Forming control system and method of CNC mold

Abstract

The invention discloses a forming control system and method for a CNC mold. The system comprises a data acquisition module which is configured to acquire graphic data and performance data of a to-be-processed mold; the data processing module is configured to generate a first tool path used for machining the to-be-machined mold on the basis of the graphic data and the performance data; the monitoring module is configured to obtain monitoring data of a plurality of first preset positions arranged on the first tool path; the correction module is configured to execute correction on the first tool path based on the monitoring data to obtain a second tool path; and a compensation module configured to generate a compensation signal and perform predictive compensation of a plurality of second preset positions of the second tool path. The method can comprehensively consider the influence of thermal deformation, and has real-time monitoring and self-adaptive compensation capabilities.

Description

CNC mold forming control system and method Technical Field

[0001] This invention relates to the field of numerical control technology, specifically to a forming control system and method for CNC molds. Background Technology

[0002] With the increasing demand for precision molds in modern manufacturing, CNC (Computer Numerical Control) mold machining technology has become a core process in high-precision mold manufacturing. In fields such as aerospace, automotive, and precision optics, the machining accuracy of mold cavities directly affects the performance and quality of the final product. However, during CNC machining, factors such as material thermal deformation, tool vibration, and interlayer cumulative deformation often make it difficult to achieve the design accuracy, especially when machining complex cavity structures.

[0003] Currently, traditional CNC mold machining systems mainly rely on preset fixed toolpaths for machining, lacking the ability to monitor and dynamically adjust the real-time status during the machining process. When the material undergoes thermal expansion under the influence of cutting heat, or when the tool vibrates during high-speed cutting, the system cannot promptly detect and correct the resulting machining deviations. Although some advanced systems have introduced simple compensation mechanisms, these compensations are usually based on empirical parameters or static models, failing to fully consider the dynamic relationship between material properties, geometric features, and machining parameters, resulting in limited compensation effectiveness.

[0004] Furthermore, existing systems often fail to adequately consider the matching relationship between material hardness, coefficient of thermal expansion, and other performance data and tool properties during toolpath planning. When machining high-hardness materials, failure to adjust the depth of cut and path smoothness accordingly can easily lead to accelerated tool wear and decreased surface quality. When machining areas requiring high precision, failure to improve path interpolation accuracy makes it difficult to meet stringent tolerance requirements. These factors collectively limit the accuracy and efficiency of CNC mold machining, making it difficult to meet the demands of modern high-precision mold manufacturing. Summary of the Invention

[0005] To address the above problems, this invention provides a CNC mold forming control system and method.

[0006] A first aspect of the present invention provides a forming control system for CNC mold processing, comprising: a data acquisition module configured to acquire graphic data and performance data of a mold to be processed; a data processing module configured to generate a first toolpath for processing the mold to be processed based on the graphic data and the performance data; a monitoring module configured to acquire monitoring data at a plurality of first preset positions set on the first toolpath; a correction module configured to perform correction on the first toolpath based on the monitoring data to obtain a second toolpath; and a compensation module configured to generate a compensation signal and perform predictive compensation at a plurality of second preset positions on the second toolpath.

[0007] As a preferred embodiment, when the data processing module generates the first toolpath, it performs the following steps: It obtains mold cavity data from the graphic data, the mold cavity data including the three-dimensional contour of the cavity and the coordinates of key feature points; based on the material thermal expansion coefficient in the performance data and the total mold height in the dimensional data, it divides the mold cavity into multiple layers to be processed, wherein the thickness of each layer to be processed is adjusted according to the material thermal expansion coefficient to compensate for thermal deformation during processing; for each layer to be processed, based on the contour dimension of that layer in the dimensional data and the material hardness in the performance data, it matches tool attribute parameters, including tool diameter, tool length, and depth of cut, and determines the first path for that layer to be processed based on the matching result, wherein: when the material hardness is higher than a preset threshold, the depth of cut is reduced and the path smoothness is increased; when the tolerance band of the contour dimension is less than a preset range, the path interpolation accuracy is improved; it determines a second path from one layer to be processed to another, the second path considering the tool length in the tool attribute parameters and the expected deformation in the performance data, and by calculating the slope and feed rate of the transition region, it avoids tool interference and compensates for cumulative deformation between layers.

[0008] As a preferred embodiment, the monitoring module is configured to perform the following steps: real-time acquisition of tool vibration amplitude data, machining area temperature data, and actual position deviation data at multiple first preset positions along the first toolpath; comparison of the tool vibration amplitude data with a preset vibration threshold to generate a vibration exceeding signal; comparison of the actual position deviation data with the theoretical coordinates of the first toolpath to calculate the position deviation vector, and outputting the monitoring data.

[0009] As a preferred embodiment, the correction module performs correction on the first toolpath based on the monitoring data to obtain a second toolpath, including the following steps: analyzing the position deviation vector and vibration exceedance signal in the monitoring data to identify abnormal path segments in the first toolpath that exceed the dimensional tolerance zone; for the abnormal path segments, recalculating the offset of the tool center trajectory based on the material hardness in the performance data to generate a local correction path; adjusting the feed rate and spindle speed in the corresponding area of ​​the first toolpath based on the vibration exceedance signal to suppress vibration and reduce cutting force fluctuations; integrating the local correction path and the adjusted speed parameters to generate the second toolpath, wherein the second toolpath includes a corrected geometric trajectory and optimized speed parameters.

[0010] As a preferred embodiment, the compensation module generates a compensation signal and performs predictive compensation for multiple second preset positions of the second toolpath, including the following steps: based on the historical records of the monitoring data and the current execution state of the second toolpath, predicting the path deviation trend caused by material thermal deformation and tool wear in subsequent machining at the second preset position in the second toolpath; calculating the predicted compensation amount, which includes a path coordinate offset and a feed rate adjustment, wherein the path coordinate offset is generated based on the expected deformation amount in the performance data, and the feed rate adjustment is corrected in real time based on the temperature data in the monitoring data; generating a compensation signal to adjust the tool position and speed in real time at the second preset position to compensate for the predicted deviation and ensure machining accuracy.

[0011] As a preferred embodiment, the compensation module is further configured to: continuously receive monitoring data updated by the monitoring module and update the predicted compensation amount during the execution of the second toolpath; when the position deviation vector in the monitoring data exceeds a threshold, trigger an emergency compensation mechanism to generate an additional compensation signal to correct the remaining part of the second toolpath; and output a compensated execution command to enable the tool to achieve accuracy compensation at the second preset position.

[0012] As a preferred embodiment, the compensation module is further configured to perform the following steps: Calculate a cumulative deformation trend based on historical corrections and thermal deformation data generated during the execution of the first toolpath, wherein the historical corrections include the offset vector of the local correction path determined by the correction module when generating the second toolpath, and the thermal deformation data includes the temperature change rate, material thermal expansion coefficient, and interlayer deformation transfer amount collected by the monitoring module; assign an influence coefficient of the cumulative deformation trend according to the layering position of each layer to be processed in the mold cavity, wherein the influence coefficient of the bottom layer to be processed is amplified based on the layer height weight in the dimensional data to reflect the cumulative effect of deformation transfer upwards, while the influence coefficient of the top layer to be processed is attenuated based on the expected deformation amount in the performance data to compensate for deformation convergence caused by surface heat dissipation; for multiple second preset positions of the second toolpath, multiply the influence coefficient by the cumulative deformation trend to calculate a position compensation component and a speed compensation component, wherein the position compensation component adjusts the tool coordinate offset according to the current layer sequence of the layer to be processed, and the speed compensation component corrects the feed rate in real time according to the temperature gradient in the thermal deformation data to eliminate the influence of interlayer cumulative deformation on machining accuracy.

[0013] A second aspect of the present invention provides a forming control method for CNC mold machining, comprising the following steps: acquiring graphic data and performance data of the mold to be machined; generating a first tool path based on the graphic data and the performance data; acquiring monitoring data of a plurality of first preset positions on the first tool path; correcting the first tool path based on the monitoring data to obtain a second tool path; generating a compensation signal and performing predictive compensation on a plurality of second preset positions on the second tool path.

[0014] Compared with existing technologies, this invention has the following advantages: First, through a layered dynamic adjustment mechanism in the data processing module, this invention achieves precise matching between toolpath and material properties. Based on the material's thermal expansion coefficient and the total height of the mold, the system divides the mold cavity into multiple layers to be processed, and dynamically matches tool property parameters according to the contour dimensions and material hardness of each layer. When the material hardness is higher than a preset threshold, the cutting depth is automatically reduced and the path smoothness is increased; when the contour dimension tolerance zone is smaller than a preset range, the path interpolation accuracy is improved. This adaptive path planning based on material properties significantly improves the stability of the machining process and the surface quality.

[0015] Secondly, this invention provides comprehensive and real-time status awareness for the machining process through multi-source data fusion technology in the monitoring module. The system integrates a vibration sensor array, an infrared temperature sensor, and a high-precision position encoder to collect vibration amplitude, temperature changes, and position deviation data in real time at key locations along the toolpath, and dynamically adjusts the data fusion weights according to the material type. This multi-dimensional status monitoring provides a reliable data foundation for subsequent path correction and compensation, effectively solving the problem of insufficient monitoring in traditional systems.

[0016] Third, the correction module of this invention achieves dual optimization of geometric trajectory and speed parameters, effectively solving the vibration and deformation problems. The system can not only identify abnormal path segments exceeding the dimensional tolerance zone and recalculate the tool center trajectory offset, but also dynamically adjust the feed rate and spindle speed based on vibration exceedance signals. This synergistic optimization of geometric and dynamic parameters significantly reduces vibration and cutting force fluctuations during machining, resulting in a marked improvement in the surface quality of curved surfaces.

[0017] The most innovative aspect of this invention is that the compensation module overcomes the limitations of traditional single-point compensation through cumulative deformation trend analysis and layered differential compensation. The system calculates the cumulative deformation trend based on historical correction values ​​and thermal deformation data, and dynamically allocates influence factors according to the location of the layer to be processed. This layered differential compensation mechanism accurately reflects the physical characteristics of deformation at the bottom layer being transmitted upwards and amplified, while deformation at the top layer converges due to heat dissipation, effectively eliminating the impact of interlayer cumulative deformation on processing accuracy.

[0018] This invention significantly improves the machining accuracy of mold cavities. Compared to traditional CNC machining systems, it effectively addresses accuracy deviations caused by material deformation and vibration, greatly enhancing the consistency and reliability of mold machining and providing strong technical support for high-precision mold manufacturing. Furthermore, its modular design and parametric configuration give it excellent adaptability and scalability, allowing for flexible adjustments to molds of different materials and structures, thus possessing broad application prospects and market value. Attached Figure Description

[0019] The present invention will be further described with reference to the accompanying drawings, but the embodiments in the drawings do not constitute any limitation on the present invention. For those skilled in the art, other drawings can be obtained based on the following drawings without creative effort.

[0020] Figure 1 is a schematic diagram of the system provided in an embodiment of the present invention. Detailed Implementation

[0021] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] This disclosure provides a forming control system for CNC mold machining, as shown in Figure 1, including a data acquisition module, a data processing module, a monitoring module, a correction module, and a compensation module. This system aims to acquire mold machining data, correct toolpaths in real time, and perform predictive compensation, thereby solving the accuracy deviation problem caused by material deformation and vibration in traditional CNC machining and significantly improving the machining quality of mold cavities.

[0023] A first aspect of this embodiment provides a forming control system for CNC mold processing, comprising: a data acquisition module configured to acquire graphic data and performance data of a mold to be processed; a data processing module configured to generate a first toolpath for processing the mold to be processed based on the graphic data and the performance data; a monitoring module configured to acquire monitoring data set at a plurality of first preset positions on the first toolpath; a correction module configured to perform correction on the first toolpath based on the monitoring data to obtain a second toolpath; and a compensation module configured to generate a compensation signal and perform predictive compensation at a plurality of second preset positions on the second toolpath.

[0024] As a preferred embodiment, when the data processing module generates the first toolpath, it performs the following steps: It obtains mold cavity data from the graphic data, the mold cavity data including the three-dimensional contour of the cavity and the coordinates of key feature points; based on the material thermal expansion coefficient in the performance data and the total mold height in the dimensional data, it divides the mold cavity into multiple layers to be processed, wherein the thickness of each layer to be processed is adjusted according to the material thermal expansion coefficient to compensate for thermal deformation during processing; for each layer to be processed, based on the contour dimension of that layer in the dimensional data and the material hardness in the performance data, it matches tool attribute parameters, including tool diameter, tool length, and depth of cut, and determines the first path for that layer to be processed based on the matching result, wherein: when the material hardness is higher than a preset threshold, the depth of cut is reduced and the path smoothness is increased; when the tolerance band of the contour dimension is less than a preset range, the path interpolation accuracy is improved; it determines a second path from one layer to be processed to another, the second path considering the tool length in the tool attribute parameters and the expected deformation in the performance data, and by calculating the slope and feed rate of the transition region, it avoids tool interference and compensates for cumulative deformation between layers.

[0025] As a preferred embodiment, the monitoring module is configured to perform the following steps: real-time acquisition of tool vibration amplitude data, machining area temperature data, and actual position deviation data at multiple first preset positions along the first toolpath; comparison of the tool vibration amplitude data with a preset vibration threshold to generate a vibration exceeding signal; comparison of the actual position deviation data with the theoretical coordinates of the first toolpath to calculate the position deviation vector, and outputting the monitoring data.

[0026] As a preferred embodiment, the correction module performs correction on the first toolpath based on the monitoring data to obtain a second toolpath, including the following steps: analyzing the position deviation vector and vibration exceedance signal in the monitoring data to identify abnormal path segments in the first toolpath that exceed the dimensional tolerance zone; for the abnormal path segments, recalculating the offset of the tool center trajectory based on the material hardness in the performance data to generate a local correction path; adjusting the feed rate and spindle speed in the corresponding area of ​​the first toolpath based on the vibration exceedance signal to suppress vibration and reduce cutting force fluctuations; integrating the local correction path and the adjusted speed parameters to generate the second toolpath, wherein the second toolpath includes a corrected geometric trajectory and optimized speed parameters.

[0027] As a preferred embodiment, the compensation module generates a compensation signal and performs predictive compensation for multiple second preset positions of the second toolpath, including the following steps: based on the historical records of the monitoring data and the current execution state of the second toolpath, predicting the path deviation trend caused by material thermal deformation and tool wear in subsequent machining at the second preset position in the second toolpath; calculating the predicted compensation amount, which includes a path coordinate offset and a feed rate adjustment, wherein the path coordinate offset is generated based on the expected deformation amount in the performance data, and the feed rate adjustment is corrected in real time based on the temperature data in the monitoring data; generating a compensation signal to adjust the tool position and speed in real time at the second preset position to compensate for the predicted deviation and ensure machining accuracy.

[0028] As a preferred embodiment, the compensation module is further configured to: continuously receive monitoring data updated by the monitoring module and update the predicted compensation amount during the execution of the second toolpath; when the position deviation vector in the monitoring data exceeds a threshold, trigger an emergency compensation mechanism to generate an additional compensation signal to correct the remaining part of the second toolpath; and output a compensated execution command to enable the tool to achieve accuracy compensation at the second preset position.

[0029] As a preferred embodiment, the compensation module is further configured to perform the following steps: Calculate a cumulative deformation trend based on historical corrections and thermal deformation data generated during the execution of the first toolpath, wherein the historical corrections include the offset vector of the local correction path determined by the correction module when generating the second toolpath, and the thermal deformation data includes the temperature change rate, material thermal expansion coefficient, and interlayer deformation transfer amount collected by the monitoring module; assign an influence coefficient of the cumulative deformation trend according to the layering position of each layer to be processed in the mold cavity, wherein the influence coefficient of the bottom layer to be processed is amplified based on the layer height weight in the dimensional data to reflect the cumulative effect of deformation transfer upwards, while the influence coefficient of the top layer to be processed is attenuated based on the expected deformation amount in the performance data to compensate for deformation convergence caused by surface heat dissipation; for multiple second preset positions of the second toolpath, multiply the influence coefficient by the cumulative deformation trend to calculate a position compensation component and a speed compensation component, wherein the position compensation component adjusts the tool coordinate offset according to the current layer sequence of the layer to be processed, and the speed compensation component corrects the feed rate in real time according to the temperature gradient in the thermal deformation data to eliminate the influence of interlayer cumulative deformation on machining accuracy.

[0030] A second aspect of this embodiment provides a forming control method for CNC mold processing, comprising the following steps: acquiring graphic data and performance data of the mold to be processed; generating a first tool path based on the graphic data and the performance data; acquiring monitoring data of multiple first preset positions on the first tool path; correcting the first tool path based on the monitoring data to obtain a second tool path; generating a compensation signal and performing predictive compensation on multiple second preset positions on the second tool path.

[0031] Specifically, in this embodiment, the data acquisition module is configured to acquire graphic data and performance data of the mold to be processed. In this embodiment, the graphic data includes a 3D model file in STL format, containing the surface coordinate point cloud and dimensional tolerance zone information of the mold cavity. The performance data includes material hardness, coefficient of thermal expansion, and expected deformation. The data acquisition module connects to the CAD design system via an industrial Ethernet interface, acquires data in real time, and stores it in a local cache. The sampling accuracy of the graphic data is 0.01 mm, and the update frequency of the performance data is 10 Hz, ensuring that the system can respond promptly to changes in material properties. This module employs a data verification mechanism; when the graphic data is found to be missing key feature point coordinates, a retransmission request is automatically triggered to ensure the integrity of the data in subsequent processing.

[0032] Specifically, in this embodiment, the data processing module is configured to generate a first toolpath based on graphic data and performance data. In this embodiment, the data processing module first extracts the three-dimensional contour data of the mold cavity from the graphic data, with an accuracy of 0.005 mm, and the coordinates of key feature points, totaling 128 feature points; then, based on the material thermal expansion coefficient in the performance data, ranging from 12 to 18 × 10⁻⁶, it generates a first toolpath. -6 / °C, and the total height of the mold in the dimensional data, ranging from 50mm to 300mm, divide the mold cavity into 20 to 150 layers to be processed, with the thickness of each layer adjusted according to the thermal expansion characteristics, for example, when the coefficient of thermal expansion is 15×10. -6 At a temperature of / °C and a total mold height of 200mm, the layer thickness compensation is 0.06mm. For each layer to be processed, the system matches tool attribute parameters based on the layer's contour dimensions, with a minimum feature size of 0.5mm, and material hardness ranging from 30 to 60HRC. Tool attribute parameters include tool diameter, tool length, and depth of cut. When the material hardness is higher than 45HRC, a 3mm diameter carbide ball end mill is automatically selected, with a tool length of 50mm, and the depth of cut is reduced from 0.2mm to 0.1mm, while the path smoothness parameter is increased from 0.8 to 0.95. When the contour dimension tolerance is less than ±0.01mm, the path interpolation accuracy is increased from 0.001mm to 0.0005mm. The calculation of the second path between layers considers a tool length of 50mm and the expected deformation, ranging from 50μm to 200μm. The slope of the transition region is fitted using a B-spline curve, and the feed rate is calculated using the formula F=F0×(1-δ / δ). max Adjustment: F0 is the reference rate of 1000 mm / min, δ is the deformation of the current layer, δ max The maximum deformation is 200μm, ensuring no interference during interlayer transition.

[0033] Specifically, the monitoring module in this embodiment is configured to acquire monitoring data at multiple first preset positions along the first toolpath. In this embodiment, the monitoring module integrates a vibration sensor array, an infrared temperature sensor, and a high-precision position encoder, setting the first preset positions at 5mm intervals along the first toolpath. The system collects three types of data in real time: tool vibration amplitude (generating a vibration exceeding the limit signal when the measured value exceeds 2.5g), machining area temperature (used for thermal deformation analysis), and actual position deviation (calculated by comparing the encoder with theoretical coordinates, with a maximum allowable deviation of ±5μm). For example, when machining aerospace aluminum alloy molds with a material hardness of 40HRC, the system densifies monitoring points in key curved surface areas to one every 2mm, increasing the temperature sampling frequency to 100Hz to ensure accurate capture of thermal deformation.

[0034] Specifically, in this embodiment, the correction module is configured to correct the first toolpath based on monitoring data to obtain a second toolpath. In this embodiment, the correction module first analyzes the position deviation vector in the monitoring data, for example, detecting a +8μm deviation in the cavity bottom region and a vibration exceeding the standard signal of three consecutive vibrations higher than 3g in the curved transition area. Then, it identifies abnormal path segments that exceed the dimensional tolerance zone. Subsequently, for the abnormal segments, the tool center trajectory offset is recalculated based on the material hardness of 45HRC, using the formula Δr=K×(H-H0), K=0.02μm / HRC, and H0 is the reference hardness of 40HRC, to generate a local correction path with an offset of +2.5μm. At the same time, based on the vibration exceeding the standard signal, the feed rate in the corresponding area is reduced from 1000mm / min to 700mm / min, and the spindle speed is reduced from 8000rpm to 6000rpm to suppress vibration. Finally, the local correction path and speed parameters are integrated to generate the second toolpath. In this embodiment, the core difference between the second toolpath and the first toolpath is that the geometric trajectory is offset and the speed parameters are optimized according to spatial location partitions, thereby improving the surface quality of the curved surface.

[0035] Specifically, the compensation module in this embodiment is configured to generate compensation signals and perform predictive compensation at multiple second preset positions on the second toolpath. In this embodiment, the compensation module first stores the most recent 100 monitoring points based on the historical records of monitoring data, the current execution status of the second toolpath, the remaining path length, and the current layer sequence, to predict the path deviation trend in subsequent machining. For example, when the temperature gradient is higher than 10°C / mm, the predicted X-axis deviation trend caused by thermal deformation is +0.5μm / mm. Then, the predicted compensation amount is calculated, and the path coordinate offset is calculated according to the formula Δx=β×δ. e Generate, β is the material deformation coefficient 0.7, δ e To achieve an expected deformation of 150 μm, the feed rate adjustment is corrected based on temperature data using the formula ΔF = F × (T - T0) / T0, where T0 = 25°C. Finally, a compensation signal is generated, and at the second preset position, at each key feature point of the layer, the tool position is adjusted with an accuracy of ±0.1 μm, and the speed is adjusted in steps of 50 mm / min. In this embodiment, the system further performs cumulative deformation compensation. Based on the historical corrections generated during the execution of the first toolpath, the cumulative offset vector is 12.5 μm, and the thermal deformation data, with a temperature change rate of 5°C / min and an inter-layer deformation transfer of 30%, the cumulative deformation trend is calculated. An influence coefficient is assigned according to the position of the layer to be processed, with the influence coefficient = 1.5 - k × current layer sequence, where k is the average deformation weight. Finally, for the second preset position, the position compensation component is calculated as cumulative deformation trend × influence coefficient, with a compensation amount of +15.6 μm for the bottom layer and +7.2 μm for the top layer. The speed compensation component is adjusted in real-time according to the temperature gradient, with a 15% speed reduction when the gradient exceeds 8°C / mm.

[0036] Specifically, in this embodiment, the compensation module is configured to continuously update the predicted compensation amount. In this embodiment, the system updates the cumulative deformation trend model after completing each layer to be processed. When the position deviation vector in the monitoring data exceeds the threshold three times consecutively (threshold = current layer sequence × 0.05 μm), an emergency compensation mechanism is triggered, generating an additional compensation signal, reducing the feed rate of the remaining path by 20%, and inserting a micro-compensation path segment with a length of 0.1 mm at key feature points. The compensation amount is equal to the deviation vector × 1.2. When processing an automotive body panel mold with a total height of 180 mm, the system detects a position deviation vector of +6.2 μm at layer 120, with a threshold of 6.0 μm. Emergency compensation is immediately executed to ensure that the final cavity size accuracy meets the requirements.

[0037] The compensation module is also configured for layer-specific compensation. In this embodiment, for a 150-layer mold structure, the influence coefficient of the bottom layer is amplified to 1.2 to 1.5 times, the influence coefficient of the middle layer remains at 1.0 times, and the influence coefficient of the top layer is attenuated to 0.6 to 0.8 times. For example, when machining a stainless steel mold, the coefficient of thermal expansion is 17 × 10⁻⁶. -6 At / °C, the cumulative deformation trend of the bottom layer is 18μm, which is compensated to 25.2μm after being amplified by a factor of 1.4, while the same trend of the top layer is compensated to 12.6μm after being attenuated by a factor of 0.7, effectively eliminating the interlayer deformation transmission effect.

[0038] In this embodiment, the compensation module is configured to: dynamically allocate influence coefficients based on the position of the layer to be processed, wherein the influence coefficients are calculated using the formula I = I0 - k × n, where I is the influence coefficient, I0 is the maximum value of the bottom layer influence coefficient, k is the average deformation weight, and n is the current layer sequence; the compensation module is configured to dynamically adjust the maximum value I0 of the bottom layer influence coefficient based on the mold's graphic data and performance data, specifically including: determining an initial preset value based on the total height H of the mold, wherein the initial value is 1.2 when H < 100mm, 1.4 when 100mm ≤ H < 200mm, and 1.6 when H ≥ 200mm; and correcting the initial preset value based on the material's thermal expansion coefficient α, wherein when α < 13 × 10 -6 At / °C, subtract 0.1 from the initial value; when 13×10 -6 / °C≤α≤16×10 -6 No adjustment is made at / °C, and when α>16×10 -6At / °C, add 0.1 to the initial value; make a final adjustment to the corrected value based on the cavity complexity C, adding 0.1 when C>0.8, where the cavity complexity C is calculated by the curvature change rate and feature point density; the compensation module is configured to calculate the average deformation weight k, where k=(I0-a) / (N-1), N is the total number of processing layers, and a is the minimum value of the top layer influence coefficient; the compensation module is configured to calculate the material expected deformation δ e Determine the minimum value 'a' of the top-level influence coefficient, when δ e When <100μm, a=0.8; when 100μm≤δ e When ≤150μm, a=0.7, when δ e When the thickness is >150μm, a=0.6; the compensation module is configured to calculate the position compensation component based on the influence coefficient, so that the bottom influence coefficient amplifies the cumulative deformation trend to reflect the cumulative deformation effect, and the top influence coefficient attenuates the cumulative deformation trend to compensate for the deformation convergence caused by surface heat dissipation.

[0039] The cavity complexity C is calculated using the following formula: C = w1 × (σK / K) max )+ w2×(P / S), where σK is the standard deviation of the Gaussian curvature of the M sampling points on the mold cavity surface, and K max The preset maximum curvature standard deviation threshold is 100mm. -2 P is the number of key feature points, S is the cavity surface area, w1 and w2 are weighting coefficients with w1=0.6 and w2=0.4; the compensation module is configured to calculate the average deformation weight k, where k=(I0-a) / (N-1), N is the total number of processing layers, and a is the minimum value of the top layer influence coefficient; the compensation module is configured to calculate the average deformation weight k based on the expected material deformation δ. e Determine the minimum value 'a' of the top-level influence coefficient, when δ e When <100μm, a=0.8; when 100μm≤δ e When ≤150μm, a=0.7, when δ e When the thickness is >150μm, a=0.6; the compensation module is configured to calculate the position compensation component based on the influence coefficient, so that the bottom influence coefficient amplifies the cumulative deformation trend to reflect the cumulative deformation effect, and the top influence coefficient attenuates the cumulative deformation trend to compensate for the deformation convergence caused by surface heat dissipation.

[0040] Specifically, as illustrated in the example, the value of k, as the average deformation weight, is calculated considering the minimum influence coefficient 'a' of the top layer and the total number of processing layers N. The formula is k = (maximum influence coefficient of the bottom layer - a) / (N - 1). The value of 'a' is based on the expected material deformation δ. e Determine: When δ e When <100μm, a=0.8; when 100μm≤δ eWhen ≤150μm, a=0.7; when δ e When the diameter is greater than 150 μm, a = 0.6. For example, for a sample with a total height of 180 mm and a coefficient of thermal expansion of 14 × 10⁻⁶... -6 For a mold with a temperature of 1°C, an expected deformation of 120 μm, and a cavity complexity of 0.7, the system calculates that the maximum value of the bottom layer influence coefficient is 1.4, and the value of 'a' is 0.7. If the total number of layers is 120, then k = 0.0059, and the influence coefficient = 1.4 - 0.0059 × current layer sequence. This mechanism ensures that the bottom layer influence coefficient amplifies the deformation trend to reflect the cumulative effect, while the top layer influence coefficient attenuates the deformation trend to compensate for the deformation convergence caused by surface heat dissipation, enabling the position compensation component to accurately reflect the physical characteristics of interlayer deformation transmission.

[0041] The data processing module is also configured for tool attribute matching. In this embodiment, the system establishes a tool parameter library containing attribute parameters for five types of tools. When a contour dimension tolerance zone is detected to be less than ±0.005mm, a high-precision tool with a radial runout of less than 1μm is automatically matched, and the NURBS interpolation algorithm is enabled. In the curved surface transition region, the system adjusts the tool tip radius compensation amount by a minimum of 0.3mm based on the radius of curvature of the key feature point coordinates. This mechanism improves the surface machining accuracy when machining precision optical molds.

[0042] The monitoring module is also configured for multi-source data fusion. In this embodiment, the system weights and fuses vibration amplitude data, temperature data, and position deviation vectors. The weighting coefficients are set according to the material type. For example, when machining aluminum alloy, the temperature weight is 0.6 and the vibration weight is 0.3; when machining hardened steel, the vibration weight is 0.7 and the temperature weight is 0.2. The fused comprehensive deviation value is used to correct the abnormal path identification of the module. The infrared temperature sensor uses non-contact temperature measurement, with the measurement point 2mm away from the cutting point of the tool and a response time of 5ms, ensuring the real-time nature of the thermal deformation data.

[0043] This disclosure also provides a forming control method for CNC mold processing, including the following steps: Step S1: Obtain graphic data and performance data of the mold to be processed. In this embodiment, the system obtains data from the MES system via the OPCUA protocol. The graphic data includes the three-dimensional contour of the cavity with an accuracy of 0.005 mm, and the performance data includes material hardness of 42 HRC and coefficient of thermal expansion of 14 × 10⁻⁶. -6 / °C.

[0044] Step S2: Generate the first toolpath. In this embodiment, the cavity is divided into 120 layers, each with a thickness of 0.5mm. After thermal expansion compensation, a 3mm diameter tool is matched to the 45th layer, with a cutting depth of 0.15mm and a path interpolation accuracy of 0.0008mm.

[0045] Step S3: Obtain monitoring data at the first preset position. In this embodiment, monitoring points are set every 5 mm. At the 60 mm position, a vibration amplitude of 3.2g, a temperature of 85°C, and a position deviation of +7.3 μm are detected.

[0046] Step S4: Correct and obtain the second toolpath. In this embodiment, the toolpath offset is recalculated to +2.8μm for the out-of-range area, and the feed rate is reduced from 1200mm / min to 900mm / min, generating a second toolpath with 7 speed zones.

[0047] Step S5: Perform predictive compensation. In this embodiment, based on the cumulative deformation trend, the bottom layer is 18.5μm, and the layering influence coefficient is 1.35. At the second preset position, a position compensation component of +25.0μm and a speed compensation component are applied, reducing the speed by 18% to ensure that the machining accuracy meets the design specifications.

[0048] This disclosed embodiment achieves precise matching between toolpath and material properties through a layered adjustment mechanism in the data processing module; multi-source data fusion technology in the monitoring module provides a reliable basis for correction; dual optimization of geometric trajectory and speed parameters in the correction module solves vibration and deformation problems; and cumulative deformation trend analysis and layered differentiated compensation in the compensation module overcome the limitations of traditional single-point compensation. This system significantly improves the machining accuracy of mold cavities, achieving mirror-like surface quality, and is particularly suitable for machining high-precision molds such as aero-engine blades and optical lenses.

[0049] This embodiment of the disclosure achieves precise matching between tool path and material properties through the hierarchical adjustment mechanism of the data processing module; the multi-source data fusion technology of the monitoring module provides a reliable basis for correction; the dual optimization of geometric trajectory and speed parameters of the correction module solves vibration and deformation problems; and the cumulative deformation trend analysis and hierarchical differentiated compensation of the compensation module break through the limitations of traditional single-point compensation.

[0050] The foregoing description and accompanying drawings fully illustrate embodiments of this disclosure to enable those skilled in the art to practice them. Other embodiments may include structural, logical, electrical, procedural, and other changes. The embodiments represent only possible variations. Individual components and functions are optional unless explicitly required, and the order of operations may vary. Parts and features of some embodiments may be included in or replace parts and features of other embodiments. Moreover, the terminology used in this application is for describing embodiments only and is not intended to limit the claims. As used in the description of embodiments and claims, the singular forms “a,” “an,” and “the” are intended to equally include the plural forms unless the context clearly indicates otherwise. Similarly, the term “and / or” as used in this application means including one or more of the associated listed items and all possible combinations thereof. Additionally, when used in this application, the term "comprise" and its variations "comprises" and / or "comprising" refer to the presence of stated features, integrals, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components, and / or groups thereof. Without further limitations, an element defined by the phrase "comprises a..." does not exclude the presence of other identical elements in the process, method, or apparatus that includes said element. In this document, each embodiment may focus on the differences from other embodiments, and similar or identical parts between embodiments can be referred to mutually. For methods, products, etc., disclosed in the embodiments, if they correspond to the method section disclosed in the embodiments, the relevant parts can be referred to the description of the method section.

[0051] Those skilled in the art will recognize that the units and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented using electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are performed in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods for each specific application to achieve the described functions, but such implementation should not be considered beyond the scope of the embodiments of this disclosure. Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the specific working processes of the described devices, apparatuses, and units can be referred to the corresponding processes in the foregoing method embodiments, and will not be repeated here.

[0052] The flowcharts and block diagrams in the accompanying drawings illustrate the architecture, function, and operation of possible implementations of apparatus, methods, and computer program products according to embodiments of the present disclosure. In this regard, each block in a flowchart or block diagram may represent a module, segment, or portion of code containing one or more executable instructions for implementing a specified logical function. In some alternative implementations, the functions indicated in the blocks may occur in a different order than those indicated in the drawings. For example, two consecutive blocks may actually be executed substantially in parallel, and they may sometimes be executed in reverse order, depending on the functions involved. In the descriptions corresponding to the flowcharts and block diagrams in the accompanying drawings, the operations or steps corresponding to different blocks may also occur in a different order than those disclosed in the description; sometimes there is no specific order between different operations or steps. For example, two consecutive operations or steps may actually be executed substantially in parallel, and they may sometimes be executed in reverse order, depending on the functions involved. Each block in a block diagram and / or flowchart, and combinations of blocks in a block diagram and / or flowchart, can be implemented using a dedicated hardware-based device that performs the specified function or action, or using a combination of dedicated hardware and computer instructions.

Claims

1. A forming control system for CNC mold processing, characterized in that, include: The data acquisition module is configured to acquire graphic and performance data of the mold to be processed; The data processing module is configured to generate a first toolpath for machining the mold to be machined based on graphical and performance data. The monitoring module is configured to acquire monitoring data set at multiple first preset positions along the first toolpath; The correction module is configured to correct the first toolpath based on the monitoring data to obtain the second toolpath; The compensation module is configured to generate compensation signals and perform predictive compensation for multiple second preset positions of the second toolpath.

2. The forming control system for CNC mold processing according to claim 1, characterized in that, When the data processing module generates the first toolpath, it performs the following steps: It obtains mold cavity data from the graphic data, including the three-dimensional contour of the cavity and the coordinates of key feature points; based on the material thermal expansion coefficient in the performance data and the total mold height in the dimensional data, it divides the mold cavity into multiple layers to be processed, wherein the thickness of each layer is adjusted according to the material thermal expansion coefficient to compensate for thermal deformation during processing; for each layer to be processed, based on the contour dimensions of that layer in the dimensional data and the material hardness in the performance data, it matches tool attribute parameters, including tool diameter, tool length, and depth of cut, and determines the first path for that layer based on the matching result, wherein: when the material hardness is higher than a preset threshold, the depth of cut is reduced and the path smoothness is increased; when the tolerance zone of the contour dimensions is less than a preset range, the path interpolation accuracy is improved; it determines a second path from one layer to another, considering the tool length in the tool attribute parameters and the expected deformation in the performance data, and by calculating the slope and feed rate of the transition region, it avoids tool interference and compensates for accumulated deformation between layers.

3. The forming control system for CNC mold processing according to claim 2, characterized in that, The monitoring module is configured to perform the following steps: real-time acquisition of tool vibration amplitude data, machining area temperature data, and actual position deviation data at multiple first preset positions along the first toolpath; comparison of the tool vibration amplitude data with a preset vibration threshold to generate a vibration exceeding signal; comparison of the actual position deviation data with the theoretical coordinates of the first toolpath to calculate the position deviation vector, and outputting the monitoring data.

4. The forming control system for CNC mold processing according to claim 3, characterized in that, The correction module performs correction on the first toolpath based on the monitoring data to obtain the second toolpath, including the following steps: analyzing the position deviation vector and vibration exceedance signal in the monitoring data to identify abnormal path segments in the first toolpath that exceed the dimensional tolerance zone; for the abnormal path segments, recalculating the offset of the tool center trajectory based on the material hardness in the performance data to generate a local correction path; adjusting the feed rate and spindle speed in the corresponding area of ​​the first toolpath based on the vibration exceedance signal to suppress vibration and reduce cutting force fluctuations; integrating the local correction path and the adjusted speed parameters to generate the second toolpath, wherein the second toolpath includes the corrected geometric trajectory and optimized speed parameters.

5. The forming control system for CNC mold processing according to claim 4, characterized in that, The compensation module generates compensation signals and performs predictive compensation for multiple second preset positions of the second toolpath, including the following steps: Based on the historical records of the monitoring data and the current execution state of the second toolpath, predict the path deviation trend caused by material thermal deformation and tool wear in subsequent machining at the second preset position in the second toolpath; calculate the predicted compensation amount, which includes path coordinate offset and feed rate adjustment, wherein the path coordinate offset is generated based on the expected deformation amount in the performance data, and the feed rate adjustment is corrected in real time based on the temperature data in the monitoring data; generate compensation signals to adjust the tool position and speed in real time at the second preset position to compensate for the predicted deviation and ensure machining accuracy.

6. The forming control system for CNC mold processing according to claim 5, characterized in that, The compensation module is further configured to: continuously receive monitoring data updated by the monitoring module during the execution of the second toolpath, and update the predicted compensation amount; when the position deviation vector in the monitoring data exceeds a threshold, trigger an emergency compensation mechanism to generate an additional compensation signal to correct the remaining part of the second toolpath; The output of the compensated execution command enables the tool to achieve accuracy compensation at the second preset position.

7. The forming control system for CNC mold processing according to claim 6, characterized in that, The compensation module is further configured to perform the following steps: Calculate the cumulative deformation trend based on historical corrections and thermal deformation data generated during the execution of the first toolpath, wherein the historical corrections include the offset vector of the local correction path determined by the correction module when generating the second toolpath, and the thermal deformation data includes the temperature change rate collected by the monitoring module, the material thermal expansion coefficient in the performance data, and the interlayer deformation transfer amount; Assign an influence coefficient of the cumulative deformation trend according to the layering position of each layer to be processed in the mold cavity, wherein the influence coefficient of the bottom layer to be processed is amplified based on the layer height weight in the dimensional data to reflect the cumulative effect of deformation transfer upwards, while the influence coefficient of the top layer to be processed is attenuated based on the expected deformation amount in the performance data to compensate for deformation convergence caused by surface heat dissipation; For multiple second preset positions of the second toolpath, the influence coefficient is multiplied by the cumulative deformation trend to calculate the position compensation component and the speed compensation component. The position compensation component adjusts the tool coordinate offset according to the current layer sequence of the layer to be processed, and the speed compensation component corrects the feed rate in real time according to the temperature gradient in the thermal deformation data to eliminate the influence of interlayer cumulative deformation on machining accuracy.

8. A forming control method for CNC mold processing, characterized in that, The system implementation based on claim 7 includes the following steps: acquiring the graphic data and performance data of the mold to be processed; generating the first tool path based on the graphic data and performance data; acquiring the monitoring data of multiple first preset positions on the first tool path; Based on the monitoring data, the first tool path is corrected to obtain the second tool path; a compensation signal is generated and predictive compensation is performed on multiple second preset positions on the second tool path.

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