A progressive cutting and composite method for integrated processing of variable thickness and surface texture of sheet metal components
By integrating cutting edges with smooth, rounded tool heads and using CNC programs to control the rotation direction and motion trajectory, the process of varying thickness and surface texture of sheet metal components can be integrated. This solves the problems of low efficiency and high cost caused by process separation in traditional methods, and enables the efficient and low-cost manufacturing of complex sheet metal components.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- SHANGHAI JIAOTONG UNIV
- Filing Date
- 2025-12-12
- Publication Date
- 2026-07-03
AI Technical Summary
Existing technologies cannot achieve integrated processing of sheet metal components with varying thickness and surface texture through simple motion control in the same process, resulting in fragmented production processes, low efficiency, and high overall costs.
By employing a tool head that integrates cutting edges and smooth rounded corners, and controlling the rotation direction and movement trajectory of the tool head, synchronous processing of varying thickness and surface texture can be achieved. Combining progressive forming and milling, the rotation direction and movement trajectory of the tool head are controlled by a CNC program to achieve integrated synchronous processing.
It simplifies the processing steps, reduces manufacturing costs, and improves production efficiency. It can efficiently and accurately control the thickness distribution and surface morphology of sheet metal components and is suitable for manufacturing complex sheet metal components.
Smart Images
Figure CN121374178B_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of sheet metal processing technology, and in particular to a progressive-cutting composite method for the integrated processing of variable thickness and surface texture of sheet metal components. Background Technology
[0002] In aerospace, automotive body panels, and other fields, variable thickness sheet metal components can significantly improve overall lightweighting and structural mechanical properties, while surface texture design can improve the friction, heat dissipation, or aesthetic characteristics of the components. In traditional methods, variable thickness processing requires multiple stamping passes or local heat treatment, while surface texture relies on etching or laser engraving, which are cumbersome and costly.
[0003] Chinese patent CN 118218983A proposes a five-axis additive-subtractive manufacturing equipment and method incorporating a digital 3D scanner. This method uses a 3D scanner to capture the geometry and surface texture of the workpiece, enabling defect detection and machining error detection. Chinese patent CN 113664039A proposes a forming method for variable-thickness metal components, employing roll forming to achieve pad-free forming of variable-thickness panels without heating. Chinese patent CN 119304531A proposes a manufacturing method for variable-thickness multi-bent thin-walled parts with reinforcing grooves, using a process of "CNC milling blanking + sheet metal forming + chemical milling," which improves both geometric accuracy and surface quality. However, while these methods have made breakthroughs in the processing and surface texturing of variable-thickness components, their processing schemes still suffer from cumbersome processes and complex equipment operation. In particular, traditional stamping and roll forming methods still require presses and molds, resulting in relatively high manufacturing costs and complex mold designs.
[0004] In summary, existing technologies generally suffer from a common defect: variable thickness forming and surface texture processing cannot be completed simultaneously in the same process using the same tool through simple motion control, resulting in a fragmented production process, low efficiency, and increased overall costs. Summary of the Invention
[0005] The purpose of this invention is to overcome the shortcomings of the prior art by providing a progressive-cutting composite method for the integrated processing of sheet metal components with varying thickness and surface texture. This method 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 starting point of this invention, progressive sheet forming is a sheet forming technology that has emerged in recent years. It features flexible forming methods and good forming performance, making it particularly suitable for the production and processing of single-piece and small-batch metal sheet products. Combining it with milling and cutting processes can quickly and flexibly achieve variable thickness processing of thin-walled components and optimized surface texture design, which has significant practical application value for reducing production costs and improving production efficiency.
[0007] The objective of this invention can be achieved through the following technical solutions:
[0008] This invention provides a progressive-cutting composite method for integrated processing of variable thickness and surface texture of sheet metal components. It utilizes a tool head that integrates both a cutting edge and smooth fillet, and achieves integrated and simultaneous processing of variable thickness and surface texture design by controlling the rotation direction of the tool head. Specifically, it includes the following steps:
[0009] S1. Fix the sheet material to be processed onto the worktable of the processing machine tool;
[0010] 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.
[0011] 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;
[0012] 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.
[0013] Furthermore, the end of the tool head has a hemispherical structure;
[0014] The cutting edges are evenly distributed on the surface of the tool head, with the number of cutting edges being 2 to 6. The helix angle of each cutting edge relative to the axis of the tool head is 30° to 60°, preferably 45°, to balance cutting efficiency and surface quality.
[0015] The radius of the smooth fillet is 2mm to 5mm, preferably 3mm, and the material of the smooth fillet is hard alloy or coated high-speed steel to enhance wear resistance and forming stability.
[0016] 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 during progressive forming and milling.
[0017] 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 to accommodate the machining needs of deep cavities or complex curved surfaces.
[0018] Furthermore, the smooth rounded corner is located at the end of the tool head;
[0019] The cutting edge is a cemented carbide cutting tooth;
[0020] The cutting edge of the cutting tool is located within the theoretical profile surface of the smooth fillet.
[0021] or,
[0022] The outermost contour point of the smooth rounded corner is set to protrude relative to the cutting edge of the cutting blade;
[0023] 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.
[0024] Furthermore, in S2, the tool head motion trajectory design adopts a layered slicing algorithm, including the following steps:
[0025] The 3D model of the target component is decomposed into multiple processing layers, each with a thickness of 0.1mm to 0.5mm;
[0026] 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.
[0027] Trajectory optimization is verified through finite element simulation, predicting sheet thinning and texture formation to avoid over-processing;
[0028] The trajectory data is exported as G-code, including rotation direction instructions.
[0029] Furthermore, in S2, the specific combinations of rotation directions for each processing stage are planned as follows:
[0030] 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.
[0031] The direction switching is achieved through the spindle steering command in the CNC program.
[0032] Furthermore, in S3, when setting the spindle speed and feed rate parameters for incremental forming, the spindle speed is set in the range of 300 to 800 rpm, and the feed rate is set in a matching manner according to the target thickness reduction rate and material plasticity, thereby ensuring that the material accumulation and surface quality of the incremental forming process are controllable.
[0033] Furthermore, 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 to ensure that the cutting edge obtains an effective cutting speed. At the same time, the feed rate is optimized based on the geometric features of the surface texture and the depth of cut, thereby controlling the cutting force and thermal effects while removing the material to form texture.
[0034] Furthermore, in S4, the alternating execution of forming and cutting processes includes:
[0035] 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.
[0036] Furthermore, 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.
[0037] Furthermore, 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.
[0038] Compared with the prior art, the present invention has the following beneficial effects:
[0039] (1) Compared with traditional stamping, the method of the present invention is simple and easy to implement, and does not require molds and wedges, which has a huge advantage in the manufacturing cost of sheet metal components.
[0040] (2) Compared with single incremental forming and milling, the method of the present invention has achieved innovation in the machining tool head, which can realize the variable thickness processing and surface texture optimization design of components with minimal manufacturing cost. The process is simple and easy to operate, which has great practical value for broadening the application of incremental forming and milling in the manufacturing field.
[0041] (3) The method of the present invention utilizes the orderly control of cutting parameters and forming parameters to precisely adjust the thickness variation and texture characteristics, which can meet the functional feature processing requirements of complex components, has wide applicability and high processing accuracy. Attached Figure Description
[0042] Figure 1 This is a schematic diagram of the processing procedure of the method of the present invention;
[0043] Figure 2 This is a partial schematic diagram of the method for processing variable thickness components according to the present invention;
[0044] Figure 3 This is a partial schematic diagram of the surface texture processed by the method of the present invention.
[0045] In the diagram: 1. Tool head holding area; 2. Smooth rounded corners of the tool head; 3. Cutting edge of the tool head; 4. Forming area during machining; 5. Cutting area during machining; 6. Sheet metal; 7. Forming process; 8. Cutting process; 9. Texture that needs to be adjusted by cutting. Detailed Implementation
[0046] Overall, this invention is applicable to the integrated generation of sheet metal components with varying thicknesses and surface textures. Utilizing a specially designed tool head with smooth rounded corners and cutting edges, the rotation direction and trajectory of the tool head are controlled to simultaneously process the functional features of different areas of the sheet metal. Specifically, when milling with the cutting edges, the sheet metal is significantly thinned, and the surface texture is dominated by cutting characteristics. When using smooth rounded corners for progressive forming, the sheet metal thinning is relatively minor, and the surface texture is dominated by forming characteristics. Through this method, and with appropriate process flow design, the thickness distribution of sheet metal components can be efficiently and accurately controlled, and their surface morphology optimized. Compared with existing technologies, this invention can simultaneously achieve variable thickness processing and surface texture design for sheet metal components, reducing processing steps, offering flexible and moldless processing methods, and lower manufacturing costs. It can efficiently complete the processing of sheet metal components with special surface textures and varying thicknesses, and has high practical application value in the manufacturing of complex sheet metal components in aerospace, transportation, and other fields.
[0047] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments. Any preparation methods, materials, structures, or compositional ratios not explicitly described in this technical solution are considered common technical features disclosed in the prior art.
[0048] Example 1
[0049] This embodiment employs a progressive-cutting composite method for integrated processing of sheet metal components with varying thickness and surface texture. It utilizes a tool head that integrates both a cutting edge and smooth fillet, achieving synchronized processing of varying thickness and surface texture design by controlling the tool head's rotation direction. Specifically, the method includes the following steps:
[0050] S1. Fix the sheet material to be processed onto the worktable of the processing machine tool;
[0051] 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.
[0052] In specific implementation, the end of the tool head used in this invention has a hemispherical structure;
[0053] The cutting edges are evenly distributed on the surface of the tool head, with the number of cutting edges being 2 to 6. The helix angle of each cutting edge relative to the axis of the tool head is 30° to 60°, preferably 45°, to balance cutting efficiency and surface quality.
[0054] The radius of the smooth fillet is 2mm to 5mm, preferably 3mm, and the material of the smooth fillet is hard alloy or coated high-speed steel to enhance wear resistance and forming stability.
[0055] 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 during progressive forming and milling.
[0056] 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 to accommodate the machining needs of deep cavities or complex curved surfaces.
[0057] In practice, the smooth fillet is located at the end of the tool head;
[0058] The cutting edge is a cemented carbide cutting tooth;
[0059] The cutting edge of the cutting tool is located within the theoretical profile surface of the smooth fillet.
[0060] or,
[0061] The outermost contour point of the smooth rounded corner is set to protrude relative to the cutting edge of the cutting blade;
[0062] 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.
[0063] In specific implementation, S2 uses a layered slicing algorithm to design the tool head motion trajectory, including the following steps:
[0064] The 3D model of the target component is decomposed into multiple processing layers, each with a thickness of 0.1mm to 0.5mm;
[0065] 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.
[0066] Trajectory optimization is verified through finite element simulation, predicting sheet thinning and texture formation to avoid over-processing;
[0067] The trajectory data is exported as G-code, including rotation direction instructions.
[0068] In specific implementation, in S2, the combination of rotation directions for each processing stage is planned as follows:
[0069] 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.
[0070] The direction switching is achieved through the spindle steering command in the CNC program.
[0071] The core of step S2 is the use of a specialized tool head with a hemispherical end structure, integrating smooth rounded corners made of carbide or high-speed steel and multiple helical cutting edges. The machining task is assigned by precisely controlling its rotation direction. Structurally, the outermost contour point of the smooth rounded corner of the tool head is set to protrude beyond the cutting edge, or geometrically ensures that the cutting edge is within the rounded corner contour surface. This key design ensures that during axial feed, counterclockwise rotation guarantees that the smooth rounded corner preferentially contacts and compresses the sheet metal for progressive forming, while clockwise rotation allows the cutting edge to effectively cut into the material for milling.
[0072] Based on this, the motion trajectory planning adopts a layered slicing algorithm, which decomposes the 3D model of the target component into preset layer thicknesses, and pre-embeds corresponding rotation direction command combinations in the generated path according to the required thickness reduction or texture processing requirements of each layer. This planning process is verified and optimized through finite element simulation, ultimately forming a CNC program that includes feed path, machining depth, and spindle rotation commands. This allows for precise coordination of the tool head's forming and cutting actions in both space and time, achieving integrated control from geometric design to physical machining.
[0073] 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;
[0074] In practice, in S3, when setting the spindle speed and feed rate parameters for incremental forming, the spindle speed is set in the range of 300 to 800 rpm, and the feed rate is set in a matching manner according to the target thickness reduction rate and material plasticity, so as to ensure that the material accumulation and surface quality of the incremental forming process are controllable.
[0075] In specific implementation, 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 to ensure that the cutting edge obtains an effective cutting speed. At the same time, 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.
[0076] Step S3 targets progressive forming processes dominated by smooth fillets, where material removal relies primarily on extrusion and plastic flow rather than shearing. Therefore, the spindle speed is set to a relatively low range of 300 to 800 revolutions per minute to reduce instantaneous force and heat input. Simultaneously, the feed rate is set according to the target thickness reduction rate and the specific sheet plasticity to collaboratively control material flow and deposition behavior and surface quality. In contrast, for milling processes dominated by cutting edges, the goal is to efficiently and accurately remove material to create texture. Therefore, the spindle speed is significantly increased to 1500 to 5000 revolutions per minute to provide sufficient linear velocity for the cutting edge to create effective shearing. The feed rate is optimized based on the micro-geometry and depth of cut required for the desired texture. The core principle is to suppress excessive cutting force and heat through coordinated control of speed parameters, avoiding machining damage while ensuring texture forming accuracy. These two sets of optimized spindle speed and feed parameters are synchronously compiled into the tool head's trajectory data, together forming a complete CNC program driving the composite machining process.
[0077] 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.
[0078] In specific implementation, S4 includes the alternating execution of forming and cutting processes, including:
[0079] 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.
[0080] In specific implementation, in S4, the CNC program controlling the tool head to run its 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.
[0081] In specific implementation, in S4, when the CNC program for the tool head 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.
[0082] The principle of step S4 lies in executing a CNC program that integrates motion trajectory, rotation direction, and process parameters to drive the tool head to dynamically switch its working mode and motion form during machining, ultimately achieving synchronous and precise forming of variable thickness structures and surface textures in space. Its core is that the CNC system controls the tool head to move along a preset path according to program instructions, and switches the spindle rotation direction in real time according to the target thickness and texture requirements at each point on the path. This allows for alternating progressive forming and milling operations on a single continuous path, seamlessly integrating the geometric features generated by the two machining modes. To further control the texture morphology, the program adds micro-amplitude reciprocating motion or vibration to the tool head's axial direction during the milling stage. This additional motion, combined with the main feed motion, drives the cutting edge to etch a micro-structure array with specific three-dimensional features onto the component surface.
[0083] To ensure the final component thickness accuracy, when switching from forming to milling in a local area, the system will automatically calculate and adjust the milling depth as compensation based on the actual material thinning caused by the previous forming step. This ensures that the remaining thickness in the area accurately matches the design value while generating the texture. The specific compensation algorithm logic is existing technology and will not be elaborated here.
[0084] The essence of the whole process is to integrate and control the spatial movement, rotation state, axial vibration and cutting depth of the tool head in real time with the help of CNC program, so as to complete two machining operations with different mechanisms in sequence in one clamping.
[0085] Application Example 1
[0086] like Figure 1As shown, the specially designed tool head used is based on a hemispherical forming tool head with several cutting edges 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 entire tool head, and its shank should have a certain length to ensure that the machining area of the tool head can extend into the part of the component that needs to be machined. The smooth fillet 2 has a fillet radius of 3mm and is used for progressive forming. The surface texture of the forming area 4 produced by it has an undulation height of 0.02~0.2mm, and the texture pattern includes wavy patterns, arc protrusions, etc. The cutting edge 3 has a helical blade structure with a cutting edge inclination angle of 45° and is used for milling. The surface texture of the cutting area 5 produced by it has a depth of 0.05~0.5mm, and the texture pattern includes fish scale patterns, grid patterns, etc.
[0087] In specific implementation, such as Figure 2 The image shows an embodiment of machining a component with varying thickness using this tool head, including the following steps:
[0088] Step 1: Fix the sheet metal to the worktable of the processing machine at a suitable angle;
[0089] Step 2: Based on the thickness variation law of the target component, first set the spindle to rotate counterclockwise. At this time, the smooth rounded corner 2 of the tool head comes into contact with the sheet material and applies plastic deformation to the sheet material along the forming process 7. The sheet material thinning rate is relatively low and it is used to process areas with larger thickness.
[0090] Step 3: Switch the tool head to clockwise rotation. At this time, the cutting edge 3 of the tool head contacts the surface of the sheet material and further thins the sheet material along the cutting process 8, thereby processing a region with a smaller thickness.
[0091] like Figure 3 The image shows an embodiment of adjusting the surface texture of a component using this tool head, including the following steps:
[0092] Step 1: Fix the sheet metal to the worktable of the processing machine at a suitable angle;
[0093] Step 2: First, set the spindle to rotate counterclockwise. At this time, the smooth rounded corner 2 of the tool head comes into contact with the sheet material and applies plastic deformation to the sheet material along the forming process 7 to shape the basic texture features of the sheet material surface.
[0094] Step 3: According to the surface texture requirements of the board, switch the tool head to rotate clockwise so that the cutting edge 3 of the tool head contacts the surface of the board at the texture 9 that needs to be cut and adjusted, thereby achieving the shaping of special texture features.
[0095] The above description of the embodiments is provided to enable those skilled in the art to understand and use the invention. It will be apparent to those skilled in the art that various modifications can be made to these embodiments, and the general principles described herein can be applied to other embodiments without inventive effort. Therefore, the present invention is not limited to the above embodiments, and any 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 invention should be within the protection scope of the present invention.
Claims
1. A progressive cutting and composite method for integrated processing of thickness variation and surface texture of sheet metal components, characterized by, 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 tool head is controlled to alternately perform 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. 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. 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.
2. The method of claim 1, wherein the method is a hybrid method of incremental cutting and progressive cutting for the integrated processing of the variable thickness and surface texture of the sheet metal member. 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.
3. The method of claim 1, wherein the method is a hybrid method of incremental cutting and progressive cutting for the integrated processing of the variable thickness and surface texture of the sheet metal member. 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.
4. The method of claim 1, wherein the method is a hybrid method of incremental cutting and progressive cutting for the integrated processing of the variable thickness and surface texture of the sheet metal member. 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.
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 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.
6. The method of claim 1, wherein the method is a hybrid method of incremental cutting and progressive cutting for the integrated processing of the variable thickness and surface texture of the sheet metal member. 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.
7. The method of claim 1, wherein the method is a hybrid method of incremental cutting and material removal for the integrated processing of variable thickness and surface texture of sheet metal components. 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.
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, 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.