0079] Preferably, the laser scanning device 205 comprises a laser emitting module, a reflected light collecting module and a data processing module. The device can detect the tool at any stage or in a preset period of the machining process, so as to realize real-time monitoring of the state of the tool.

[0080] The clamping unit 3 is used for fixing and clamping the workpiece, so as to ensure the positioning accuracy and stability of the workpiece in the machining process. The unit can adopt a pneumatic, hydraulic or electric driving mode to realize clamping and loosening actions, so as to adapt to metal blanks of different specifications and shapes.

[0081] The machining assembly 4 is used for cutting machining of the workpiece, and comprises a second frame body 403, a third driving module 404, a fourth driving module 402 and a driving motor 401.

[0082] The third driving module 404 is fixedly arranged on the second frame body 403 and is used for driving the fourth driving module 402 to move along a first direction (such as an X axis);

[0083] The fourth driving module 402 is used for driving the driving motor 401 to move along a second direction (such as a Y axis), and the second direction is perpendicular to the moving direction of the third driving module 404;

[0084] The output end of the driving motor 401 is provided with a tool bit, which is used for cutting, milling, drilling or boring operation of the workpiece.

[0085] Through the cooperation of the bidirectional driving module, multidimensional movement of the tool in space can be realized, thereby meeting the needs of complex surface or high-precision machining.

[0086] The cleaning assembly 5 is used to clean the tool surface before machining gap or detection, so as to remove the attached chips or cooling liquid and ensure the accuracy of laser detection. The assembly comprises:

[0087] The air pump 501, the first branch pipe 502, the first one-way valve 503, the annular pipe 504, the plurality of spray heads 505, the second branch pipe 506, the second one-way valve 507, the limiting rod 508, the sliding sleeve 509, the electromagnetic valve 510, the cylinder 511, the piston rod 512, the sliding rod 513, the spring 514 and the protruding block 515.

[0088] The air inlet end of the air pump 501 is connected to the second branch pipe 506, the second one-way valve 507 and the cylinder 511 in sequence, and the air outlet end is connected to the first branch pipe 502, the first one-way valve 503, the annular pipe 504 and the plurality of spray heads 505 in sequence;

[0089] The annular pipe 504 and the plurality of spray heads 505 are installed outside the tool head, and the tool head is located at the center position of the annular pipe 504, so as to realize 360° uniform blowing;

[0090] The electromagnetic valve 510 is arranged on the cylinder 511 and is used to control air pressure balance;

[0091] The piston rod 512 is in sliding connection with the cylinder 511, and the end thereof is fixedly connected with the sliding rod 513;

[0092] The sliding rod 513 is in sliding cooperation with the protruding block 515, the spring 514 is sleeved on the sliding rod 513 and is connected with the protruding block 515 and the two ends of the piston rod 512 respectively;

[0093] The limiting rod 508 is fixed on the driving motor 401, and the outer wall thereof is provided with the sliding sleeve 509, the sliding sleeve 509 is connected with the annular pipe 504 through the connecting rod and is used to guide the synchronous movement of the annular pipe.

[0094] When the tool surface needs to be cleaned, the air pump 501 is started, and the 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 and compresses the internal space of the cylinder 511, forming a negative pressure area.

[0095] At the same time, the air is transported to the annular pipe 504 through the first branch pipe 502 and the first one-way valve 503, and is uniformly sprayed out through the plurality of spray heads 505, so as to clean the tool surface in all directions.

[0096] During the advancing of the piston rod 512, the slide rod 513 and the slide sleeve 509 are driven to move towards the driving motor 401, thereby driving the annular tube 504 to move towards the cutter synchronously, so as to realize the dynamic cleaning effect.

[0097] After the cleaning is completed, the air pump 501 is closed and the electromagnetic valve 510 is opened, so that the air pressure inside and outside the cylinder 511 is balanced. At this time, the spring 514 releases the reset force, and pushes the piston rod 512 and the slide rod 513 to automatically reset, so as to prepare for the next cleaning action.

[0098] Compared with the prior art, the device has the following remarkable advantages: the integrated laser detection and cleaning system realizes the full-automatic linkage of machining, detection and maintenance; the double driving modules realize the high-precision spatial positioning and multi-directional cutting of the cutter; the cleaning assembly adopts the annular blowing and the pneumatic reset structure, so that the cleaning efficiency is high and the structure is stable; the degree of automation is high, so that the detection precision of the cutter can be ensured and the service life of the cutter is prolonged.

[0099] Finally, it should be noted that: the above only describes the preferred embodiments of the present application, and is not used to limit the present application, although the present application has been described in detail with reference to the foregoing embodiments, for those skilled in the art, the technical solutions recorded in the foregoing embodiments can still be modified, or some technical features can be replaced equivalently. Any modification, equivalent replacement, improvement, etc. within the spirit and principles of the present application shall be included in the protection scope of the present application.

Claims

1. An integrated processing of a metal product, characterized by, The process comprises a device for integrated processing of metal products, the device comprising a cabinet (1), a monitoring unit (2) arranged inside the cabinet (1), a clamping unit (3) and a processing assembly (4), and a cleaning assembly (5) arranged on the processing assembly (4); The processing assembly (4) comprises a driving motor (401) with a tool bit mounted on the output end; The monitoring unit (2) comprises a laser scanning device (205); The cleaning assembly (5) comprises: an air pump (501), a first branch pipe (502), a first one-way valve (503), an annular pipe (504), a plurality of spray heads (505), a second branch pipe (506), a second one-way valve (507), a limiting rod (508), a sliding sleeve (509), an electromagnetic valve (510), a cylinder (511), a piston rod (512), a sliding rod (513), a spring (514) and a protrusion (515); The air inlet end of the air pump (501) is sequentially connected with the second branch pipe (506), the second one-way valve (507) and the cylinder (511), and the air outlet end is sequentially connected with the first branch pipe (502), the first one-way valve (503), the annular pipe (504) and the plurality of spray heads (505); The annular pipe (504) and the plurality of spray heads (505) are installed outside the tool bit, and the tool bit is located at the center position of the annular pipe (504) to realize 360° uniform blowing; The cylinder (511) is provided with the electromagnetic valve (510) for controlling air pressure balance; The piston rod (512) is in sliding connection with the cylinder (511), and the end thereof is fixedly connected with the sliding rod (513); The sliding rod (513) is in sliding cooperation with the protrusion (515), the spring (514) is sleeved on the sliding rod (513) and connected with the protrusion (515) and the two ends of the piston rod (512) respectively; The limiting rod (508) is fixed on the driving motor (401), and the outer wall thereof is provided with the sliding sleeve (509), the sliding sleeve (509) is connected with the annular pipe (504) through a connecting rod for guiding synchronous movement of the annular pipe; The process comprises the following steps: S1: using the device to sequentially perform rough machining, semi-finishing and finishing on a metal blank to obtain a required geometric shape; S2: using the laser scanning device (205) to perform non-contact scanning on the surface of a currently used or to-be-detected tool at any stage or in a set period during the processing process to obtain tool surface topography information; S3: comparing the three-dimensional point cloud data of the tool obtained by laser scanning with an initial reference model of the tool or a model detected last time to generate tool damage characteristic parameters; S4: judging whether the tool surface has wear, chipping, cracking or edge defect according to the comparison result, and comparing the obtained damage characteristic parameters with a preset threshold value; S5: when the detection result shows that the tool damage exceeds a preset limit value, the system automatically performs tool replacement, processing parameter compensation or alarm prompting; S6: recording the three-dimensional topography data, damage characteristic parameters, processing parameters and tool use time obtained by each laser detection to a tool management system for subsequent life prediction and process optimization. The process also includes: cleaning the tool surface before the machining gap or detection, during the advancement of the piston rod (512), the sliding rod (513) and the sliding sleeve (509) are moved towards the driving motor (401), thereby driving the annular tube (504) to move towards the tool, achieving a dynamic cleaning effect.

2. The integrated processing of metal articles of claim 1 wherein, The laser scanning device (205) is fixedly installed near the tool detection position or automatic tool changer of the machine tool workspace, and the scanning timing is controlled by the numerical control system to realize automatic switching between machining and detection.

3. The integrated processing of metal articles of claim 1 wherein, The laser scanning device (205) includes a laser emission module, a reflected light collection module, and a data processing module. The laser emission module emits a focused laser beam to irradiate the tool edge region, and the reflected light collection module receives the reflected signal and generates three-dimensional point cloud data.

4. The integrated processing of metal articles of claim 1 wherein, The data processing module compares the point cloud model to calculate the tool edge radius variation, edge height deviation, notch depth, crack length, and surface roughness to quantitatively evaluate the tool surface damage degree.

5. The integrated processing of metal articles of claim 1 wherein, When any parameter in the detection result exceeds the preset threshold, the system triggers the control logic to perform one or a combination of the following operations: A1: automatically pause machining and prompt to replace the tool; A2: automatically enable the backup tool to continue machining; A3: automatically adjust the feed speed, spindle speed, or cutting depth to compensate for tool wear; A4: upload the detection information to the tool life database.

6. The integrated processing of metal articles of claim 1 wherein, The resolution of laser scanning is 1 µm~10 µm, and the scanning period is less than 10 seconds, which can realize online rapid detection without affecting the machining rhythm.

7. The integrated processing of metal articles of claim 1 wherein, The tool topography comparison uses shape reconstruction algorithm or optical surface deviation analysis algorithm, which can automatically identify the tool surface crack boundary and wear distribution.

8. The integrated processing of metal articles of claim 1 wherein, The machining system interacts with the numerical control machine tool control system through the communication interface.

9. The integrated processing of metal articles of claim 1 wherein, The process is suitable for turning, milling, boring, or drilling of steel, aluminum, titanium alloy, and hard alloy materials.

10. The integrated processing of metal articles of claim 1 wherein, After statistical analysis, the tool detection data can be used to establish a tool life prediction model.

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