Round corner chamfering equipment and round corner chamfering machining method

Abstract

The invention relates to the technical field of part machining, and provides a rounding device and a rounding machining method.The rounding device comprises a workbench provided with a workpiece mounting position; the rounding robot is arranged on one side of the workbench, and the rounding robot comprises a robot base, a mechanical arm and a rotating main shaft which are connected in sequence; the rotary file is detachably mounted at the tail end of the rotary main shaft and used for roughing the to-be-machined position of the workpiece; the rounding milling cutter is detachably mounted at the tail end of the rotating main shaft and is used for rounding the workpiece after the position to be machined is roughed; the controller is connected with the mechanical arm and the rotating main shaft and used for controlling movement of the mechanical arm and the rotating main shaft. Through combination of staged machining and robot intelligent control, the limitation of a traditional technology in the aspects of adaptability, quality consistency and tool loss is overcome, and high-quality and high-efficiency rounding machining is achieved.

Description

Technical Field

[0001] This application relates to the field of parts processing technology, specifically to a filleting device and a filleting processing method. Background Technology

[0002] Some piston heads and valve bodies require rounding at the cross-holes and fluid passages. Currently, this is mainly done manually using hand tools to remove burrs from the cross-holes, reduce resistance to fluid flow, improve workpiece life, and increase fluid flow efficiency. Traditional rounding methods, primarily manual filing, have the following drawbacks: inconsistent quality and difficulty in controlling overall quality; high labor intensity; and the generation of large amounts of dust during grinding, posing a threat to worker health.

[0003] To improve processing efficiency and quality, several automated or semi-automated technical solutions have emerged in the existing technology. For example, one approach is to use a dedicated stamping die, immediately after punching, to press the hole opening with a punch with a rounded cutting edge, forming a rounded corner in one step. This method is highly efficient, but it is generally only suitable for workpieces of specific specifications and simple structures. Furthermore, the die is costly and lacks flexibility, making it unsuitable for multi-variety, small-batch production. Another more advanced solution is to develop dedicated automatic chamfering equipment. This type of equipment typically integrates a tool magazine and an automatic tool changer, capable of switching between chamfering tools of different angles according to a preset program, reducing manual intervention to some extent. However, such equipment is often structurally complex, and its processing paths and tool functions are relatively fixed. Its adaptability remains insufficient when dealing with workpiece contours with complex spatial curved surfaces. Simultaneously, when processing high-hardness materials, the tool wear rate is rapid, and frequent downtime for tool changes not only affects processing efficiency (low equipment availability) but also increases production costs.

[0004] Therefore, the following challenges still exist in the field of fillet machining: traditional fillet equipment has poor adaptability and is difficult to handle a variety of workpieces; tools wear out quickly and require frequent tool replacements, resulting in low equipment availability; and automation is low, with most operations being manual and inefficient. Summary of the Invention

[0005] The purpose of this application is to provide a filleting device and a filleting processing method to at least solve the technical problems of insufficient flexible manufacturing capability and low continuous operation efficiency caused by the high specialization of equipment, rapid tool wear and high dependence on manual labor in the prior art.

[0006] To solve the above-mentioned technical problems, the embodiments of this application adopt the following technical solutions:

[0007] In a first aspect, embodiments of this application provide a filleting processing device, comprising:

[0008] A workbench is provided with a workpiece mounting position.

[0009] A rounded corner robot is located on one side of the workbench. The rounded corner robot includes a robot base, a robotic arm, and a rotating spindle connected in sequence.

[0010] A rotary file, detachably mounted at the end of the rotary spindle, is used to roughen the workpiece at the location to be machined.

[0011] A fillet end mill is detachably mounted at the end of the rotary spindle and is used to fillet the workpiece after roughing the workpiece at the location to be machined.

[0012] The controller is connected to the robotic arm and the rotating spindle respectively, and is used to control the movement of the robotic arm and the rotating spindle.

[0013] In some embodiments, the rotary file is mounted to the end of the rotary spindle via a quick-change tool holder.

[0014] In some embodiments, the rounded corner robot is a six-axis robot, and the rounded corner milling cutter is a reverse R-milling cutter.

[0015] Secondly, embodiments of this application provide a method for rounding corners, including:

[0016] The roughing path is planned based on the workpiece model of the workpiece;

[0017] The rotary file is controlled according to the roughing path to cut the workpiece layer by layer;

[0018] Construct a rounded corner trajectory line based on the workpiece shape;

[0019] The rounding end mill is controlled to cut into the workpiece to perform rounding machining according to the rounding trajectory line.

[0020] In some embodiments, before roughing the workpiece at the location to be machined, the method includes:

[0021] The tool parameters of the rotary file are determined based on the workpiece material and / or workpiece shape, wherein the tool parameters of the rotary file include at least one of the rotary file material and the rotary file shape;

[0022] The cutting speed of the rotary file is determined based on the material of the workpiece and / or the material of the rotary file;

[0023] The feed rate of the rotary file is determined based on the machining allowance and surface quality of the workpiece.

[0024] In some embodiments, during the roughing process of the workpiece, the method further includes:

[0025] The cutting force of the rotary file is monitored by a force sensor installed on the rounded corner robot;

[0026] If the cutting force of the rotary file exceeds a preset threshold, the cutting parameters of the rotary file are adjusted, wherein the cutting parameters of the rotary file include at least one of feed rate and cutting speed.

[0027] In some embodiments, controlling the rotary file to perform layer-by-layer cutting on the workpiece according to the roughing path includes:

[0028] The rotary file is controlled to approach the workpiece along a preset first trajectory at a first speed;

[0029] When the rotary file moves to a preset safe distance from the workpiece, the rotary file is controlled to reduce its speed to a first cutting speed;

[0030] The rotary file is controlled to cut layer by layer along a preset second trajectory at the first cutting speed. After each layer of cutting is completed, the robotic arm is controlled to lift the rotary file at a preset lifting height and move to the starting position of the next layer of cutting at the first speed, and then reduce the speed to the first cutting speed to enter the cutting state.

[0031] In some embodiments, before rounding the corners of the workpiece, the method includes:

[0032] Based on the workpiece parameters, determine the tool parameters of the fillet milling cutter;

[0033] The workpiece parameters include at least one of the fillet radius and workpiece accuracy.

[0034] If the fillet radius of the workpiece is a preset radius, determine that the cutting edge radius of the fillet end mill matches the preset radius;

[0035] If the workpiece is a high-precision workpiece, the cutting edge size deviation of the fillet milling cutter is determined to be within a preset deviation range.

[0036] In some embodiments, controlling the fillet milling cutter to cut into the workpiece to perform fillet machining according to the fillet trajectory line includes:

[0037] The rounded end mill is controlled to cut into the workpiece at a preset entry angle and a second speed;

[0038] The fillet end mill is controlled to cut the workpiece along the fillet trajectory at a second cutting speed, wherein the second cutting speed is greater than the second speed;

[0039] The rounded end mill is controlled to cut the workpiece at a preset cut-out angle and a third speed, wherein the cut-in angle and the cut-out angle are matched, and the second speed and the third speed are matched.

[0040] In some embodiments, during the process of rounding the corners of the workpiece, the method further includes:

[0041] Based on at least one of the workpiece material, the cutting force it bears, and the surface quality of the machined surface, adjust the cutting parameters of the fillet end mill and / or control the fillet end mill to perform parameter compensation on the workpiece;

[0042] The cutting parameters of the fillet end mill include at least one of feed rate and cutting speed, and the parameter compensation includes at least one of radius compensation and length compensation.

[0043] Thirdly, embodiments of this application provide an electronic device, including at least a memory and a processor, wherein the memory stores a computer program, and the processor implements the above-described rounding corner processing method when executing the computer program in the memory.

[0044] Fourthly, embodiments of this application provide a computer-readable storage medium storing a computer program thereon, which, when executed by a processor, implements the above-described rounding corner processing method.

[0045] This application provides a filleting device and a filleting processing method, comprising a worktable, a filleting robot, a rotary file, a filleting end mill, and a controller. The worktable has a workpiece mounting position. The filleting robot is located on one side of the worktable and includes a robot base, a robotic arm, and a rotary spindle connected in sequence. The rotary file is detachably mounted at the end of the rotary spindle for roughing the workpiece at the desired machining position. The filleting end mill is detachably mounted at the end of the rotary spindle for filleting the workpiece after roughing the desired machining position. The controller is connected to the robotic arm and the rotary spindle respectively. The connection is used to control the movement of the robotic arm and the rotary spindle. It adopts a combination of staged processing and intelligent robot control. By first using a rotary file to efficiently roughen the workpiece at the position to be processed, and then switching to a fillet milling cutter to perform precise filleting along a preset trajectory, the process achieves the purpose of quickly removing excess material in roughing and accurately forming the contour in finishing. This results in a significant improvement in processing efficiency, a significant improvement in fillet size consistency and surface finish. In turn, it solves the technical problems of poor processing adaptability, unstable product quality and rapid tool wear caused by the single function of traditional equipment, rough processing technology and low degree of automation. Attached Figure Description

[0046] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0047] Figure 1 This is a schematic diagram of the overall structure of the fillet processing equipment according to an embodiment of this application;

[0048] Figure 2 This is a partial structural diagram of the robot end effector of the rounded corner processing equipment according to an embodiment of this application;

[0049] Figure 3 This is a schematic diagram of the filleting process of the filleting equipment according to an embodiment of this application;

[0050] Figure 4 This is a schematic diagram of the structure of the rotary file of the rounding corner processing equipment according to an embodiment of this application;

[0051] Figure 5 This is a schematic diagram of the structure of the fillet milling cutter of the fillet milling equipment according to an embodiment of this application;

[0052] Figure 6 This is a flowchart of a filleting method according to an embodiment of this application.

[0053] Figure label:

[0054] 10-Workbench, 11-Workpiece mounting position, 20-Round corner robot, 21-Robot base, 22-Mechanical arm, 23-Rotary spindle, 30-Rotary file, 40-Round corner milling cutter, 401-Round corner contour line, 50-Quick change tool holder. Detailed Implementation

[0055] Various embodiments and features of this application are described herein with reference to the accompanying drawings.

[0056] It should be understood that various modifications can be made to the embodiments described herein. Therefore, the above description should not be considered as limiting, but merely as an example of embodiments. Other modifications within the scope and spirit of this application will be apparent to those skilled in the art.

[0057] The accompanying drawings, which are included in and form part of this specification, illustrate embodiments of the present application and, together with the general description of the present application given above and the detailed description of the embodiments given below, serve to explain the principles of the present application.

[0058] These and other features of this application will become apparent from the following description of preferred forms of embodiments given as non-limiting examples, with reference to the accompanying drawings.

[0059] It should also be understood that although this application has been described with reference to some specific examples, those skilled in the art can certainly implement many other equivalent forms of this application, which have the features described in the claims and are therefore all within the scope of protection defined herein.

[0060] The above and other aspects, features and advantages of this application will become more apparent when taken in conjunction with the accompanying drawings and in view of the following detailed description.

[0061] Specific embodiments of this application are described thereafter with reference to the accompanying drawings; however, it should be understood that the claimed embodiments are merely examples of this application, which can be implemented in various ways. Well-known and / or repeated functions and structures are not described in detail to avoid unnecessary or redundant details that could obscure the application. Therefore, the specific structural and functional details claimed herein are not intended to be limiting, but merely serve as the basis and representative basis for the claims to teach those skilled in the art to use this application in a variety of substantially any suitable detailed structures.

[0062] This specification may use the phrases “in one embodiment,” “in another embodiment,” “in yet another embodiment,” or “in other embodiments,” all of which may refer to one or more of the same or different embodiments according to this application.

[0063] Example 1

[0064] Figure 1 This paper shows a schematic diagram of the overall structure of the fillet processing equipment according to an embodiment of the present application. Figure 2 A partial structural schematic diagram of the robot end effector of the rounding corner processing equipment according to an embodiment of this application is shown. Figure 3 This paper shows a schematic diagram of the filleting process using a filleting equipment according to an embodiment of this application. Figure 4 A schematic diagram of the structure of the rotary file according to an embodiment of this application is shown. Figure 5 A schematic diagram of the fillet milling cutter according to an embodiment of this application is shown. Figures 1 to 5 As shown in the figure, an embodiment of this application provides a filleting processing device, comprising:

[0065] Workbench 10, wherein a workpiece mounting position 11 is provided on the workbench 10;

[0066] A rounded corner robot 20 is disposed on one side of the workbench 10. The rounded corner robot 20 includes a robot base 21, a robotic arm 22 and a rotating spindle 23 connected in sequence.

[0067] A rotary file 30 is detachably mounted at the end of the rotary spindle 23 and is used to roughen the workpiece at the position to be processed.

[0068] The fillet end mill 40 is detachably mounted at the end of the rotary spindle 23 and is used to fillet the workpiece after roughing the workpiece at the position to be machined.

[0069] The controller is connected to the robotic arm 22 and the rotating spindle 23 respectively, and is used to control the movement of the robotic arm 22 and the rotating spindle 23.

[0070] The worktable 10 is used to clamp gear parts and can achieve precise indexing rotation.

[0071] The rounding robot 20 is responsible for carrying cutting tools (including a rotary file 30 and a rounding end mill 40) and performing complex movements in three-dimensional space. The rounding robot 20 includes a robot base 21, a robotic arm 22, and a rotary spindle 23 connected in sequence. The robot base 21 provides a stable mounting foundation, ensuring the stability of the robot body. The robotic arm 22 refers to the arm structure of the robot with multiple joints, possessing extremely high degrees of freedom and flexibility, capable of reaching different positions and angles of the workpiece to be machined, and adapting to complex contours. The rotary spindle 23, mounted at the end of the robotic arm 22, is the power output unit. Its main function is high-speed rotation, providing the power and torque required for cutting the rotary file 30 or the rounding end mill 40. The workpiece mounting position 11 includes a piston head to be rounded. The workpiece is mounted on the piston head, and the rotary spindle 23, driven by the robotic arm 22, moves above the piston head, driving the cutting tool to cut the workpiece and machine the rounded corners.

[0072] The rotary file 30 is used for roughing. Roughing refers to the process of quickly and extensively removing excess material before the final shape of the workpiece. In this application, it refers to the initial cutting of the workpiece's workpiece location using the rotary file 30. The rotary file 30 is characterized by its large chip space and high cutting efficiency. Its main task is to quickly and extensively remove excess material from the workpiece's opening, thereby approximating the final fillet shape.

[0073] The fillet end mill 40 is mounted at the end of the rotary spindle 23 and is used to fillet the workpiece after roughing the workpiece at the desired location. Filleting refers to a precision machining process where, after roughing, sharp edges or openings of the workpiece are cut to form a rounded transition of a specific radius. In this application, filleting refers to the final shaping process performed on the workpiece using the fillet end mill 40, such as... Figure 3 As shown, the fillet milling cutter 40 can cut along the fillet contour line 401 to obtain a fillet.

[0074] The controller can be an integrated computer control system, based on an industrial PC or a high-performance PLC. The controller is connected to the robotic arm 22 and the rotary spindle 23 respectively, controlling their movements to control the tool movement and cutting. The controller also coordinates the entire rounding process: based on the workpiece's CAD model, it calculates the optimal trajectory for the robotic arm 22 to drive the tool; precisely controls the movement of each joint of the robotic arm 22 and the start / stop and speed of the spindle; manages the machining sequence, such as controlling automatic tool changing and switching between machining stages; receives feedback signals from force sensors and other sources, and adjusts cutting parameters in real time to cope with tool wear or material changes, ensuring stable machining quality, etc.

[0075] The workflow of the fillet machining equipment can be summarized as follows: First, the workpiece is clamped on the fixture of the worktable 10. Then, the controller instructs the robotic arm 22 to move to the tool change position, install the rotary file 30, and then perform efficient roughing on all the holes to be machined on the workpiece according to the preset path. After roughing is completed, the robotic arm 22 returns to the tool change position, automatically unloads the rotary file 30, and replaces it with a fillet end mill 40. Next, the controller instructs the robotic arm 22 to carry the fillet end mill 40 and fillet the hole openings along the finishing trajectory to form high-quality fillets. Finally, the machining is completed, the robotic arm 22 resets, and the workpiece is removed, thus achieving high efficiency and full automation of the machining process.

[0076] In some embodiments, such as Figure 2 As shown, the rotary file 30 is mounted on the end of the rotary spindle 23 via a quick-change tool holder 50.

[0077] Specifically, the quick-change tool holder 50 is a precision interface device used to achieve rapid and accurate connection and disconnection between the cutting tool and the machine tool spindle. The quick-change tool holder 50 allows for quick replacement of the rotary file 30 at the end of the rotary spindle 23. Furthermore, the fillet end mill 40 can also be mounted at the end of the rotary spindle 23 via the quick-change tool holder 50 during operation. This application employs a staged machining method, that is, roughing is first performed using the rotary file 30, and then finishing is performed by switching to the fillet end mill 40.

[0078] In some embodiments, the rounded corner robot 20 is a six-axis robot, and the rounded corner milling cutter 40 is a reverse R-milling cutter.

[0079] In this embodiment, the rounded corner robot 20 is a six-axis robot. The six-axis robot has six independently controllable rotary joints, and its range of motion almost simulates the entire movement of a human arm from shoulder to wrist. The six-axis robot can easily and precisely deliver the cutting tool to these openings in any desired spatial orientation, solving the problems of poor equipment adaptability and difficulty in handling various types of workpieces.

[0080] The fillet end mill 40 is preferably a reverse radius end mill. R represents radius, and a reverse radius end mill is a form end mill whose cutting edge is precisely ground into a concave arc. The radius of this arc matches the fillet radius (R-angle) required on the workpiece drawing. When machining fillets with a conventional end mill, complex programming is required to control the fillet end mill 40 to move along a three-dimensional curve, approximating the fillet shape through multiple points. This method is inefficient and requires extremely high programming and machine tool precision, making it difficult to guarantee consistency. However, the cutting edge of the reverse radius end mill itself is the "negative shape" of the target fillet. Therefore, during machining, the rounded cutting edge of the fillet end mill 40 only needs to move along the edge of the hole once to directly machine a fillet with accurate dimensions, making it a highly efficient and precise forming process.

[0081] The chamfering processing equipment provided in this embodiment includes a worktable 10, a chamfering robot 20, a rotary file 30, a chamfering end mill 40, and a controller. The worktable 10 has a workpiece mounting position 11. The chamfering robot 20 is located on one side of the worktable 10 and includes a robot base 21, a robotic arm 22, and a rotary spindle 23 connected in sequence. The rotary file 30 is detachably mounted at the end of the rotary spindle 23 for roughing the workpiece at the desired processing position. The chamfering end mill 40 is detachably mounted at the end of the rotary spindle 23 for chamfering the workpiece after roughing the desired processing position. The controller is connected to the robotic arm 22 and the workpiece mounting position 11. The rotating spindle 23 is connected to control the movement of the robotic arm 22 and the rotating spindle 23. It adopts a combination of staged processing and intelligent robot control. By first using a rotating file 30 to efficiently roughen the workpiece to be processed, and then using a fillet milling cutter 40 to precisely fillet the corners along a preset trajectory, the process achieves the purpose of quickly removing excess material in roughing and accurately forming the contour in finishing. This achieves the technical effect of significantly improving processing efficiency, significantly improving the consistency of fillet dimensions and surface finish, and thus solving the technical problems of poor processing adaptability, unstable product quality and rapid tool wear caused by the single function of traditional equipment, rough processing technology and low degree of automation.

[0082] Example 2

[0083] Figure 6 A flowchart of the filleting method according to an embodiment of this application is shown, as follows: Figure 6 As shown in the figure, this application provides a method for rounding corners, including:

[0084] S101: Calculate the roughing path based on the workpiece model of the workpiece;

[0085] S102: Control the rotary file 30 to cut the workpiece layer by layer according to the roughing path;

[0086] S103: Construct a rounded corner trajectory line based on the workpiece shape;

[0087] S104: Control the fillet milling cutter 40 to cut into the workpiece to perform fillet machining according to the fillet trajectory line.

[0088] In step S101, the robot plans the roughing path based on the workpiece model. First, it obtains the accurate model of the workpiece through a 3D scanning device or CAD model import. The control system uses the built-in path planning algorithm to plan the movement trajectory of the tool on the model according to the roughing process requirements, such as removing material uniformity and avoiding collision between the tool and the workpiece.

[0089] Then, in step S102, specifically, the rotary file 30 is controlled to perform layer-by-layer cutting on the workpiece according to the roughing path, including:

[0090] S1021: Control the rotary file 30 to approach the workpiece along a preset first trajectory at a first speed;

[0091] S1022: When the rotary file 30 moves to a preset safe distance from the workpiece, control the rotary file 30 to reduce its speed to the first cutting speed;

[0092] S1023: Control the rotary file 30 to perform layer-by-layer cutting along a preset second trajectory at the first cutting speed. After each layer of cutting is completed, control the robotic arm 22 to lift the rotary file 30 at a preset lifting height, and control the robotic arm 22 to move to the starting position of the next layer of cutting at the first speed, and reduce the speed to the first cutting speed to enter the cutting state.

[0093] First, the robotic arm 22, carrying the rotary file 30, approaches the workpiece at a first speed along a preset first trajectory. The first trajectory is an optimized spatial path, designed primarily to avoid collisions with the workpiece and fixtures, and secondarily to minimize the path length, ensuring the tool moves smoothly from one safe point to another. The first speed refers to the rapid traverse speed. During the non-cutting phase, the highest speed allowed by the equipment is used to minimize auxiliary time and improve overall machining efficiency.

[0094] Then, when the distance to the workpiece reaches a preset safe distance, the speed gradually decreases, entering the first cutting speed. The preset safe distance is based on the robot's motion characteristics and the response time of the control system, ensuring sufficient time and distance for the tool to decelerate smoothly and avoid impacting the workpiece at excessive speed. The first cutting speed refers to the optimal cutting line speed set for the roughing stage. This speed is scientifically calculated or empirically set based on factors such as workpiece material and tool material, aiming to balance machining efficiency and tool life.

[0095] Finally, the rotary file 30 begins cutting along a preset second path. The second path is the machining path the tool travels to remove material on the current cutting layer. The second path typically involves cutting layer by layer along the contour of the workpiece, with the depth of cut for each layer controlled within a suitable range, generally between 0.5 and 2 millimeters. The specific value is determined based on factors such as the workpiece material, the size of the rotary file 30, and the cutting parameters.

[0096] In this process, after each layer of cutting is completed, the robotic arm 22 lifts the rotary file 30 to a preset lifting height, quickly moves it to the starting position of the next layer, reduces its speed again, and enters the cutting state at the first speed. This process is repeated until all roughing tasks are completed. The lifting height refers to the distance the tool is lifted upward along the Z-axis after completing one layer of cutting. It is necessary to ensure that the tool can safely pass over the workpiece and fixture and move to the starting point of the next layer without collision.

[0097] For example, when roughening the edges of a cuboid workpiece, path planning might follow the workpiece's edge contour, employing a layered, progressively deeper approach. Each layer maintains a consistent cutting depth, with some overlap between adjacent layers to ensure uniform material removal. Layer-by-layer cutting divides the total machining allowance into multiple thin layers, cutting one layer at a time. For instance, a 3mm total depth allowance might be divided into three layers, each with a 1mm depth of cut. This method reduces the load on a single cut, facilitates chip removal and heat dissipation, protects the tool, and achieves a relatively uniform machining allowance, preparing the workpiece for finishing.

[0098] In step S103, a fillet trajectory line is constructed based on the workpiece shape. First, the starting point, ending point, and transition curve of the fillet are determined through analysis of the workpiece model. For simple straight-line edge fillets, the trajectory line is an arc tangent to the edge; for complex curved surface edges, the trajectory line needs to be precisely calculated using mathematical algorithms, such as spline curve fitting, to ensure the trajectory line smoothly conforms to the curved surface edge. When compiling the machining program based on the trajectory line, specialized offline programming software is used to convert the coordinate data of the trajectory line into code that the CNC system can recognize. During programming, parameters such as tool movement speed, feed rate, and depth of cut are set.

[0099] In step S104, specifically, controlling the fillet milling cutter 40 to cut into the workpiece according to the fillet trajectory line to perform fillet machining includes:

[0100] S1041: Control the rounded corner end mill 40 to cut into the workpiece at a preset entry angle and a second speed;

[0101] S1042: Control the fillet end mill 40 to cut the workpiece along the fillet trajectory line at a second cutting speed, wherein the second cutting speed is greater than the second speed;

[0102] S1043: Control the rounded end mill 40 to cut the workpiece at a preset cutting angle and a third speed, wherein the cutting angle and the cutting angle are matched, and the second speed and the third speed are matched.

[0103] In step S1041, when the robot performs fillet machining with the fillet end mill 40, the fillet end mill 40 slowly cuts into the workpiece at a preset entry angle and a second speed. The entry angle is generally between 10° and 30° to avoid the large impact force generated when the fillet end mill 40 cuts directly perpendicularly, which could damage the fillet end mill 40 and the workpiece. The second speed refers to the use of a lower feed rate at the moment of contact, approximately 50%-70% of the normal cutting speed. The lower entry speed reduces the instantaneous cutting force, giving the control system sufficient response time to stabilize the cutting process and further avoid impact.

[0104] In step S1042, the fillet end mill 40 cuts the workpiece along the fillet trajectory line generated in step S103 at a second cutting speed to ensure that the fillet end mill 40 produces accurate and correctly shaped fillets. The second cutting speed is greater than the second speed, achieving maximum machining efficiency while ensuring surface quality and the lifespan of the fillet end mill 40.

[0105] In step S1043, after machining is completed, the fillet end mill 40 cuts out the workpiece in a manner similar to the entry process. The exit angle and the third speed are matched with those during the entry process, thereby ensuring that the machined fillet is not damaged during the exit process. The matching of the entry and exit angles ensures the mechanical symmetry of the entire contact and separation process, avoiding uneven force at the end of the workpiece. The matching of the second and third speeds ensures that the exit process is as gentle as the entry process.

[0106] In some embodiments, before roughing the workpiece at the location to be machined, the method includes:

[0107] S201: Determine the tool parameters of the rotary file 30 according to the workpiece material and / or workpiece shape, wherein the tool parameters of the rotary file 30 include at least one of the rotary file 30 material and the rotary file 30 shape;

[0108] S202: Determine the cutting speed of the rotary file 30 based on the workpiece material and / or the material of the rotary file 30;

[0109] S203: Determine the feed rate of the rotary file 30 based on the machining allowance and surface quality of the workpiece.

[0110] In step S201, on the one hand, the material of the rotary file 30 is selected according to the workpiece material. If the workpiece is a high-hardness alloy steel, a rotary file 30 made of high-performance high-speed steel or cemented carbide should be selected. Rotary files 30 made of these materials have high hardness and strong wear resistance, which can effectively meet the cutting requirements of alloy steel. If the workpiece is a softer material such as aluminum alloy, an ordinary high-speed steel rotary file 30 can be selected, which has a lower cost and can meet the processing requirements. On the other hand, the shape of the rotary file 30 is determined according to the shape of the workpiece. For roughing of flat or large-curvature surfaces, a cylindrical or conical rotary file 30 can be selected. For some workpieces with complex contours, such as those with grooves or corners, ball-head or irregularly shaped rotary files 30 are more suitable.

[0111] In step S202, the cutting speed is set according to the workpiece material and the material of the rotary file 30. For workpieces with high hardness, such as hardened steel, the cutting speed will be relatively low in order to ensure the durability of the tool, generally around tens of meters per minute; while for softer materials, such as copper alloys, the cutting speed can be appropriately increased, reaching hundreds of meters per minute.

[0112] In step S203, the feed rate is adjusted according to the machining allowance and surface quality requirements of the workpiece. When the machining allowance is large, the feed rate can be appropriately increased to improve machining efficiency. However, an excessively large feed rate may affect the surface quality, so a balance needs to be found between the two. For example, in the roughing stage, the allowance may be several millimeters, in which case a larger feed rate can be selected to achieve efficient material removal. If the surface after roughing is not required to be too rough, the feed rate needs to be appropriately reduced while ensuring efficiency to obtain a relatively smooth surface to be finished.

[0113] In some embodiments, during the roughing process of the workpiece, the method further includes:

[0114] S301: The cutting force of the rotary file 30 is monitored by a force sensor installed on the rounded corner robot 20;

[0115] S302: If the cutting force of the rotary file 30 exceeds a preset threshold, adjust the cutting parameters of the rotary file 30, wherein the cutting parameters of the rotary file 30 include at least one of feed rate and cutting speed.

[0116] Specifically, during the cutting process, the force sensor of the rounding robot 20 monitors the cutting force of the rotary file 30 in real time. When the cutting force of the rotary file 30 exceeds a preset threshold, the controller automatically adjusts the cutting parameters, such as reducing the feed rate or increasing the cutting speed, to ensure the stability of the cutting process. For example, when tool wear causes the cutting force to increase slowly, appropriately increasing the rotational speed may change the cutting state and slow down the upward trend of the force. This embodiment improves the ability of the rounding robot 20 to cope with various abnormal situations such as uneven material, compensating for tool wear, and adapting to changes in machining allowance, significantly reducing the risk of failures such as tool breakage and machine collisions.

[0117] In some embodiments, before rounding the corners of the workpiece, the method includes:

[0118] S401: Determine the tool parameters of the fillet end mill 40 based on the workpiece parameters;

[0119] S402: Wherein, the workpiece parameters include at least one of the fillet radius and workpiece accuracy.

[0120] S403: If the fillet radius of the workpiece is a preset radius, determine that the cutting edge radius of the fillet end mill 40 matches the preset radius;

[0121] S404: If the workpiece is a high-precision workpiece, determine that the cutting edge size deviation of the rounded corner milling cutter 40 is within the preset deviation range.

[0122] Specifically, first, select a fillet milling cutter 40 according to the fillet radius of the workpiece. If the required fillet radius of the workpiece is 5 mm, then select a fillet milling cutter 40 with a matching cutting edge radius to ensure that the required fillet radius can be accurately machined.

[0123] Secondly, for workpieces requiring high precision, such as aero-engine parts, the selected rounded end mill 40 should have high precision, and the dimensional deviation of the cutting edge should be controlled within a very small range, generally within ±0.01 mm.

[0124] In addition, in terms of material properties, the fillet end mill 40 is usually made of cemented carbide, which has high hardness and good wear resistance. It can withstand high-speed cutting and large cutting forces, ensuring the dimensional accuracy and cutting performance of the fillet end mill 40 during long-term machining.

[0125] In some embodiments, during the process of rounding the corners of the workpiece, the method further includes:

[0126] S501: Adjust the cutting parameters of the fillet end mill 40 and / or control the fillet end mill 40 to perform parameter compensation on the workpiece according to at least one of the workpiece material, the cutting force it bears, and the surface quality of the machined surface;

[0127] S502: Wherein, the cutting parameters of the fillet end mill 40 include at least one of feed rate and cutting speed, and the parameter compensation includes at least one of radius compensation and length compensation.

[0128] During the rounding process, the cutting parameters are adjusted in real time according to the workpiece material, the cutting force, and the surface quality. If obvious scratches or roughness that does not meet the requirements are found on the machined surface, the cutting speed or feed rate is reduced appropriately. If the cutting force is too small, the feed rate can be increased appropriately to improve the machining efficiency.

[0129] This embodiment considers the compensation function of the fillet end mill 40, such as radius compensation or length compensation, to ensure the accuracy of the machined fillet dimensions. Radius compensation refers to compensating for radial wear of the fillet end mill 40. After use, the radius of the fillet end mill 40's cutting edge arc will slightly decrease due to wear, resulting in a fillet radius smaller than the theoretical value. The system predicts or measures the actual radius wear of the fillet end mill 40 based on its lifespan management or online measurement. Then, when generating the fillet end mill 40 path, the system is instructed to offset the fillet end mill 40 trajectory outwards from the workpiece by a compensation value (e.g., 0.01mm), thereby machining a circle with accurate dimensions. Length compensation refers to compensating for axial installation errors or length wear of the fillet end mill 40. After each tool change, the extended length of the fillet end mill 40 may vary by micrometers; the end face of the fillet end mill 40 will also wear slightly. The system measures the deviation between the actual length of the fillet end mill 40 and the standard value using a tool setter or contact sensor. During machining, the system will make a corresponding offset in the Z-axis direction to ensure accurate cutting depth.

[0130] The filleting method provided in this application corresponds to the filleting equipment in the above embodiments. Any option in the filleting equipment embodiments is also applicable to the embodiments of the filleting method, and will not be repeated here.

[0131] The above description is merely a preferred embodiment of this application and an explanation of the technical principles employed. Those skilled in the art should understand that the scope of disclosure in this application is not limited to technical solutions formed by specific combinations of the above-described technical features, but should also cover other technical solutions formed by arbitrary combinations of the above-described technical features or their equivalents without departing from the above-described concept. For example, technical solutions formed by substituting the above features with (but not limited to) technical features with similar functions disclosed in this application.

[0132] Furthermore, while the operations are described in a specific order, this should not be construed as requiring these operations to be performed in the specific order shown or in a sequential order. Multitasking and parallel processing may be advantageous in certain environments. Similarly, while several specific implementation details are included in the above discussion, these should not be construed as limiting the scope of this application. Certain features described in the context of individual embodiments may also be implemented in combination in a single embodiment. Conversely, various features described in the context of a single embodiment may also be implemented individually or in any suitable sub-combination in multiple embodiments.

Claims

1. A corner rounding device, characterized in that, include: A workbench is provided with a workpiece mounting position. A rounded corner robot is located on one side of the workbench. The rounded corner robot includes a robot base, a robotic arm, and a rotating spindle connected in sequence. A rotary file, detachably mounted at the end of the rotary spindle, is used to roughen the workpiece at the location to be machined. A fillet end mill is detachably mounted at the end of the rotary spindle and is used to fillet the workpiece after roughing the workpiece at the location to be machined. The controller is connected to the robotic arm and the rotating spindle respectively, and is used to control the movement of the robotic arm and the rotating spindle.

2. The filleting device according to claim 1, characterized in that, The rotary file is mounted to the end of the rotary spindle via a quick-change tool holder.

3. The filleting device according to claim 1, characterized in that, The rounded corner robot is a six-axis robot, and the rounded corner milling cutter is a reverse R-milling cutter.

4. A method for rounding corners, characterized in that, The method, applied to the filleting device according to any one of claims 1 to 3, comprises: The roughing path is planned based on the workpiece model of the workpiece; The rotary file is controlled according to the roughing path to cut the workpiece layer by layer; Construct a rounded corner trajectory line based on the workpiece shape; The rounding end mill is controlled to cut into the workpiece to perform rounding machining according to the rounding trajectory line.

5. The method according to claim 4, characterized in that, Before roughing the workpiece at the location to be machined, the method includes: The tool parameters of the rotary file are determined based on the workpiece material and / or workpiece shape, wherein the tool parameters of the rotary file include at least one of the rotary file material and the rotary file shape; The cutting speed of the rotary file is determined based on the material of the workpiece and / or the material of the rotary file; The feed rate of the rotary file is determined based on the machining allowance and surface quality of the workpiece.

6. The method according to claim 4, characterized in that, During the roughing process of the workpiece, the method further includes: The cutting force of the rotary file is monitored by a force sensor installed on the rounded corner robot; If the cutting force of the rotary file exceeds a preset threshold, the cutting parameters of the rotary file are adjusted, wherein the cutting parameters of the rotary file include at least one of feed rate and cutting speed.

7. The method according to claim 4, characterized in that, The rotary file is controlled to perform layer-by-layer cutting on the workpiece according to the roughing path, including: The rotary file is controlled to approach the workpiece along a preset first trajectory at a first speed; When the rotary file moves to a preset safe distance from the workpiece, the rotary file is controlled to reduce its speed to a first cutting speed; The rotary file is controlled to cut layer by layer along a preset second trajectory at the first cutting speed. After each layer of cutting is completed, the robotic arm is controlled to lift the rotary file at a preset lifting height and move to the starting position of the next layer of cutting at the first speed, and then reduce the speed to the first cutting speed to enter the cutting state.

8. The method according to claim 4, characterized in that, Before performing filleting on the workpiece, the method includes: Based on the workpiece parameters, determine the tool parameters of the fillet milling cutter; The workpiece parameters include at least one of the fillet radius and workpiece accuracy. If the fillet radius of the workpiece is a preset radius, determine that the cutting edge radius of the fillet end mill matches the preset radius; If the workpiece is a high-precision workpiece, the cutting edge size deviation of the fillet milling cutter is determined to be within a preset deviation range.

9. The method according to claim 4, characterized in that, Controlling the fillet milling cutter to cut into the workpiece according to the fillet trajectory line to perform fillet machining includes: The rounded end mill is controlled to cut into the workpiece at a preset entry angle and a second speed; The fillet end mill is controlled to cut the workpiece along the fillet trajectory at a second cutting speed, wherein the second cutting speed is greater than the second speed; The rounded end mill is controlled to cut the workpiece at a preset cut-out angle and a third speed, wherein the cut-in angle and the cut-out angle are matched, and the second speed and the third speed are matched.

10. The method according to claim 4, characterized in that, During the process of rounding the corners of the workpiece, the method further includes: Based on at least one of the workpiece material, the cutting force it bears, and the surface quality of the machined surface, adjust the cutting parameters of the fillet end mill and / or control the fillet end mill to perform parameter compensation on the workpiece; The cutting parameters of the fillet end mill include at least one of feed rate and cutting speed, and the parameter compensation includes at least one of radius compensation and length compensation.

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