Crystal material building ornament designing and forming method

Abstract

The invention discloses a crystal material building ornament designing and forming method. The method comprises the steps that a digital model of a crystal material building ornament is constructed in three-dimensional modeling software; extracting topological data of the digital model through a script program; analyzing the topological data by using a process parameter conversion tool, and calculating core process parameters of each surface based on an analysis result, wherein the core process parameters comprise a swing angle theta, a rotation angle phi, a center distance d and a center distance d; based on the characteristic parameters of the grinding machine, further calculating machining parameters matched with the grinding machine through a parameter mapping relation, wherein the machining parameters include the machining height h, the abdication amount delta h, the slow feeding amount delta, the retention time t and the slow feeding speed v, and finally generating a process file matched with the grinding machine; and the process file is imported into a grinding machine to be machined, and the crystal material building ornament consistent with the digital model is obtained. The problems that a traditional technology is low in efficiency and low in machining precision are solved.

Description

Technical Field

[0001] This invention belongs to the field of crystal ornament processing technology. Background Technology

[0002] The traditional processing flow for crystal building crafts typically involves process engineers manually breaking down the process steps based on design drawings. First, the process path for grinding is planned according to the dimensions marked on the drawings and the technical parameters of the grinding machine (such as spindle travel and speed range). Then, the process parameters required for grinding each surface (such as swing angle θ, rotation angle φ, and center distance d) are determined manually through calculations. This process relies on the engineer's empirical formulas and geometric characteristics (such as the surface normal vector and radius of curvature). Finally, the calculation results are manually input into the grinding machine controller, and the grinding machine executes the program to complete the grinding and shaping. However, this traditional process has significant drawbacks: manually marking model cross-sections, calculating process parameters, and inputting data is time-consuming and relies on the engineer's experience, making it difficult to quickly respond to design changes; manual calculations are susceptible to subjective judgment biases (such as errors in normal vector estimation), and there is also a risk of typing errors when manually inputting data, ultimately leading to deviations in process parameters and affecting processing accuracy; simultaneously, the lack of a systematic mapping between process parameters and grinding machine characteristic parameters (such as spindle stiffness and toolpath limitations) makes it easy for parameters to exceed limits, causing equipment malfunctions or processing failures. Summary of the Invention

[0003] This invention proposes a method for designing and molding crystal building decorations and a grinding machine, which solves the problems of low efficiency and low processing precision in traditional processes.

[0004] In a first aspect, a method for designing and molding architectural ornaments made of crystal material includes: constructing a digital model of the architectural ornament made of crystal material in 3D modeling software; extracting topological data of the digital model through a script program, the topological data including: upper / lower half division information of parting processing, layered structure, geometric features of each face, and vertex coordinates; parsing the topological data using a process parameter conversion tool, and calculating the core process parameters of each face based on the parsing results: swing angle θ, rotation angle φ, and center distance d, where the center distance d is the vertical distance from the boundary contour of the digital model to the rotation axis; subsequently, based on the characteristic parameters of the grinding machine, further calculating the processing parameters adapted to the grinding machine through parameter mapping relationships: processing height h, retraction amount Δh, slow advance amount δ, dwell time t, and slow advance speed v, and finally generating a process file adapted to the grinding machine; importing the process file into the grinding machine for processing to obtain a architectural ornament made of crystal material consistent with the digital model.

[0005] In some examples, the process of the script program processing the topological data includes: spatial analysis and boundary benchmark establishment: by calculating the boundary contour of the digital model to obtain its external dimension parameters, for the crystal material architectural ornaments to be processed, a horizontal boundary benchmark surface is established for its digital model; data structure construction: an XML document is created and a root node is established, and the external dimension parameters of the digital model are written as data elements or attributes into the root node or its child nodes. For the crystal material architectural ornaments to be processed, independent child nodes are established as containers to store the topological data related to the processing; geometric data processing: traversing all faces of the digital model and calculating the geometric center coordinates of each face; face clustering based on the ordinate, and grouping faces with the same ordinate into the same level; after arranging all levels in descending order of ordinate, the levels are assigned to the corresponding partial containers according to the preset horizontal boundary benchmark surface; the topological structure of each face is recorded layer by layer, and the three-dimensional coordinate information of each vertex is stored; standardized data output: the processed geometric data is output and stored.

[0006] In some examples, the process parameter conversion tool loads the XML document and parses out the topology data.

[0007] In some examples, the processed geometric data is assembled into a formatted string according to the XML Schema specification, written into an XML document, and stored on a chosen storage medium.

[0008] In some examples, the script first detects whether there is a valid active document in the modeling software, then locates the digital model and performs a geometric validity verification.

[0009] Secondly, a grinding machine includes a spindle, a cutting tool, a rotary table, a moving platform, and a controller. The controller is equipped with a process document generated using the aforementioned method for designing and molding architectural decorations from crystal materials, and the grinding machine is controlled to process architectural decorations from crystal materials based on the process document.

[0010] In some examples, the controller drives the spindle and the rotary table to perform the grinding process layer by layer and surface by surface according to the instructions in the process document.

[0011] In some examples, a pressure sensor for monitoring the grinding status is installed on a fixed base between the rotary table and the moving platform, and the controller is configured to dynamically adjust the tool feed based on the pressure value measured by the pressure sensor to compensate for machining accuracy deviations caused by wear.

[0012] In some examples, the controller is configured to perform the following steps: before processing begins, measuring the pressure value F0 of the pressure sensor as an initial contact force reference; during processing, measuring the pressure value F0 of the pressure sensor in real time.m When F m When the pressure exceeds F0+1 kgf, it is determined to be in an effective grinding state; otherwise, it is determined to be in a non-contact state. In the effective grinding contact state, the controller monitors the real-time pressure value F. m Time integration is performed, and the integral value reflects the cumulative effect of tool wear. The tool feed rate is adjusted in real time based on the integral value to compensate for machining accuracy deviations caused by wear.

[0013] In some examples, the tool holder and the grinding wheel body are designed as a continuous, homogeneous, integrated rigid structure.

[0014] This invention addresses the processing needs of multi-faceted crystal architectural decorations by innovatively proposing a complete process solution from design model to finished product. It involves embedding a dedicated script program into 3D modeling software to extract model topology data and generate standardized intermediate files. These intermediate files are then parsed by a parameter conversion tool to calculate process parameters suitable for the characteristics of the grinding machine, ultimately generating a proprietary format process file recognizable by the processing equipment. The process file is automatically executed after being transferred to the equipment via USB flash drive, eliminating the traditional manual parameter calculation and input steps. This invention employs a dedicated tool integrating a flat grinding wheel and tool holder, achieving rapid prototyping of crystal crafts through integrated control of grinding and drilling processes. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of a multi-faceted crystal according to an embodiment of the present invention.

[0016] Figure 2 yes Figure 1 The partial topological structure of the multi-faceted crystal model.

[0017] Figure 3 This is the interface of the process parameter conversion tool in one embodiment of the present invention.

[0018] Figure 4 This is a schematic diagram of an integrated tool holder grinding wheel according to one embodiment of the present invention.

[0019] Figure 5 This is a schematic diagram of a grinding machine according to another embodiment of the present invention. Detailed Implementation

[0020] Crystal architectural decorative materials typically exhibit a three-dimensional structure with multiple facets, such as... Figure 1 The example shown is a spherical decorative piece. It's important to emphasize that the shape of these decorative items is not limited to spheres; they can also take various geometric forms such as squares, cones, and rhombuses. During the modeling stage, designers can use 3D modeling software such as FreeCAD to create digital models of the crystal ornaments and extract the topological data of the model using scripts. For example... Figure 2As shown, the topology data includes key parameters such as upper / lower half partitioning information, model hierarchical structure, geometric features of each face, and vertex coordinates.

[0021] by Figure 1 The topology of the sphere model shown is illustrated below. The model is divided into an upper part (northern hemisphere) 61 and a lower part 62. Each hemisphere contains a variable number of layers 63, and each layer 63 contains a variable number of faces 64, such as face 1 and face 2 in layer 1. Each face contains a variable number of vertices 65.

[0022] The following details the process by which the script program processes the topology data of the crystal ornament model.

[0023] Step 1, Initialize verification The script first checks if a valid active document exists in the modeling software, then locates the crystal ornament model (named "MultiFacetedSphere" by default in the FreeCAD environment). To ensure the reliability of subsequent processing, the script performs geometric validity verification, such as checking for anomalies like self-intersecting surfaces or unclosed structures.

[0024] Step 2: Spatial Analysis and Boundary Benchmark Establishment The bounding box of the digital model is calculated to obtain its external dimensions (e.g., length × width × height), which serve as a reference for subsequent processing. Whether to implement upper and lower part division depends on the type of decoration: for symmetrical structures (such as spheres), the script automatically establishes a horizontal dividing reference plane; for asymmetrical structures, the dividing strategy is dynamically determined based on design requirements.

[0025] Step 3, Data Structure Construction Create an XML document and establish a root node. Write the model dimension parameters as metadata elements or attributes into the root node or its child nodes. For the upper and lower sections, create independent child nodes as containers, reserving storage space for each section to record corresponding geometric parameters and machining information later.

[0026] Step 4, Geometric Data Processing Traverse all faces of the digital model and calculate the geometric center coordinates of each face, paying particular attention to the Z-axis coordinate value.

[0027] Surface clustering is performed based on the Z-coordinate (with a precision threshold set to 0.0001mm), grouping surfaces with the same coordinates into the same level. For example... Figure 1 The same Z-coordinate values ​​on surfaces 1 and 2 are grouped into the same layer.

[0028] After sorting all levels in descending order of Z coordinate, the levels are assigned to the corresponding partial containers according to the preset boundary benchmark.

[0029] The topological structure of each face is recorded layer by layer, and the three-dimensional coordinate information (X / Y / Z) of each vertex is stored precisely.

[0030] Step 5, Standardize data output Assemble the topology data into a formatted string according to the XML Schema specification, write it into an XML document, and select a suitable storage medium (such as a file system or database) for storage.

[0031] The above script can be written in Python.

[0032] After loading the XML document storing the topology data of the crystal ornament model, the process parameter conversion tool first parses the topology data and calculates the core process parameters for each face based on the parsing results: swing angle θ, rotation angle φ, and center distance d (the vertical distance from the model boundary to the rotation axis). Then, based on the grinding machine's characteristic parameters (such as spindle height and stroke range), it further calculates the processing parameters adapted to the grinding machine through parameter mapping relationships: processing height h, retraction amount Δh, slow feed amount δ, dwell time t, and slow feed speed v. All parameters must be strictly verified to ensure they are within the grinding machine's operating range, such as the swing angle not exceeding the safety threshold and the center distance conforming to the rotation axis stroke constraints. Finally, a process file (proprietary format) adapted to the grinding machine is generated and imported into the grinding machine for processing.

[0033] The process parameter conversion tool can be implemented using a programming language familiar to those skilled in the art. The specific calculation process for the core process parameters and the processing parameters adapted to the grinding machine is conventional technology in this field, and the specific calculation methods will not be detailed here. Figure 3 The interface of the process parameter conversion tool is shown.

[0034] like Figure 4 As shown, the cutting tool for processing crystal building decorations of this invention adopts an integrated tool holder and grinding wheel structure, wherein the flat grinding wheel and tool holder are integrally formed. The grinding wheel 1 includes a tool holder 11, a grinding wheel column 12, and a grinding wheel cap 13, all integrally formed. The tool holder 11 has a conical structure, and its taper design conforms to the ISO 7388-1 international standard. The diamond abrasive layer 14 is cured onto the surface of the grinding wheel cap 13 using traditional processes, forming a grinding component with high precision and stability.

[0035] In traditional processes, T-shaped grinding wheels are fixed to the tool holder by clamping, and then the tool holder is inserted into the spindle. Since the clamping force mainly relies on friction for transmission, it is difficult to completely counteract the cutting force and vibration generated during grinding. This can easily lead to micro-slippage or vibration of the grinding wheel, which in turn cannot guarantee the strict perpendicularity of the grinding wheel end face to the spindle axis, as well as the concentricity of the outer circle of the grinding wheel to the spindle axis.

[0036] This invention significantly improves overall bending and torsional stiffness by designing the tool holder and grinding wheel base as a continuous, homogeneous, integrated rigid structure. This design more effectively resists grinding forces (especially tangential and radial forces) and high-frequency vibrations, and has a stronger ability to suppress chatter, thus achieving a more stable and higher-load grinding process. In crystal crafts processing, this design enables high-precision, low-vibration integrated grinding and drilling operations, while also facilitating the construction of efficient and standardized production lines.

[0037] Figure 5 A grinding machine was displayed. (Example) Figure 5 As shown, the grinding machine includes a cutting tool (grinding wheel) 1, a spindle 2, a rotary table 3, a moving platform 4, and a controller. The rotary table 3 has a swing platform 31 and a rotating platform 32. The rotating platform 32 is located on the swing platform 31. The swing platform can swing back and forth, and the rotating platform 32 can rotate horizontally; the specific drive motor is not shown in the diagram. The crystal material 6 to be processed is placed on the rotating platform 32. The cutting tool 1 is mounted on the spindle 2, facing the rotating platform 32.

[0038] This invention improves the controller's control method. To coordinate with the controller's control, pressure sensors 5 are installed on four fixed seats between the rotating table 3 and the moving platform 4. Based on this, a dynamic compensation method for grinding wheel wear based on Time-Pressure Integral (TPI) is proposed. The core of this method is: 1. Contact status determination: Before processing begins, the pressure value (F0) of the pressure sensor is measured as the initial contact force reference.

[0039] Real-time monitoring of pressure values ​​(F) during processing m When F m When the value is greater than (F0+1 kgf), it is considered to be in an effective grinding state; otherwise, it is considered to be in a non-contact state (such as the grinding wheel being suspended or slipping).

[0040] 2. Wear estimation and compensation Wear estimation and compensation: Under effective grinding contact conditions, the controller estimates the real-time pressure value F. m Perform time integration ( This integral value reflects the cumulative effect of grinding wheel wear, and serves as the main basis for estimating the amount of grinding wheel wear.

[0041] The wheel feed is corrected in real time based on the integral value to compensate for the machining accuracy deviation caused by wear. Specifically, first record the height h (in millimeters) of the wheel wear caused by grinding an object for 10 minutes with a wheel on a tool shank of the same material under a pressure of 100KG. Calculate the height of wear per second under a pressure of 1KG as h / (60×10×100) millimeters. The wear amount has a linear relationship with the integral of pressure and time. After a grinding step is completed, the feed of the wheel on the tool shank is corrected in a timely manner , to compensate for the machining accuracy deviation caused by wear.

[0042] This mechanism realizes the online estimation and dynamic compensation of wheel wear by real-time sensing of the effective contact force and quantification of the wear effect, significantly improving the machining accuracy and process stability.

[0043] The processing of crystal handicrafts adopts a split processing mode. The multi-faceted crystal is divided into two independent processing areas, the upper and the lower. Each area manages the processing surfaces according to a row-column matrix. Each surface contains the following process parameters: Rough / fine grinding parameters: swing angle θ, rotation angle φ, machining height h, retraction amount Δh, slow feed amount δ, dwell time t, and slow feed speed v.

[0044] Drilling parameters: If drilling is required, embed the hole diameter, depth, and direction parameters in the XML file corresponding to the section data, and synchronize them to the equipment process file through a conversion tool.

[0045] The controller drives the drive motors of the spindle, swing platform, and rotary platform row by row and surface by surface to execute the grinding process. After each single-sided grinding is completed, the grinding machine automatically triggers the wheel wear compensation based on the integral of the real-time pressure and the effective grinding time until the entire area is processed; the cooling water system is strictly linked to the start and stop of the grinding / drilling operations, forming a solution integrating high-precision machining, dynamic wear compensation, and process closed-loop control.

[0046] The following takes a spherical crystal material architectural ornament as an example to introduce the xml document and the standardized process file format.

[0047] The generated xml document has a fixed number of 2 hemispheres (North / South). Each hemisphere contains a variable number of layers, each layer contains a variable number of faces, and each face contains a variable number of vertices; a hierarchical identification system is adopted. The layer ID format is [hemisphere prefix]_[hierarchical index] (such as North_0), the face ID format is [layer ID]-[face index] (such as North_0-0), and the vertex ID is a local number within the face (0-N).

[0048] The document structure is as follows: <Polyhedron> <Object Size> <Length>...< / Length> <Width>...< / Width> <Height>...< / Height> < / Object Dimensions> <Hemisphere Name="Northern Hemisphere"> <Layer Number="..."> <Face Number="..."> <Vertex Number="..." X="..." Y="..." Z="..." / > ... < / Face> ... < / Layer> ... < / Hemisphere> <Hemisphere Name="Southern Hemisphere"> <Layer Number="..."> <Face Number="..."> <Vertex Number="..." X="..." Y="..." Z="..." / > ... < / Face> ... < / Layer> ... < / Hemisphere> < / Polyhedron> Standardized process document, the document format is as follows: [OBJECT] objectLength =... / / Length objectWidth=... / / Width objectHeight=... / / Height faceNorthRow =... / / Number of rows on the upper hemisphere of the north face faceNorthColumn =... / / Maximum number of columns on the upper hemisphere of the north face faceSouthRow=... / / Number of rows on the lower hemisphere of the south face[[ID=Z4]] faceSouthColum =... / / Maximum number of columns on the lower hemisphere of the south face [FACE_NORTH] bC0001 =... / / Coarse grinding swing angle zC0001 =... / / Coarse grinding face rotation hC0001 =... / / Coarse grinding spindle descent height dC0001 = ... / / Slow feed rate of rough grinding spindle vC0001 = ... / / Slow feed rate of coarse grinding spindle tC0001 = ... / / Rough grinding residence time bX0001 = ... / / Fine grinding of the swing angle zX0001 = ... / / Fine grinding turning surface hX0001 = ... / / Fine grinding spindle descent height dX0001 = ... / / Slow feed rate of fine grinding spindle vX0001 = ... / / Slow feed rate for fine grinding spindle tX0001 = ... / / Fine grinding residence time [FACE_SOUTH] bC0001 = ... / / Rough grinding of the swing angle zC0001 = ... / / Rough grinding and turning hC0001 = ... / / Height of rough grinding spindle descent dC0001 = ... / / Slow feed rate of rough grinding spindle vC0001 = ... / / Slow feed rate of coarse grinding spindle tC0001 = ... / / Rough grinding residence time bX0001 = ... / / Fine grinding of the swing angle zX0001 = ... / / Fine grinding turning surface hX0001 = ... / / Fine grinding spindle descent height dX0001 = ... / / Slow feed rate of fine grinding spindle vX0001 = ... / / Slow feed rate for fine grinding spindle tX0001 = ... / / Fine grinding residence time The first two digits of the four-digit number are the layer number, and the last two digits are the surface number. The grinding machine controller can easily read the relevant parameter data of each layer and each surface.

Claims

1. A method for designing and molding architectural decorative items made of crystal material, characterized in that, include: Constructing digital models of crystal architectural ornaments using 3D modeling software; The topological data of the digital model is extracted by a script program. The topological data includes: upper / lower half division information of the parting process, layered structure, geometric features of each face, and vertex coordinates. The topology data is parsed using a process parameter conversion tool. Based on the parsing results, the core process parameters of each face are calculated: swing angle θ, rotation angle φ, and center distance d. The center distance d is the vertical distance from the boundary contour of the digital model to the rotation axis. Then, based on the characteristic parameters of the grinding machine, the processing parameters adapted to the grinding machine are further calculated through parameter mapping relationships: processing height h, retraction amount Δh, slow feed amount δ, dwell time t, and slow feed speed v. Finally, a process file adapted to the grinding machine is generated. The process document is imported into the grinding machine for processing to obtain a crystal material architectural decoration that matches the digital model.

2. The method according to claim 1, characterized in that, The process by which the script program processes the topology data includes: Spatial analysis and boundary benchmark establishment: By calculating the boundary contour of the digital model and taking its external dimension parameters, for the crystal material architectural decorations to be processed, a horizontal boundary benchmark surface of its digital model is established; Data structure construction: Create an XML document and establish a root node. Write the external dimensions of the digital model as data elements or attributes into the root node or its child nodes. For the crystal material building decorations to be processed, establish independent child nodes as containers to store the topology data related to the processing. Geometric data processing: Traverse all faces of the digital model and calculate the geometric center coordinates of each face; perform face clustering based on the ordinate, grouping faces with the same ordinate into the same level; after arranging all levels in descending order of ordinate, allocate the levels to the corresponding partial containers according to the preset horizontal boundary reference surface; record the topological structure of each face layer by layer and store the three-dimensional coordinate information of each vertex. Standardized data output: Output and store the processed geometric data.

3. The method according to claim 2, characterized in that, The process parameter conversion tool loads the XML document and parses out the topology data.

4. The method according to claim 2, characterized in that, The processed geometric data is assembled into a formatted string according to the XML Schema specification, written into an XML document, and stored on a selected storage medium.

5. The method according to claim 2, characterized in that, The script program first detects whether there is a valid active document in the modeling software, then locates the digital model and performs a geometric validity verification.

6. A grinding machine, characterized in that, It includes a spindle, cutting tool, rotary table, moving platform and controller, wherein the controller is equipped with a process document generated by the crystal material architectural decoration design and molding method according to any one of claims 1 to 5, and controls the grinding machine to process the crystal material architectural decoration based on the process document.

7. The grinding machine according to claim 6, characterized in that, The controller drives the spindle and the rotary table to perform the grinding process layer by layer and surface by surface according to the instructions in the process document.

8. The grinding machine according to claim 6, characterized in that, A pressure sensor for monitoring the grinding status is installed on the fixed base between the rotary table and the moving platform. The controller is configured to dynamically adjust the tool feed based on the pressure value measured by the pressure sensor to compensate for machining accuracy deviations caused by wear.

9. The grinding machine according to claim 8, characterized in that, The controller is configured to perform the following steps: Before processing begins, the pressure value F0 of the pressure sensor is measured and used as the initial contact force reference. The pressure value F of the pressure sensor is measured in real time during the processing. m When F m When the temperature exceeds F0+1 kgf, the grinding state is considered effective; otherwise, the state is considered non-contact. Under effective grinding contact conditions, the controller measures the real-time pressure value F. m Perform time integration; the integral value reflects the cumulative effect of tool wear. The tool feed rate is adjusted in real time based on the integral value to compensate for machining accuracy deviations caused by wear.

10. The grinding machine according to claim 6, characterized in that, The tool holder and the grinding wheel body are designed as a continuous, homogeneous, integrated rigid structure.

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