A kind of car, milling processing outer ring groove anti-collision device and numerical control processing method

Abstract

The application discloses a kind of vehicle, milling processing outer ring groove anti-collision device and numerical control processing method, belong to numerical control mechanical processing technical field.The device includes installation base, clamping assembly and prevent wrong tool setting device.Standard feature structure and multiple tool setting reference surface that are identical with the shape size of part target ring groove are equipped on tool setting device.The matched processing method realizes double insurance error proofing through tool setting macro program: firstly, the legality range of input tool wear compensation value is judged;Subsequently, tool is simulated on tool setting device Process, by measuring the actual size of feature structure after processing, the correctness of multiple parameters such as tool shape, length, coordinate, etc. is verified comprehensively.The application can actively prevent tool collision or part scrap caused by manual input error before actual cutting, with the advantages of reliable error proofing effect, wide applicability, minimal impact on production efficiency.

Description

Technical Field

[0001] This invention relates to the field of CNC machining technology, specifically to a turning and milling anti-collision device and CNC machining method for outer ring grooves. Background Technology

[0002] Engine components are expensive and have long production cycles. During processing, even basic errors can cause parts to exceed tolerances or even become unusable. Currently, CNC machining frequently encounters errors due to various human factors. For example, in actual operation, parameters such as tool wear, tool radius, tool shape, tool length, tool orientation, and coordinates must be manually entered into the machine tool. Although the probability of error is small, once an error occurs, it affects product quality, severely impacting part quality and causing significant economic losses and wasted time.

[0003] To address these risks, the industry has proposed various error prevention and collision avoidance solutions. For example, some methods focus on verifying the program itself, such as standardizing and automating the parsing of CNC machining program packages using software to reduce errors during manual transmission and inspection, as illustrated in the invention patent with publication number CN113139716A. However, these methods primarily address logical errors or version issues at the program code level and cannot physically verify the dynamically changing actual tool parameters already input into the machine tool's CNC system. Other solutions focus on real-time monitoring and protection during machining, such as installing sensors on the machine tool to monitor the distance between the tool and obstacles and automatically stopping the machine in case of an impending collision, as shown in the invention patent with publication number CN115570447A. These methods are post-mortem remediation or near-collision protection; while they can reduce collision losses, they cannot prevent machining quality defects caused by incorrect parameter settings at the source. Furthermore, the establishment of monitoring models and collision avoidance judgments are more complex for machining under complex postures such as four-axis linkage and angled heads. Summary of the Invention

[0004] The purpose of this invention is to provide a dual-insurance error-proofing device that combines an error-proofing tool calibrator and a macro program for error prevention, thereby solving the problem of manual numerical input errors in CNC lathes and CNC milling machines (four-axis + angle head).

[0005] The technical solution of the present invention: a collision prevention device for turning and milling outer ring grooves, including a disc-shaped mounting base, a clamping assembly arranged on the mounting base, the clamping assembly being a plurality of clamping plates arranged around the circumference of the part, and an error correction tool provided on the inner end face of the mounting base, wherein the main body of the error correction tool has a standard feature structure corresponding to the shape of the ring groove to be machined on the ring part. The standard feature structure has a horizontal top surface, a first positioning slope, a second positioning slope, a connecting slope, and a boss surface, and is used for tool setting and adjustment in turning and milling processes.

[0006] Preferably, the detection feature is a groove-shaped structure, the width, depth, and sidewall angle of which are consistent with the dimensions of the target annular groove of the annular part.

[0007] Preferably, the detection feature is as follows: the main body is provided with two inclined positioning slopes, one side of the first positioning slope is connected to the vertical side of the main body, the second positioning slope is connected to the horizontal top surface of the main body, a boss surface is provided at the contact point between the vertical side and the first positioning slope, and a connecting slope is formed at the connection point of the two positioning slopes.

[0008] Preferably, the outer circumferential surface of the mounting base is provided with a first stepped surface and a second stepped surface, which serve as the tool setting and tool adjustment surfaces for the outer diameter cutting tool.

[0009] Preferably, during turning, the horizontal top surface, the first positioning inclined surface, and the boss surface are used for tool setting and reaming; during milling, the horizontal top surface, the connecting inclined surface, and the second positioning inclined surface are used for tool setting and tool adjustment.

[0010] Preferably, the error-proof tool calibrator has an auxiliary positioning boss at the bottom to enhance the installation stability of the tool calibrator on the base.

[0011] A CNC machining method using a collision avoidance device includes the following steps: S1: Clamp the part onto the clamping assembly and install the error-proofing tool calibrator in the set position; S2: Execute parameter pre-verification process: Before starting to process the part, or after each tool change or tool parameter modification, run the tool calibration macro program; The macro program for calibrating the blade performs the following operations: Perform a validity check on manually input tool wear compensation values ​​within a preset range; The machine tool cutting tool is controlled to perform simulated machining on the standard feature structure of the error-proofing tool corrector using the current parameter set; S3: Measure the actual dimensions of the simulated processed standard feature structure; S4: Determine whether the actual size conforms to the preset tolerance: If it does, authorize the machine tool to use the current parameter set to execute the formal machining program on the part; if it does not, issue an alarm and wait for parameter correction, then return to step S2.

[0012] Preferably, in step S2, the logic for judging the validity of the tool wear compensation value by the tool calibration macro program is as follows: if the input value exceeds the allowed range, the program automatically jumps to the alarm segment and stops running.

[0013] Preferably, in step S2, the tool calibration macro program controls the starting point of the formal machining program through variables. When the machining process is interrupted and resumed, the machining can continue from the specified process position by modifying the variable values, without having to start from the beginning.

[0014] Preferably, the error-proof tool corrector is made of 45# steel, and the standard feature structure is formed by the actual cutting of the machine tool in simulated machining. Its dimensions are used to comprehensively reflect the accuracy of the current tool's shape compensation value, length compensation value, and workpiece coordinate system offset value.

[0015] The beneficial effects of this invention are as follows: This invention combines a tool-proofing and calibration device with a verification macro program, forming a dual error-proofing mechanism of "physical verification + logical judgment". It can proactively and comprehensively verify multiple parameters such as tool wear, shape, length, and coordinates before actual cutting, preventing tool collisions or scrap caused by input errors from the source. The device has a simple and reliable structure, and the method has wide applicability, suitable for various complex parts. The added tool-proofing time is less than 1% of the total machining time, yet it minimizes the risk of human error in the machining of extremely high-value parts, significantly improving machining safety and first-pass yield. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the specific embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a schematic diagram of the anti-collision device for machining the outer ring groove by turning and milling according to the present invention; Figure 2 This is a schematic diagram of the error-proofing and tool-correcting device of the present invention; Figure 3 This is an installation diagram of the CNC machining process according to the present invention; Figure 4 yes Figure 3 Front view; Figure 5 This is a schematic diagram of the blade calibration program logic; Reference numerals in the attached drawings: 1 - mounting base; 2 - clamping plate; 3 - anti-error tool calibrator; 4 - first positioning slope; 5 - boss surface; 6 - horizontal top surface; 7 - connecting slope; 8 - second positioning slope; 9 - first step surface; 10 - second step surface. Detailed Implementation

[0018] The present invention will be further described below with reference to the accompanying drawings and specific embodiments. However, it should not be construed that the scope of the subject matter of the present invention is limited to the following embodiments. All modifications, substitutions and alterations made based on ordinary technical knowledge and common practices in the art without departing from the above-described technical concept of the present invention are included within the scope of the present invention.

[0019] like Figure 1 and Figure 3 As shown, the anti-collision device used in this invention mainly includes a disc-shaped mounting base 1, a clamping assembly, and an anti-misalignment tool 3.

[0020] The mounting base 1 is fixed to the machine tool worktable. Several L-shaped clamping plates 2 are arranged circumferentially on it, forming a clamping assembly for clamping and positioning the ring-shaped part from the outside. On the side of the mounting base 1 facing the inner cavity of the part, a tool-correcting device 3 is fixed with screws. (Refer to...) Figure 2 The error-proof tool setting device 3 is made of 45# steel. Its core feature lies in the standard feature structure formed on its main body that is completely consistent with the shape of the annular groove to be machined on the part. This invention is a specific detection groove. In addition, two axial stepped surfaces are machined on the outer circumference of the mounting base 1. These are the first stepped surface 9 and the second stepped surface 10, which serve as tool setting references when turning the outer diameter.

[0021] The main body of the error-proof tool calibrator 3 has multiple precision-machined reference surfaces for tool setting and calibration of different tools. These reference surfaces together form a composite reference body for spatial positioning and detection. Specifically, it includes: a horizontally set top surface 6; a second positioning inclined surface 8 at a specific angle to the top surface; a first positioning inclined surface 4 at another angle to the top surface; a connecting inclined surface 7 connecting the first positioning inclined surface 4 and the second positioning inclined surface 8; and a boss surface 5 located at the intersection of the vertical side of the main body and the first positioning inclined surface 4. The bottom of the error-proof tool calibrator 3 may also be provided with an auxiliary positioning boss, which cooperates with the positioning holes on the mounting base 1 to ensure the repeatability and stability of the installation.

[0022] Example: In this example, the standard feature structure is specifically embodied in a precision-milled inspection groove. The width (7mm), depth (3mm), and sidewall angle (36.5°) of this inspection groove are all consistent with the target annular groove size of the rectifier outer ring component. This inspection groove is not pre-machined, but is formed in real-time by the currently used 6mm diameter milling cutter under the actual process parameters each time the following tool calibration program is executed. Therefore, the final size of this groove is a true physical reflection of the combined effect of a series of parameter settings such as the current machine tool coordinate system, tool length compensation, tool radius / shape compensation, and tool wear compensation. Whenever there is any change in manually input values ​​such as tool wear value, shape value, or length value during machining, the tool calibration program is run and the tool calibrator size is checked. Subsequent machining can only proceed after ensuring that the size is correct. If the tool calibrator size is found to be out of tolerance, the cause is immediately checked, and the tool calibration program is run again after confirmation that the size of the tool calibrator is correct. Subsequent machining can only proceed after the tool calibrator size is found to be acceptable.

[0023] Based on the above-described device, the CNC machining error prevention method of this embodiment is executed according to the following procedure. Step S1, Preparation and Clamping: Clamp the rectifier outer ring component onto the mounting base 1 using clamping plate 2, and confirm that the error-proof tool setter 3 is securely installed in the set position. Complete the initial tool setting for each tool (turning tool, milling cutter) and establish the workpiece coordinate system. Tools for turning the inner diameter can be set on the horizontal top surface 6, the first positioning inclined surface 4, and the boss surface 5 of the tool setter 3; tools for turning the outer diameter are set using the first step surface 9 and the second step surface 10 on the mounting base 1. Tools for milling the blade grooves can be set on the horizontal top surface 6, the connecting inclined surface 7, and the second positioning inclined surface 8.

[0024] Step S2, Parameter Pre-verification and Active Error Prevention: Before starting formal machining of the part, or after any tool or insert change or manual modification of tool parameters (wear value, shape value, length value, etc.) during machining, the tool calibration macro program must be run. This macro program executes dual error prevention logic: a) Numerical Range Validity Check: The program first checks the tool wear compensation value (such as the D value) just entered by the operator. For example, the allowable range is set to ±0.015mm. If the input value is ≥ 0.015 or ≤ -0.015, the program immediately jumps to the alarm segment, the machine tool stops running and an alarm is displayed, fundamentally preventing extreme erroneous values ​​from entering the machining process.

[0025] b) Physical simulation machining and comprehensive verification: If the numerical range judgment is passed, the program controls the current tool on the machine tool spindle to perform a round of simulated finishing on the detection groove using the current set of all parameters (including the wear value, shape value, length value, and coordinate system offset value being verified) under the guidance of the pre-made reference surface on the error correction tool 3. This process simulates the actual cutting trajectory and posture.

[0026] Step S3, Measurement and Judgment: The operator uses a measuring tool to measure the actual width of the inspection groove formed after the simulation processing in step S2.

[0027] Step S4: Determine whether the measured value is within the tolerance range of 7 ± 0.015 mm.

[0028] If the tolerance is met: This proves that the overall result of all manually input parameter settings is correct. The machine tool is authorized and can officially begin executing the formal machining program for the part. If the tolerance is not met: This indicates that at least one parameter (wear, shape, length, coordinates, etc.) is set incorrectly. The system issues an alarm (or the operator judges based on the out-of-tolerance result), and the machine must be stopped to check all relevant parameters. After correcting the error, return to step S2 to re-execute the tool calibration program until the groove size is qualified.

[0029] Reference Figure 5 The program execution flow is as follows: Startup input: First, a value is manually entered, followed by the program execution phase. Branch processing after program execution.

[0030] If a collision or overcut occurs during operation, the system will immediately stop. At this time, the correct tool shape value needs to be entered. After the input is completed, the process returns to the running program stage to continue execution.

[0031] If no collision or overcut occurs, the program will automatically move to the program head and eventually complete the part machining.

[0032] When the program moves to the program head, the correct tool wear compensation value needs to be entered. After the input is completed, the process returns to the program running stage to continue subsequent machining.

[0033] In terms of specific programming implementation, the macro program of this invention also has the following practical functions, which are illustrated using the Fanuc system code snippet provided in the embodiment as an example: The rectifier outer ring slot width is 7±0.015. A user-defined macro error prevention program is written to prevent tool compensation input errors. Taking the FanucSeries 0i-MD system as an example, the following is written in the program header: O0001 N1 #551=0 #5201=0 G0 G19 G40 G49 G80 G90 G59 #552=0.015 #553=-0.015 #10001=0 #13001=0 IF [#12001 GE #552] GOTO 500 IF [#12001 LE #553] GOTO 500 #5201=-#11003-#551 #3=0 M04 S1500 M10 G04 X1. MO4 S1500 G1 G90 G59 X_ Y_ A0 F3000 M06 T01 G04 X1. M11 ... (calibration procedure).... MO1 N2 #1=1 #551=0 #5201=0 G0 G19 G40 G49 G80 G90 G59 #552=0.015 #553=-0.015 #10001=0 #13001=0 IF [#12001 GE #552 GOTO 500 IF [#12001 LE #553] GOTO 500 #5201=-#11003-#551 #2=360 / 69 #3=#1*#2-#2 M04 S1500 N15 M10 G04 X1. G01 A#3 F3000 G04 X1. M11 MO4 S1200 G1 G90 G59 X_ Y_ F100 M06 T01 ...(processing procedure)... G40 XZ G0 X Z100 M01 #1=#1+1 #3 = #3 + #2 IF [#1LE68]GOTO 15 M5 #5201=0 G91 G28 Z0 G28X0 N500 M30 Machining a rectifier outer ring requires 9-10 hours just for milling the groove shape, and the tool needs to be changed once before rough milling, semi-finish milling, and finish milling. The time spent running the tool calibration program and measuring during machining is no more than three minutes. Turning only requires changing the insert once during finish turning, and the time spent running the tool calibration program during turning is even shorter. In short, the tool calibration program time for machining a rectifier outer ring is only one percent of the total part machining time. During machining, if any manually input value changes, the tool calibration program is executed once on the tool calibration error prevention device, and the X, Y, and Z values ​​are measured and confirmed to be correct before proceeding with subsequent machining. This ensures that the problem of manually inputting incorrect values ​​during the machining of the rectifier outer ring is eliminated. The process and method of this invention can be applied to the CNC machining of different types of parts. For other different types of parts, the shape and size of the tool calibration device can also be customized according to its size and structure to suit its specific machining needs.

[0034] The foregoing has provided a detailed description of the anti-collision device and CNC machining method for machining outer ring grooves using turning and milling, as provided by the present invention. Specific examples have been used to illustrate the structure and working principle of the invention. The descriptions of the embodiments above are merely for the purpose of helping to understand the method and core ideas of the present invention. It should be noted that those skilled in the art can make various improvements and modifications to the present invention without departing from its principles, and these improvements and modifications also fall within the scope of protection of the claims of the present invention.

Claims

1. A collision avoidance device for machining outer ring grooves by turning and milling, characterized in that: It includes a disc-shaped mounting base (1), on which a clamping assembly is arranged. The clamping assembly consists of several clamping plates (2) arranged around the circumference of the part. An error-proofing tool calibrator (3) is provided on the inner end face of the mounting base (1). The error-proofing tool calibrator (3) has a base body on which a standard feature structure corresponding to the shape of the annular groove to be processed of the annular part is formed. The base body is also machined with multiple reference surfaces for tool setting and tool calibration.

2. The anti-collision device for turning and milling outer ring grooves according to claim 1, characterized in that: The detection feature is a groove-shaped structure, the width, depth, and sidewall angle of which are consistent with the dimensions of the target annular groove of the annular part.

3. The anti-collision device for turning and milling outer ring grooves according to claim 1, characterized in that: The detection features are as follows: the main body is provided with two inclined positioning slopes, one side of the first positioning slope (4) is connected to the vertical side of the main body, the second positioning slope (8) is connected to the horizontal top surface (6) of the main body, a boss surface (5) is provided at the contact point between the vertical side and the first positioning slope (4), and a connecting slope (7) is formed at the connection point of the two positioning slopes.

4. The anti-collision device for turning and milling outer ring grooves according to claim 1, characterized in that: The mounting base (1) has a first step surface (9) and a second step surface (10) on its outer circumference surface, which serve as the tool setting and tool adjustment surfaces for the outer diameter cutting tool.

5. The anti-collision device for turning and milling outer ring grooves according to claim 1, characterized in that: During turning, the horizontal top surface (6), the first positioning inclined surface (4) and the boss surface (5) are used for tool setting and reaming; during milling, the horizontal top surface (6), the connecting inclined surface (7) and the second positioning inclined surface (8) are used for tool setting and tool adjustment.

6. The anti-collision device for turning and milling outer ring grooves according to claim 1, characterized in that: The bottom of the anti-error tool calibrator (3) is provided with an auxiliary positioning boss to enhance the installation stability of the tool calibrator on the base.

7. A CNC machining method using the anti-collision device according to any one of claims 1 to 6, characterized in that, Includes the following steps: S1: Clamp the part onto the clamping assembly and install the error-proofing tool (3) in the set position; S2: Execute parameter pre-verification process: Before starting to process the part, or after each tool change or tool parameter modification, run the tool calibration macro program; The macro program for calibrating the blade performs the following operations: a) Perform a validity check on manually input tool wear compensation values ​​within a preset range; b) Control the machine tool cutting tool to perform simulated machining on the standard feature structure of the error correction tool (3) using the current parameter set; S3: Measure the actual dimensions of the simulated processed standard feature structure; S4: Determine whether the actual size conforms to the preset tolerance: If it does, authorize the machine tool to use the current parameter set to execute the formal machining program on the part; if it does not, issue an alarm and wait for parameter correction, then return to step S2.

8. The CNC machining method according to claim 7, characterized in that: In step S2, the logic for judging the validity of the tool wear compensation value by the tool calibration macro program is as follows: if the input value exceeds the allowed range, the program will automatically jump to the alarm segment and stop running.

9. The CNC machining method according to claim 7, characterized in that: In step S2, the tool calibration macro program controls the starting point of the formal machining program through variables. When the machining process is interrupted and resumed, the variable values ​​are modified so that the machining can continue from the specified process position without having to start from the beginning.

10. The CNC machining method according to any one of claims 7 to 9, characterized in that: The error correction tool (3) is made of 45# steel. The standard feature structure is formed by the actual cutting of the machine tool in the simulation machining. Its size is used to comprehensively reflect the accuracy of the current tool shape compensation value, length compensation value and workpiece coordinate system offset value.

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