Progressive-cutting composite method for sheet metal component variable thickness and surface texture integrated machining

Abstract

The invention relates to the technical field of plate processing, in particular to a progressive-cutting composite method for integrally processing variable thickness and surface texture of a sheet metal component, which comprises the following steps of: adopting a special tool head integrated with a cutting edge and a smooth fillet, planning the motion trail and the rotation direction of the tool head, and generating a corresponding numerical control program; and the rotating direction of the tool head is dynamically switched according to a program instruction in the machining process. When the tool head rotates anticlockwise, the smooth fillet at the end of the tool head is used for leading incremental forming of the plate, and local thickness reduction is achieved; when the tool head rotates clockwise, the cutting edge on the surface of the tool head is used for conducting milling on the plate, and surface textures are formed. Compared with the prior art, manufacturing of the metal plate component with the preset thickness distribution and the surface texture can be synchronously completed, and the problems that in a traditional method, procedures are separated, efficiency is low, and cost is high are effectively solved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of sheet metal processing, in particular to a progressive-cutting composite method for integrated processing of variable-thickness and surface texture of sheet metal components. BACKGROUND

[0002] In the fields of aerospace, automobile coverings, etc., variable-thickness sheet metal components can significantly improve the overall lightweight degree and structural mechanical properties, and surface texture design can improve the friction, heat dissipation or aesthetic characteristics of the components. In traditional methods, variable-thickness processing needs to be achieved through multiple stamping or local heat treatment, while surface texture relies on etching or laser engraving, which has the problems of complicated process and high cost.

[0003] Chinese patent CN 118218983A proposes a five-axis additive-subtractive manufacturing equipment and method including a digital 3D scanner, which captures the geometric shape and surface texture of the workpiece through a three-dimensional scanner to detect defects and processing errors. Chinese patent CN 113664039A proposes a forming method for variable-thickness metal components, which uses roll forming to achieve pad-free forming of variable-thickness wall panels without heating. Chinese patent CN 119304531A proposes a variable-thickness multi-flange thin-walled part manufacturing method with a reinforcing groove structure, which uses the process method of "numerical control milling cutting + sheet metal forming + chemical milling cutting" to solve the problem of accurate geometric precision while improving the surface quality. However, the above methods have made breakthroughs in variable-thickness component processing and surface texture, but the processing scheme still has the problems of complicated process flow and complex device operation, especially the use of traditional stamping and roll forming for plastic forming still requires a press and a die, which has relatively high manufacturing cost and complex die design.

[0004] In summary, the existing technology generally has a common defect: variable-thickness forming and surface texture processing cannot be completed simultaneously in the same process by the same tool through simple motion control, resulting in fragmented production processes, low efficiency and rising comprehensive costs. SUMMARY

[0005] The purpose of the present application is to overcome the defects of the existing technology and provide a progressive-cutting composite method for integrated processing of variable-thickness and surface texture of sheet metal components, which can simultaneously complete the manufacturing of sheet metal components with predetermined thickness distribution and surface texture, effectively solving the problems of process separation, low efficiency and high cost in traditional methods.

[0006] As the beginning of the inventive concept, sheet metal incremental forming is a sheet forming technology that has emerged in recent years, with the characteristics of flexible forming mode and good forming performance, and is particularly suitable for single-piece and small-batch metal sheet product production and processing. Combined with milling material removal processing, it can quickly and flexibly realize the variable thickness processing and surface texture optimization design of thin-walled components, and has very important practical application value for reducing production cost and improving production efficiency.

[0007] The object of the application can be achieved by the following technical solutions: The application provides an incremental-cutting combined method for variable thickness and surface texture integrated processing of sheet metal components, which uses a tool head that simultaneously integrates cutting edges and smooth fillets, and realizes the integrated synchronization of variable thickness processing and surface texture design by controlling the rotation direction of the tool head, and specifically includes the following steps: S1, fixing the sheet to be processed on the workbench of the processing machine; S2, designing the motion trajectory of the tool head according to the thickness distribution law and surface texture requirements of the target component, and planning the rotation direction combination of the tool head in each processing stage, wherein the smooth fillet dominates the incremental forming processing when rotating counterclockwise, and the cutting edge dominates the milling processing when rotating clockwise; S3, setting the spindle speed and feed speed parameters of the incremental forming and milling processing respectively, and generating the numerical control program of the tool head running trajectory; S4, by executing the numerical control program, controlling the tool head to alternately perform incremental forming and milling processing according to the planned path and rotation direction, until the variable thickness and surface texture sheet metal component is completed.

[0008] Further, the end of the tool head is a hemispherical structure; The cutting edges are uniformly distributed on the surface of the tool head, wherein the number of cutting edges is 2 to 6, and the helix angle of each cutting edge relative to the axial direction of the tool head is 30° to 60°, preferably 45°, to balance the cutting efficiency and surface quality; The radius of the smooth fillet is 2mm to 5mm, preferably 3mm, and the material of the smooth fillet is cemented carbide or coated high-speed steel to enhance wear resistance and forming stability; The diameter of the tool head ranges from 10mm to 20mm, and the diameter of the tool head is dynamically adjusted according to the thickness of the sheet to reduce vibration and deformation during incremental forming and milling processing; The length of the rod connected to the end of the tool head is 50mm to 100mm, and the cutting edges extend to the middle of the rod from the tool head to adapt to the processing requirements of deep cavities or complex surfaces.

[0009] Further, the smooth fillet is provided at the end of the tool head; The cutting edge is a cemented carbide tooth; The cutting edge is a cemented carbide tooth; Or, The outermost contour point of the smooth fillet is protrudingly arranged relative to the cutting edge; The tool head first contacts the plate to cut when rotating clockwise, and the smooth fillet first contacts the workpiece to gradually form when rotating counterclockwise.

[0010] Further, in S2, the tool head motion trajectory design adopts a layered slicing algorithm, including the following steps: The three-dimensional model of the target component is decomposed into multiple processing layers, each layer having a thickness of 0.1mm to 0.5mm; The rotation direction combination of each layer is generated based on the thickness distribution map, wherein the counterclockwise rotating layer is used to build the basic forming structure, and the clockwise rotating layer is used for local milling thinning; The trajectory optimization is verified by finite element simulation to predict the plate thinning and texture formation and avoid excessive processing; The trajectory data is exported as G code, including rotation direction instructions.

[0011] Further, in S2, the rotation direction combination of each processing stage is specifically: During the movement of the tool head along the preset trajectory, the rotation direction of the tool head is dynamically switched according to the required operation mode at the current processing position, the tool head is controlled to rotate counterclockwise when local thickness thinning is required for gradual forming, and the tool head is controlled to rotate clockwise when surface texture is required to be manufactured on the formed area or original plate; The direction switching is realized through spindle direction instructions in the numerical control program.

[0012] Further, in S3, when setting the spindle speed and feed speed parameters of the gradual forming processing, the spindle speed is set in the range of 300 to 800 revolutions per minute, and the feed speed is matchedly set according to the target thickness thinning rate and material plasticity, so as to ensure the controllable material accumulation and surface quality in the gradual forming process.

[0013] Further, in S3, when setting the spindle speed and feed speed parameters of the milling processing, the spindle speed is set in the range of 1500 to 5000 revolutions per minute, so that the cutting edge obtains an effective cutting line speed, and at the same time, the feed speed is optimized according to the geometric feature size of the surface texture and the cutting depth, so as to control the cutting force and heat affected area while removing material to form texture.

[0014] Further, in S4, the alternating execution of forming and cutting processing includes: Multiple rotation direction switching in a single machining path, the switching logic is controlled by the numerical control program according to the target thickness value and texture type corresponding to different coordinate points on the path in real time, so as to realize the seamless fusion processing of the variable thickness area on the component and the complex texture pattern in space.

[0015] Further, in S4, the tool head running trajectory numerical control program controls the tool head to perform milling processing, and according to the design depth of the surface texture, the tool head is subjected to a micro reciprocating motion or vibration in the axial direction, which is superimposed with the main feeding motion of the tool head, so as to cut the micro groove or pit array with the preset depth, width and arrangement mode on the surface of the component, and form the functional surface texture.

[0016] Further, in S4, after the tool head running trajectory numerical control program controls the tool head to perform the incremental forming processing, the milling processing is switched in the same local area, and the cutting depth parameter of the milling processing is automatically compensated and set according to the actual material thickness reduction caused by the previous stage of incremental forming, so that the final component thickness is consistent with the design value and the surface texture is generated at the same time.

[0017] Compared with the prior art, the present application has the following beneficial effects: (1) Compared with the traditional stamping forming, the method is simple and easy to operate, and does not need die and wedge, which has great advantage in the manufacturing cost of sheet metal component.

[0018] (2) Compared with single incremental forming and milling processing, the method realizes innovation on the machining tool head, can realize variable thickness processing and surface texture optimization design of the component with minimum manufacturing cost, and has great practical value for widening the application of incremental forming and milling processing in the manufacturing field.

[0019] (3) The method can accurately adjust the thickness change and texture design by using the ordered control of cutting parameters and forming parameters, can meet the functional feature processing demand of complex component, has wide applicability and high machining precision. BRIEF DESCRIPTION OF DRAWINGS

[0020] Figure 1 It is a process schematic diagram of the processing process of the method of the present application; Figure 2 It is a local schematic diagram of the variable thickness component processed by the method of the present application; Figure 3 It is a local schematic diagram of the surface texture processed by the method of the present application.

[0021] In the figure: 1, tool head clamping area, 2, tool head smooth fillet, 3, tool head cutting edge, 4, forming area in the machining process, 5, cutting area in the machining process, 6, sheet metal, 7, forming process, 8, cutting process, 9, texture requiring cutting adjustment. DETAILED DESCRIPTION

[0022] Overall, the present application is suitable for the integrated generation of sheet metal components with variable thickness and surface texture, using a specially designed tool head with smooth fillets and cutting edges, by controlling the rotation direction and motion trajectory of the tool head, to realize the synchronous machining of different functional features of the sheet metal in different areas. When using the cutting edge for milling, the sheet metal is significantly thinned, and the surface texture is a cutting-dominated texture feature; when using the smooth fillet for incremental forming, the sheet metal is relatively lightly thinned, and the surface texture is a forming-dominated texture feature. By this method, through appropriate process flow combination design, the thickness distribution of the sheet metal component can be efficiently and accurately controlled, and its surface topography can be optimized. Compared with the prior art, the present application can simultaneously realize the variable thickness machining and surface texture design of sheet metal components, reduce the machining process, and has flexible and mold-free machining method, low manufacturing cost, and can efficiently complete the machining of sheet metal components with special surface texture and variable thickness, and has high practical application value in the manufacturing of complex sheet metal components in the fields of aerospace and transportation.

[0023] The present application will be described in detail below with reference to the accompanying drawings and specific examples. In this technical solution, if the preparation means, materials, structure or composition ratio and other features are not explicitly stated, they are considered as common technical features disclosed in the prior art.

[0024] Example 1 In this embodiment, the incremental-cutting composite method for integrated machining of sheet metal component variable thickness and surface texture uses a tool head that integrates cutting edges and smooth fillets, and controls the rotation direction of the tool head to realize the integrated synchronization of variable thickness machining and surface texture design, which specifically includes the following steps: S1, fixing the sheet metal to be machined on the workbench of the machining machine; S2, designing the motion trajectory of the tool head according to the thickness distribution law and surface texture requirements of the target component, and planning the rotation direction combination of the tool head in each machining stage, wherein counterclockwise rotation is dominated by smooth fillet incremental forming, and clockwise rotation is dominated by cutting edge milling; In specific implementation, the end of the tool head used in the present application is a hemispherical structure; The cutting edges are uniformly distributed on the surface of the tool head, wherein the number of cutting edges is 2 to 6, and the helix angle of each cutting edge relative to the axial direction of the tool head is 30° to 60°, preferably 45°, to balance the cutting efficiency and surface quality; The radius of the smooth fillet is 2mm to 5mm, preferably 3mm, and the material of the smooth fillet is cemented carbide or coated high speed steel to enhance wear resistance and form stability; The diameter of the tool head ranges from 10mm to 20mm, and the diameter of the tool head is dynamically adjusted according to the thickness of the sheet metal to ensure reduced vibration and deformation in incremental forming and milling; The length of the rod connected to the end of the tool head is 50mm to 100mm, and the cutting edge extends from the tool head to the middle of the rod to meet the processing needs of deep cavities or complex surfaces.

[0025] In specific implementation, the smooth fillet is provided at the end of the tool head; The cutting edge is a cemented carbide tooth; The cutting edge is located within the theoretical profile surface of the smooth fillet, Or,The outermost contour point of the smooth fillet is protruding relative to the cutting edge; When the tool head rotates clockwise, the tooth first contacts the sheet metal for cutting, and when it rotates counterclockwise, the smooth fillet first contacts the workpiece for incremental forming. In specific implementation, in S2, the tool head motion trajectory design adopts a layered slicing algorithm, including the following steps:

[0026] The three-dimensional model of the target component is decomposed into multiple processing layers, each with a thickness of 0.1mm to 0.5mm; The rotation direction combination of each layer is generated based on the thickness distribution map, where counterclockwise rotating layers are used to build the basic forming structure, and clockwise rotating layers are used for local milling thinning; Trajectory optimization is verified by finite element simulation to predict sheet metal thinning and texture formation and avoid excessive processing; The trajectory data is exported as G code, including rotation direction instructions.

[0027] In specific implementation, in S2, the rotation direction combination of each processing stage is specifically: During the movement of the tool head along the preset trajectory, the rotation direction of the tool head is dynamically switched according to the required operation mode at the current processing position, and when incremental forming for local thickness thinning is required, the tool head is controlled to rotate counterclockwise, and when surface texture is required on the formed area or original sheet metal, the tool head is controlled to rotate clockwise; The direction switching is realized through spindle direction instructions in the numerical control program.

[0028] The core of step S2 is to use a special tool head with a hemispherical structure at the end and integrated with a smooth fillet made of hard alloy or high-speed steel and multiple spiral cutting edges, and to distribute the machining tasks by precisely controlling the rotation direction. In terms of structure, the outermost contour point of the smooth fillet of the tool head is arranged to protrude from the cutting edge, or in geometric relationship, the cutting edge is ensured to be located within the fillet contour surface. This key design enables the smooth fillet to preferentially contact and extrude the sheet material to realize gradual forming when rotating counterclockwise in the axial feed, while the cutting edge effectively cuts into the material to mill when rotating clockwise.

[0029] Based on this, the planning of the motion trajectory adopts a layered slicing algorithm, which decomposes the three-dimensional model of the target component according to a preset layer thickness, and embeds the corresponding rotation direction instruction combination in the generated path according to the thickness reduction or texture processing requirements of each layer area. The planning process is verified and optimized through finite element simulation, and finally forms a numerical control program containing the feed path, machining depth and spindle rotation direction instructions, so as to accurately coordinate the forming and cutting actions of the tool head in space and time sequence, and realize integrated control from geometric design to physical machining.

[0030] S3, set the spindle speed and feed speed parameters of gradual forming and milling respectively, and generate the numerical control program of the tool head running track; In specific implementation, in S3, when setting the spindle speed and feed speed parameters of gradual forming, the spindle speed is set in the range of 300 to 800 revolutions per minute, and the feed speed is set in matching with the target thickness reduction rate and material plasticity, so as to ensure the controllable material accumulation and surface quality in the gradual forming process.

[0031] In specific implementation, in S3, when setting the spindle speed and feed speed parameters of milling, the spindle speed is set in the range of 1500 to 5000 revolutions per minute, so that the cutting edge obtains effective cutting line speed, and at the same time, the feed speed is optimized according to the geometric feature size of the surface texture and the cutting depth, so as to control the cutting force and heat affected zone while removing material to form texture.

[0032] Step S3, for the gradual forming process dominated by smooth round corners, the material removal mainly relies on extrusion and plastic flow rather than shear, so the spindle speed is set in the range of 300 to 800 rpm, to reduce the instantaneous force and heat input, and the feed speed is set according to the target thickness reduction rate and the specific sheet metal plasticity, to cooperatively control the material flow accumulation behavior and the forming surface quality. In contrast, for the milling process dominated by cutting edges, the goal is to efficiently and accurately remove material to form textures, so the spindle speed is greatly increased to 1500 to 5000 rpm, to provide sufficient linear speed for the cutting edges to form effective shear, and the feed speed is optimized according to the micro-geometric size of the desired texture and the cutting depth, the core of which is to suppress excessive cutting force and cutting heat through the cooperative control of speed parameters to avoid processing damage while ensuring the accuracy of texture forming. These two sets of optimized speed and feed parameters are compiled into the tool head's running trajectory data, together forming a complete numerical control program to drive the execution of the composite machining process.

[0033] S4, by executing the numerical control program, controls the tool head to alternately perform gradual forming and milling machining according to the planned path and rotation direction, until the variable thickness and surface textured sheet metal component is completed.

[0034] In specific implementation, in S4, the alternately performed forming and cutting machining includes: Multiple rotation direction switches on a single machining path, with the switching logic being controlled by the numerical control program in real time according to the target thickness values and texture types corresponding to different coordinate points on the path, to achieve seamless fusion machining of the variable thickness region and complex texture pattern on the component in space.

[0035] In specific implementation, in S4, when the tool head running trajectory numerical control program controls the tool head in the milling machining stage, a micro-amplitude reciprocating motion or vibration is applied to the tool head in the axial direction according to the design depth of the surface texture, and this motion is superimposed with the main feed motion of the tool head to cut micro-groove or pit arrays with a preset depth, width and arrangement on the component surface, forming a functional surface texture.

[0036] In specific implementation, in S4, when the tool head running trajectory numerical control program controls the tool head to switch from gradual forming machining to milling machining in the same local area, the cutting depth parameter of the milling machining is automatically compensated and set according to the actual material thickness reduction caused by the previous stage of gradual forming, so that the final component thickness is consistent with the design value and the surface texture is generated at the same time.

[0037] The principle of step S4 is to drive the tool head to dynamically switch its working mode and motion form during the machining process by executing a numerical control program integrating the motion trajectory, rotation direction and process parameters, and finally to realize the synchronous and accurate forming of the variable-thickness structure and surface texture in space. The core is that the numerical control system controls the tool head to move along the preset path according to the program instructions, and switches the spindle rotation direction in real time according to the target thickness and texture requirements of each point on the path, so as to alternately perform incremental forming and milling on a single continuous path, and make the geometric characteristics generated by the two processing modes seamlessly integrated. In order to further control the texture morphology, the program will superimpose a micro reciprocating motion or vibration on the axial direction of the tool head during the milling stage. The superimposed motion and the main feed motion are combined to drive the cutting edge to etch a microstructure array with specific three-dimensional features on the surface of the component.

[0038] In order to ensure the thickness accuracy of the final component, when the forming is switched to milling in a local area, the system will automatically calculate and adjust the cutting depth of the milling as compensation according to the actual material thinning caused by the previous forming step, so as to generate texture while making the remaining thickness of the area accurate to the design value. The specific compensation algorithm logic is not described here.

[0039] The essence of the whole process is to integrate and control the spatial motion of the tool head, the rotation state, the axial vibration and the cutting depth by means of the numerical control program, so as to sequentially complete two different processing operations in one clamping.

[0040] Application Example 1 As shown in Figure 1 , the special tool head used is a forming tool head with a hemispherical end, and a number of cutting edges are machined on it. It includes a clamping area 1, a smooth fillet 2 and a cutting edge 3. The clamping area 1 is used to clamp the overall tool head, and the rod part should have a certain length to ensure that the machining area of the tool head can extend into the part to be machined. The smooth fillet 2 has a fillet radius of 3mm, which is used for incremental forming. The surface texture of the formed area 4 has a height of 0.02~0.2mm, and the texture form includes wave pattern, circular convex, etc. The cutting edge 3 is a spiral blade structure with an edge angle of 45°, which is used for milling. The surface texture of the cutting area 5 has a depth of 0.05~0.5mm, and the texture form includes fish scale pattern, grid pattern, etc.

[0041] In specific implementation, as shown in Figure 2 , it is an embodiment of using the tool head to process a variable-thickness component, including the following steps: Step one, fix the plate at a suitable angle on the workbench of the machining machine tool; Step two, according to the thickness variation law of the target component, first set the spindle to rotate counterclockwise, at this time the tool head smooth fillet 2 is in contact with the sheet, along the forming process 7 to apply plastic deformation to the sheet, the sheet thinning rate is low, used for processing the area with larger thickness.

[0042] Step three, switch the tool head to clockwise rotation, at this time the tool head cutting edge 3 is in contact with the sheet surface, along the cutting process 8 to make the sheet further thin, thereby processing the area with smaller thickness.

[0043] As Figure 3 shown, is an embodiment of using the tool head to adjust the surface texture of the component, including the following steps: Step one, fix the sheet at a suitable angle on the machining bed workbench; Step two, first set the spindle to rotate counterclockwise, at this time the tool head smooth fillet 2 is in contact with the sheet, along the forming process 7 to apply plastic deformation to the sheet, used for shaping the basic texture features of the sheet surface.

[0044] Step three, according to the texture requirements of the sheet surface, switch the tool head to clockwise rotation, so that the tool head cutting edge 3 is in contact with the sheet surface at the texture 9 which needs to be cut and adjusted, thereby realizing the shaping of special texture features.

[0045] The above description of the embodiments is for the purpose of enabling and using the invention by those of ordinary skill in the art. Those skilled in the art can easily make various modifications to these embodiments, and apply the general principles described herein to other embodiments without having to go through creative labor. Therefore, the present invention is not limited to the above embodiments, and the improvements and modifications made by those skilled in the art based on the disclosure of the present invention without departing from the scope of the present invention should be within the protection scope of the present invention.

Claims

1. A progressive-cutting composite method for integrated processing of variable thickness and surface texture of sheet metal components, characterized in that, Using a tool head that integrates both a cutting edge and smooth rounded corners, variable thickness machining and surface texture design are achieved simultaneously by controlling the rotation direction of the tool head. This includes the following steps: S1. Fix the sheet material to be processed onto the worktable of the processing machine tool; S2. Based on the thickness distribution pattern and surface texture requirements of the target component, design the motion trajectory of the tool head and plan the rotation direction combination of the tool head in each processing stage. When rotating counterclockwise, the smooth rounded corners dominate the progressive forming process, and when rotating clockwise, the cutting edge dominates the milling process. S3. Set the spindle speed and feed rate parameters for progressive forming and milling respectively, and generate the CNC program for the tool head running trajectory; S4. By executing the CNC program, the control tool head alternately performs progressive forming and milling operations according to the planned path and rotation direction until the sheet metal component with variable thickness and surface texture is completed.

2. The progressive-cutting composite method for integrated processing of variable thickness and surface texture of sheet metal components according to claim 1, characterized in that, The end of the tool head has a hemispherical structure; The cutting edges are evenly distributed on the surface of the tool head, with 2 to 6 cutting edges. Each cutting edge has a helix angle of 30° to 60° relative to the axis of the tool head to balance cutting efficiency and surface quality. The radius of the smooth fillet is 2mm to 5mm, and the material of the smooth fillet is hard alloy or coated high-speed steel; The diameter of the tool head ranges from 10mm to 20mm, and the diameter of the tool head is dynamically adjusted according to the thickness of the sheet material. The length of the shank connected to the end of the tool head is 50mm to 100mm, and the cutting edge extends from the tool head to the middle of the shank.

3. The progressive-cutting composite method for integrated processing of variable thickness and surface texture of sheet metal components according to claim 1, characterized in that, The smooth rounded corner is located at the end of the tool head; The cutting edge is a cemented carbide cutting tooth; The cutting edge of the cutting tool is located within the theoretical profile surface of the smooth fillet. or, The outermost contour point of the smooth rounded corner is set to protrude relative to the cutting edge of the cutting blade; When the tool head rotates clockwise, the cutting teeth first contact the sheet metal for cutting; when it rotates counterclockwise, the smooth rounded corners first contact the workpiece for progressive shaping.

4. The progressive-cutting composite method for integrated processing of variable thickness and surface texture of sheet metal components according to claim 1, characterized in that, In S2, the tool head motion trajectory design adopts a layered slicing algorithm, including the following steps: The 3D model of the target component is decomposed into multiple processing layers, each with a thickness of 0.1mm to 0.5mm; The combination of rotation directions for each layer is generated based on the thickness distribution map, where counterclockwise rotating layers are used to construct the basic forming structure, and clockwise rotating layers are used for local milling and thinning. Trajectory optimization was verified through finite element simulation to predict sheet thinning and texture formation; The trajectory data is exported as G-code, including rotation direction instructions.

5. The progressive-cutting composite method for integrated processing of variable thickness and surface texture of sheet metal components according to claim 1, characterized in that, In S2, the specific combination of rotation directions for each processing stage is planned as follows: During the movement of the tool head along the preset trajectory, the rotation direction of the tool head is dynamically switched according to the operation mode required for the current processing position. When it is necessary to perform progressive forming with local thickness reduction, the tool head is controlled to rotate counterclockwise. When it is necessary to create surface texture on the formed area or the original sheet, the tool head is controlled to rotate clockwise. The direction switching is achieved through the spindle steering command in the CNC program.

6. The progressive-cutting composite method for integrated processing of variable thickness and surface texture of sheet metal components according to claim 1, characterized in that, In S3, when setting the spindle speed and feed rate parameters for progressive forming, the spindle speed is set in the range of 300 to 800 rpm, and the feed rate is set according to the target thickness reduction rate and the material plasticity.

7. The progressive-cutting composite method for integrated processing of variable thickness and surface texture of sheet metal components according to claim 1, characterized in that, In S3, when setting the spindle speed and feed rate parameters for milling, the spindle speed is set in the range of 1500 to 5000 rpm, while the feed rate is optimized according to the geometric features of the surface texture and the depth of cut, thereby controlling the cutting force and thermal effects while removing the texture formed by the material.

8. The progressive-cutting composite method for integrated processing of variable thickness and surface texture of sheet metal components according to claim 1, characterized in that, In S4, the alternating execution of forming and cutting processes includes: Multiple rotation direction changes are performed on a single processing path. The switching logic is controlled in real time by the CNC program based on the target thickness value and texture type corresponding to different coordinate points on the path, thereby achieving seamless spatial integration of variable thickness areas and complex texture patterns on the component.

9. The progressive-cutting composite method for integrated processing of variable thickness and surface texture of sheet metal components according to claim 1, characterized in that, In S4, the CNC program controlling the tool head's running trajectory controls the tool head to apply a small axial reciprocating motion or vibration to the tool head during the milling stage, based on the designed depth of the surface texture. This motion is superimposed on the main feed motion of the tool head, thereby cutting out micro-grooves or pit arrays with preset depth, width and arrangement on the surface of the component, forming a functional surface texture.

10. The progressive-cutting composite method for integrated processing of variable thickness and surface texture of sheet metal components according to claim 1, characterized in that, In S4, when the CNC program for the tool head's running trajectory switches to milling in the same local area immediately after controlling the tool head to perform progressive forming, the cutting depth parameter of the milling will be automatically compensated and set according to the actual material thinning thickness caused by the progressive forming in the previous stage, so that the final component thickness is consistent with the design value and surface texture is generated at the same time.

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