A method for processing a shell workpiece and a hydraulic clamp system used in the method

Abstract

The application discloses a kind of shell workpiece processing method and the hydraulic fixture system used in the method, processing method includes the following steps: S1: processing and positioning installation bottom plate;S2: installation and debugging hydraulic clamping mechanism;S3: workpiece clamping and trial processing;S4: batch processing, the method is through optimizing bottom plate design, positioning mode and hydraulic system control, realize the accurate processing of workpiece.This application adopts modular bottom plate structure, designs and installs the positioning datum of workpiece positioning and the positioning processing of workpiece high point on bottom plate, ensure that workpiece can be strongly supported when processing;Hydraulic system integrates separate pressure adjustment and sequential locking function, can independently set clamping force according to the characteristics of different regions of workpiece, and complete positioning and locking according to preset logic step by step.This application effectively solves the problems of large positioning error of traditional fixture, workpiece is easy to deform, manual labor is strong, significantly improves the stability and finished product precision of processing process, is suitable for batch production scene of complex shell parts.

Description

Technical Field

[0001] This invention belongs to the field of machining technology, and in particular relates to a machining method for shell-shaped workpieces and a hydraulic clamping system used in the method. Background Technology

[0002] In existing technologies, the clamping of shell-shaped workpieces on machining centers mostly employs traditional manual clamping methods. This requires operators to manually perform a series of operations, including workpiece alignment, positioning point determination, support position adjustment, and clamping position calibration. The entire process is cumbersome, time-consuming, and labor-intensive. Because shell-shaped workpieces typically have irregular shapes and complex internal structures, the alignment and positioning process requires operators to rely on extensive experience for repeated adjustments, which not only consumes a significant amount of time but also makes it difficult to guarantee consistent positioning accuracy due to variations in human operation. In actual production, the time spent clamping the workpiece often far exceeds the workpiece's actual machining time, severely restricting the production efficiency of the machining center. This problem is particularly pronounced in batch processing scenarios, significantly reducing the overall uptime of the production line.

[0003] Furthermore, the clamping structure of traditional fixtures is fixed, and the clamping shape of the clamping points cannot be flexibly adjusted according to the contact area, outline, and processing requirements of shell-like workpieces. For special structural workpieces such as irregularly shaped shells and thin-walled shells, problems such as uneven clamping force and localized stress concentration are prone to occur, further increasing the risk of workpiece deformation. At the same time, the clamping sequence of the various clamping points of traditional fixtures cannot be adjusted, making it difficult to adapt to the processing priority requirements of different parts of shell-like workpieces. An unreasonable clamping sequence can easily lead to workpiece positioning deviation, affecting processing quality.

[0004] As the manufacturing industry develops towards large-scale, high-precision, and high-efficiency operations, batch processing scenarios place higher demands on the clamping efficiency, positioning accuracy, and clamping stability of shell-type workpieces. Existing manual clamping methods can no longer meet actual production needs, and there is an urgent need for a clamping solution that can solve the above-mentioned defects, achieve fast, accurate, and stable clamping of shell-type workpieces, shorten clamping time, ensure processing accuracy and consistency, improve the production efficiency of batch processing, and reduce production costs and risks caused by human error. Summary of the Invention

[0005] The problem this invention aims to solve is that manual alignment and clamping of shell-type workpieces is slow, time-consuming, and labor-intensive. Uneven clamping force at multiple clamping points can easily occur, causing workpiece clamping deviations and resulting in unstable machining accuracy when the equipment processes the workpiece.

[0006] To address the aforementioned technical problems, the present invention provides a method for processing shell-type workpieces, comprising the following steps:

[0007] S1: Machining and positioning mounting base plate: Based on the workpiece contour dimensions, machining center table dimensions, workpiece machining position and equipment machining depth, an integrated design is carried out to design and prepare a suitable mounting base plate to ensure a reasonable spatial layout;

[0008] S2: Installation and debugging of hydraulic clamping mechanism: According to the clamping requirements and processing torque requirements of the workpiece to be processed, design and install 90-degree hydraulic rotary cylinders on the mounting base plate. Configure the number of hydraulic rotary cylinders according to the processing strength and anti-deformation requirements of the workpiece. Equip a hydraulic station and debug each hydraulic rotary cylinder to ensure that the locking pressure of each hydraulic rotary cylinder can be adjusted individually to adapt to the different locking force requirements of different positions of the workpiece. At the same time, debug the hydraulic control system to realize the flexible adjustment of the clamping sequence of each clamping point and prevent the workpiece positioning from shifting during the locking process.

[0009] S3: Workpiece clamping and trial processing: Accurately install the workpiece onto the mounting base plate using the workpiece positioning device on the mounting base plate, perform positioning checks, and after the positioning is qualified, start the hydraulic system of the hydraulic clamping mechanism. After the hydraulic clamping mechanism clamps normally, start the machine tool to perform trial cutting processing on the workpiece and observe the stability of the workpiece during the processing. If any abnormality occurs, adjust the locking pressure and clamping position of the hydraulic rotary cylinder, or adjust the processing state of the machine tool to ensure that the locking state is stable and reliable during the workpiece processing.

[0010] S4: Batch processing: After the trial processing is confirmed to be qualified, the batch workpieces are clamped and processed according to the clamping process of steps S2 to S3. During the processing, the locking pressure of each hydraulic rotary cylinder can be adjusted individually according to the processing requirements of the workpiece, or the clamping sequence of each clamping point can be adjusted. Each cylinder can be locked one by one or all cylinders can be controlled to move at the same time to ensure accurate positioning and stable clamping of the workpieces during batch processing, and to ensure consistent processing accuracy.

[0011] According to an embodiment of this application, step S1 further includes the following steps:

[0012] S11: Mill the mounting base plate to ensure that both sides of the base plate are parallel. Then, machine a mounting groove parallel to the worktable surface of the machining center on the base plate to ensure that the mounting base plate can be reliably and firmly installed parallel to the worktable surface of the equipment.

[0013] S12: Based on the outer contour dimensions of the workpiece to be processed, design and install the workpiece positioning reference on the mounting base plate. The positioning reference adopts cylindrical positioning or hole positioning to ensure that the workpiece will not deviate after positioning.

[0014] S13: For parts of the workpiece that are too high relative to the positioning datum, the mounting base plate is adapted to the high point of the workpiece. For the high point area of ​​the workpiece, the base plate is locally thickened by milling and grinding to ensure that the positioning surface fits the workpiece without gaps.

[0015] S14: A groove parallel to the worktable surface is machined on the base plate to ensure that the base plate can be reliably and securely installed parallel to the worktable surface of the equipment.

[0016] According to an embodiment of this application, two T-shaped mounting slots parallel to the worktable surface of the machining center are machined on the base plate. The spacing between the T-shaped slots matches the spacing between the mounting holes on the worktable, ensuring that the base plate can be parallel to the worktable surface and securely installed when it is fixed to the worktable with bolts.

[0017] According to an embodiment of this application, based on the outer contour of the workpiece to be processed, two cylindrical locating pins are designed and installed on the mounting base as positioning references. The positions of the cylindrical locating pins correspond to the positioning holes on the workpiece, ensuring that the workpiece will not deviate after installation.

[0018] According to an embodiment of this application, step S2 further includes the following steps: adjusting the installation support height of the hydraulic rotary cylinder or the height of the hydraulic rotary cylinder locking block according to the height difference of the workpiece clamping part, so that the hydraulic rotary cylinder can be accurately aligned with the workpiece clamping part; configuring a hydraulic station for the hydraulic clamping mechanism, adjusting the pressure of the hydraulic station to meet the pressure required for workpiece processing, configuring a reversing valve and control button for the hydraulic station, and achieving precise control of the working state of the hydraulic rotary cylinder through the hydraulic station, reversing valve and control button;

[0019] The pressure control uses an independent proportional pressure regulating valve group to ensure that the locking pressure of each hydraulic rotary cylinder can be adjusted individually; the control logic of the hydraulic clamping mechanism realizes the automated process of "positioning → pre-tightening → clamping → processing → releasing" through PLC programming.

[0020] According to an embodiment of this application, four 90-degree hydraulic rotary cylinders are symmetrically installed on the mounting base plate, corresponding to the four clamping parts of the workpiece respectively; the hydraulic station is equipped with four directional valves, corresponding to the four hydraulic rotary cylinders respectively, as well as one main control button and four individual control buttons. The main control button controls all cylinders to operate simultaneously, and the individual control buttons enable individual control of a single cylinder.

[0021] According to the embodiments of this application, the step S3 of confirming that the hydraulic clamping mechanism is clamping normally specifically includes: operating the control button to rotate the corresponding hydraulic rotary cylinder to the workpiece clamping part, observing the contact between the cylinder locking block and the workpiece clamping part to ensure tight contact and no deviation; starting the hydraulic system, pressing the release button to control all cylinders to release, and observing whether the workpiece shakes. If the workpiece does not shake, it indicates that the hydraulic clamping mechanism is clamping normally.

[0022] According to embodiments of this application, the trial cutting process includes milling the workpiece end face and drilling the internal cavity.

[0023] According to an embodiment of this application, the contact area between the workpiece and the mounting base plate is not less than 85% of the effective support surface.

[0024] Another aspect of this application discloses a hydraulic clamping system applied in a machining method for a shell-type workpiece as described above, comprising:

[0025] 4 sets of double-acting hydraulic rotary cylinders, with a rated thrust of ≥5 kN;

[0026] An independent proportional pressure regulating valve assembly allows for individual adjustment of the pressure at each clamping point within a range of 0.5-10 MPa;

[0027] The PLC control system realizes the automated process of "positioning → pre-tensioning → clamping → processing → releasing", with a response time of ≤0.5 seconds for each action switching.

[0028] The hydraulic power unit consists of a variable vane pump, an accumulator, and a cooling system. The working pressure of the hydraulic power unit is stable at 6-8 MPa, and the flow rate fluctuation is ≤±2%.

[0029] The advantages of the present invention over the prior art are:

[0030] 1. Through the modular collaborative design of base plate-positioning-hydraulic system, high precision, high stability and high efficiency of workpiece clamping are achieved, meeting the process requirements for batch processing of shell-type workpieces.

[0031] 2. The use of hydraulic clamping replaces the traditional manual clamping, eliminating the need for operators to manually align and tighten screws, significantly shortening the clamping time and solving the problem that clamping time is longer than workpiece processing time in traditional machining. This significantly improves production clamping efficiency and overall machining efficiency.

[0032] 3. By precisely controlling the locking pressure of the hydraulic rotary cylinder through the hydraulic station, the pressure of each clamping point is made uniform and stable, and the pressure of each clamping point can be adjusted individually. This avoids the defects of traditional manual clamping, where the locking force depends on experience and cannot be quantified. It effectively prevents the workpiece from shifting due to insufficient clamping force or deforming due to over-clamping, and ensures the consistency of processing accuracy of the same batch of workpieces.

[0033] 4. This application allows for adjustment of the height of the hydraulic rotary cylinder and locking block according to the height of the workpiece clamping part, and adjustment of the clamping structure according to the workpiece contact area and processing requirements. At the same time, the clamping sequence of each clamping point can be flexibly adjusted to adapt to shell-type workpieces with different shapes and structures (including irregular shells and thin-walled shells), effectively avoiding problems such as uneven clamping force and positioning offset.

[0034] 5. The hydraulic clamping mechanism can be started, stopped, and adjusted via control buttons, reducing the labor intensity of operators and minimizing human error. Hydraulic clamping is highly reliable and can effectively avoid safety accidents such as workpiece flying off and tool collisions that occur with traditional manual clamping, thus improving the safety of the machining process. Attached Figure Description

[0035] Figure 1 A flowchart illustrating the steps of a shell-type workpiece processing method as an example of the present invention;

[0036] Figure 2 This is a top view of a shell-type workpiece processing scenario as an example of the present invention;

[0037] Figure 3 This is a side view of a shell-type workpiece processing scenario as an example of the present invention.

[0038] The annotations in the attached figures are explained as follows:

[0039] 1. Mounting base plate, 2. Hydraulic rotary cylinder, 3. Hydraulic pressure plate, 4. Positioning pin. Detailed Implementation

[0040] The present invention will be further described below with reference to the accompanying drawings and specific embodiments. The following embodiments are used to illustrate the present invention, but are not intended to limit the scope of the present invention.

[0041] Please see Figure 1 As shown, this application discloses a method for machining shell-type workpieces, including the following steps: S1: machining and positioning the base plate; S2: installing and debugging the hydraulic clamping mechanism; S3: workpiece clamping and trial machining; S4: batch machining. This method achieves precise machining of the workpiece by optimizing the base plate design, positioning method, and hydraulic system control. Key technical points include the adoption of a modular base plate structure, with positioning references for workpiece positioning and positioning machining of workpiece high points designed and installed on the base plate to ensure strong support during workpiece machining; the hydraulic system innovatively integrates individual pressure adjustment and sequential locking functions, allowing independent setting of clamping force according to the characteristics of different areas of the workpiece, and step-by-step completion of positioning and locking according to preset logic. This method effectively solves the problems of large positioning errors, easy workpiece deformation, and high manual labor intensity associated with traditional fixtures, significantly improving the stability of the machining process and the accuracy of the finished product.

[0042] In this embodiment, a method for processing a shell-type workpiece includes the following steps:

[0043] S1: Machining and positioning mounting base plate 1: Based on the workpiece contour dimensions, machining center worktable dimensions, workpiece machining position and equipment machining depth, an integrated design is carried out to design and prepare a suitable mounting base plate 1 to ensure reasonable spatial layout.

[0044] Specifically, step S1 further includes the following steps:

[0045] S11: Mill the mounting base plate 1 to ensure that the two sides of the base plate are parallel. Then, machine the mounting groove on the base plate that is parallel to the worktable of the machining center to ensure that the mounting base plate 1 can be reliably and firmly installed parallel to the worktable of the equipment.

[0046] S12: Based on the outer contour dimensions of the workpiece to be processed, design and install the workpiece positioning reference on the mounting base plate 1. The positioning reference adopts cylindrical positioning or hole positioning to ensure that the workpiece will not deviate after positioning.

[0047] S13: For the parts of the workpiece that are too high relative to the positioning reference, the mounting base plate 1 is adapted to the high point of the workpiece. For the high point area of ​​the workpiece, the base plate is locally thickened by milling and grinding to make the positioning surface fit the workpiece without gap.

[0048] S14: A groove parallel to the worktable surface is machined on the base plate to ensure that the base plate can be reliably and securely installed parallel to the worktable surface of the equipment.

[0049] Specifically, two T-shaped mounting slots parallel to the worktable surface of the machining center are machined on the base plate. The spacing between the T-shaped slots matches the spacing between the mounting holes on the worktable, ensuring that the base plate 1 can be parallel to the worktable surface and securely installed when it is fixed to the worktable with bolts.

[0050] Specifically, the contact area between the workpiece and the mounting base plate 1 is not less than 85% of the effective support surface, ensuring that the contact area between the workpiece and the base plate is maximized and that the workpiece can be strongly supported during processing.

[0051] Specifically, the base plate is required to have a certain strength and thickness, and is preferably made of high-strength steel.

[0052] Specifically, based on the outline of the workpiece to be processed, two cylindrical locating pins 4 are designed and installed on the mounting base plate 1 as positioning references. The positions of the cylindrical locating pins 4 correspond to the positioning holes on the workpiece to ensure that the workpiece will not deviate after installation.

[0053] S2: Installation and debugging of hydraulic clamping mechanism: According to the clamping requirements and processing torque requirements of the workpiece to be processed, design and install 90-degree hydraulic rotary cylinders 2 on the mounting base plate 1. Configure the number of hydraulic rotary cylinders 2 according to the processing strength and anti-deformation requirements of the workpiece. Equip with a hydraulic station and debug each hydraulic rotary cylinder 2 to ensure that the locking pressure of each hydraulic rotary cylinder 2 can be adjusted individually to adapt to the different locking force requirements of different positions of the workpiece. At the same time, debug the hydraulic control system to realize the flexible adjustment of the clamping sequence of each clamping point and prevent the workpiece positioning from shifting during the locking process.

[0054] Specifically, step S2 further includes the following steps: based on the height difference of the workpiece clamping part, adjust the installation support height of the hydraulic rotary cylinder 2, or adjust the height of the locking block of the hydraulic rotary cylinder 2, so that the hydraulic rotary cylinder 2 can be accurately aligned with the workpiece clamping part; configure a hydraulic station for the hydraulic clamping mechanism, adjust the pressure of the hydraulic station to meet the pressure required for workpiece processing, configure a reversing valve and control button for the hydraulic station, and achieve precise control of the working state of the hydraulic rotary cylinder 2 through the hydraulic station, reversing valve and control button.

[0055] Understandably, the pressure control described above uses an independent proportional pressure regulating valve group to ensure that the locking pressure of each hydraulic rotary cylinder 2 can be adjusted individually. The control logic of the hydraulic clamping mechanism is implemented through PLC programming to achieve an automated process of "positioning → pre-tightening → clamping → machining → releasing". The locking position between the hydraulic rotary cylinder 2 and the workpiece can be adjusted as needed, and each hydraulic rotary cylinder 2 can independently adjust its locking pressure as needed to ensure that the locking cylinder can both lock the workpiece and avoid excessive locking pressure that could cause slight deformation of the workpiece. The hydraulic rotary cylinder 2 can clamp one workpiece at a time as needed, or the rotary hydraulic cylinders can operate simultaneously to clamp the workpiece. To prevent workpiece deformation, a hydraulic top-clamping cylinder can be designed under the workpiece to support it before clamping. The hydraulic rotary clamping block can be adjusted according to the machining requirements of the workpiece and the magnitude of the clamping force to ensure that the clamping block is in close contact with the workpiece without interfering with the machining process.

[0056] Specifically, the hydraulic clamping mechanism design includes four key elements: in terms of the number of cylinders, four sets of double-acting hydraulic cylinders are configured according to the workpiece clamping force requirements; pressure control adopts an independent proportional pressure regulating valve group, which can realize individual adjustment of the pressure of each clamping point within the range of 0.5-10 MPa; the sequential control logic realizes the automated process of "positioning → pre-tightening → clamping → machining → releasing" through PLC programming, and the switching response time of each action is ≤0.5 seconds; the hydraulic station consists of a variable vane pump, an accumulator and a cooling system.

[0057] Specifically, four 90-degree hydraulic rotary cylinders 2 are symmetrically installed on the mounting base plate 1, corresponding to the four clamping parts of the workpiece respectively; the hydraulic station is equipped with four directional valves, corresponding to the four hydraulic rotary cylinders 2, one main control button, and four individual control buttons. The main control button controls all cylinders to operate simultaneously, and the individual control buttons enable individual control of each cylinder.

[0058] S3: Workpiece clamping and trial machining: Accurately install the workpiece onto the workpiece base plate using the workpiece positioning device on the base plate, perform positioning checks, and after the positioning is qualified, start the hydraulic system of the hydraulic clamping mechanism. After the hydraulic clamping mechanism clamps normally, start the machine tool to perform trial cutting of the workpiece and observe the stability of the workpiece during the machining process. If any abnormality occurs, adjust the locking pressure and clamping position of the hydraulic rotary cylinder 2, or adjust the machine tool machining state to ensure that the locking state is stable and reliable during the workpiece machining process.

[0059] Specifically, step S3, which confirms that the hydraulic clamping mechanism is clamping normally, includes: operating the control button to rotate the corresponding hydraulic rotary cylinder 2 to the workpiece clamping part, observing the contact between the cylinder locking block and the workpiece clamping part to ensure tight contact and no deviation; starting the hydraulic system, pressing the release button to control all cylinders to release, and observing whether the workpiece shakes. If the workpiece does not shake, it means that the hydraulic clamping mechanism is clamping normally.

[0060] S4: Batch processing: After the trial processing is confirmed to be qualified, the batch workpieces are clamped and processed according to the clamping process of steps S2 to S3. During the processing, the locking pressure of each hydraulic rotary cylinder 2 can be adjusted individually according to the processing requirements of the workpiece, or the clamping sequence of each clamping point can be adjusted. Each cylinder can be locked one by one or all cylinders can be controlled to move at the same time to ensure accurate positioning and stable clamping of the workpiece during batch processing, and to ensure consistent processing accuracy.

[0061] Specifically, the trial cutting process includes milling the end face of the workpiece and drilling the internal cavity.

[0062] Another aspect of this application discloses a hydraulic clamping system applied in the above-described method for machining a shell-shaped workpiece, characterized in that it comprises:

[0063] 4 sets of double-acting hydraulic rotary cylinders 2, with a rated thrust of ≥5 kN for each hydraulic rotary cylinder 2;

[0064] An independent proportional pressure regulating valve assembly allows for individual adjustment of the pressure at each clamping point within a range of 0.5-10 MPa;

[0065] The PLC control system realizes the automated process of "positioning → pre-tensioning → clamping → processing → releasing", with a response time of ≤0.5 seconds for each action switching.

[0066] The hydraulic power unit consists of a variable vane pump, an accumulator, and a cooling system. The working pressure of the hydraulic power unit is stable at 6-8 MPa, and the flow rate fluctuation is ≤±2%.

[0067] Example 1

[0068] Working process of hydraulic clamping mechanism:

[0069] Based on the clamping requirements and machining torque (maximum machining torque 50 N·m) of the irregular thin-walled shell, four 90-degree hydraulic rotary cylinders 2 are symmetrically installed on the mounting base plate 1, corresponding to the four clamping parts of the workpiece. Since the height of the four clamping parts of the workpiece differs by 5-10 mm, the height of the mounting support of the hydraulic rotary cylinders 2 is adjusted to ensure that the locking block of each cylinder is precisely aligned with the corresponding clamping part. The height of the cylinder support for the two lower clamping parts is adjusted to 100 mm, and the height of the cylinder support for the two higher clamping parts is adjusted to 110 mm. A small hydraulic station is configured for the hydraulic clamping mechanism, and the output pressure of the hydraulic station is adjusted to 0.8 MPa to meet the requirements of workpiece processing. Clamping pressure is required; the hydraulic station is equipped with 4 directional valves (corresponding to 4 hydraulic rotary cylinders 2 respectively), 1 main control button, and 4 individual control buttons. The main control button can control all cylinders to operate simultaneously, and the individual control buttons can control a single cylinder individually; each hydraulic rotary cylinder 2 is tested, and the locking pressure of each cylinder is adjusted through the directional valves. The locking pressure of the cylinder corresponding to the thin-walled part of the workpiece is adjusted to 0.6MPa, and the locking pressure of the cylinder corresponding to the non-thin-walled part is adjusted to 0.8MPa; the control system is tested, and the clamping sequence is set as follows: first clamp the two cylinders of the non-thin-walled part of the workpiece, and then clamp the two cylinders of the thin-walled part to prevent the workpiece from deforming or shifting during the clamping process.

[0070] Example 2

[0071] The complete workflow for machining a shell-type workpiece is as follows:

[0072] 1. High-strength alloy steel plate is selected as the mounting base plate 1. It is milled on both sides by a precision milling machine, and the flatness and parallelism meet 0.02mm / 100mm. T-slots or rectangular mounting slots are machined on the base plate. The slot system is parallel to the base plate reference surface to ensure that the parallelism meets the standard after being fastened to the machine tool worktable.

[0073] 2. For example Figure 2 As shown, according to the outline of the shell-type workpiece, cylindrical pins are arranged on the base plate as positioning pins 4, or positioning holes and stepped surfaces are combined for positioning; for the high point area of ​​the workpiece, the base plate is locally thickened by milling and grinding so that the positioning surface fits the workpiece without gaps, and the contact area between the workpiece and the base plate is not less than 85% of the effective support surface.

[0074] 3. For example Figure 2 , Figure 3As shown, 90° hydraulic rotary cylinders 2 are evenly arranged around the workpiece contour. Hydraulic pressure plates 3 are provided on the hydraulic rotary cylinders 2, and auxiliary cylinders are added in weak areas. The cylinder base is equipped with height adjustment pads, and the locking blocks adopt a replaceable stepped structure to adapt to different clamping heights. Each cylinder is equipped with an independent pressure regulating valve to achieve 0-10MPa graded pressure adjustment. The clamping sequence adopts the strategy of first positioning reference, then peripheral auxiliary, and first low point and then high point to prevent positioning deviation.

[0075] The hydraulic station's rated pressure matches the maximum locking requirements of the workpiece, and it is equipped with relief valves and check valves to ensure stable pressure. The directional valve adopts a two-position four-way or three-position four-way structure, and works with the button box to achieve single-action / linkage control, and has functions for clamping in place and abnormal pressure feedback.

[0076] 4. Gently place the workpiece into the positioning unit, manually straighten it, and then shake it slightly to confirm that there is no movement; observe that the oil cylinder rotates to the clamping position without interference, start the hydraulic station to raise it to the set pressure; execute the loosening-clamping cycle, and the workpiece is qualified to be clamped if it does not loosen; perform a small depth of cut and low feed trial cut, monitor vibration and dimensional deviation, optimize the processing state by adjusting the pressure and position, and maintain a stable locking pressure throughout the formal processing.

[0077] In summary, the technical solution of this application has the following beneficial effects:

[0078] 1. Through the modular collaborative design of base plate-positioning-hydraulic system, high precision, high stability and high efficiency of workpiece clamping are achieved, meeting the process requirements for batch processing of shell-type workpieces.

[0079] 2. The use of hydraulic clamping replaces the traditional manual clamping, eliminating the need for operators to manually align and tighten screws, significantly shortening the clamping time and solving the problem that clamping time is longer than workpiece processing time in traditional machining. This significantly improves production clamping efficiency and overall machining efficiency.

[0080] 3. By precisely controlling the locking pressure of the hydraulic rotary cylinder through the hydraulic station, the pressure of each clamping point is made uniform and stable, and the pressure of each clamping point can be adjusted individually. This avoids the defects of traditional manual clamping, where the locking force depends on experience and cannot be quantified. It effectively prevents the workpiece from shifting due to insufficient clamping force or deforming due to over-clamping, and ensures the consistency of processing accuracy of the same batch of workpieces.

[0081] 4. This application allows for adjustment of the height of the hydraulic rotary cylinder and locking block according to the height of the workpiece clamping part, and adjustment of the clamping structure according to the workpiece contact area and processing requirements. At the same time, the clamping sequence of each clamping point can be flexibly adjusted to adapt to shell-type workpieces with different shapes and structures (including irregular shells and thin-walled shells), effectively avoiding problems such as uneven clamping force and positioning offset.

[0082] 5. The hydraulic clamping mechanism can be started, stopped, and adjusted via control buttons, reducing the labor intensity of operators and minimizing human error. Hydraulic clamping is highly reliable and can effectively avoid safety accidents such as workpiece flying off and tool collisions that occur with traditional manual clamping, thus improving the safety of the machining process.

[0083] The above are merely preferred embodiments of the present invention and are not intended to limit the implementation methods and protection scope of the present invention. Those skilled in the art should recognize that any equivalent substitutions and obvious changes made based on the description and illustrations of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for machining a shell-shaped workpiece, characterized in that, Includes the following steps: S1: Machining and positioning mounting base plate: Based on the workpiece contour dimensions, machining center table dimensions, workpiece machining position and equipment machining depth, an integrated design is carried out to design and prepare a suitable mounting base plate to ensure a reasonable spatial layout; S2: Installation and debugging of hydraulic clamping mechanism: According to the clamping requirements and processing torque requirements of the workpiece to be processed, design and install 90-degree hydraulic rotary cylinders on the mounting base plate. Configure the number of hydraulic rotary cylinders according to the processing strength and anti-deformation requirements of the workpiece. Equip a hydraulic station and debug each hydraulic rotary cylinder to ensure that the locking pressure of each hydraulic rotary cylinder can be adjusted individually to adapt to the different locking force requirements of different positions of the workpiece. At the same time, debug the hydraulic control system to realize the flexible adjustment of the clamping sequence of each clamping point and prevent the workpiece positioning from shifting during the locking process. S3: Workpiece clamping and trial processing: Accurately install the workpiece onto the workpiece base plate using the workpiece positioning device on the base plate, perform positioning checks, and after the positioning is qualified, start the hydraulic system of the hydraulic clamping mechanism. After the hydraulic clamping mechanism clamps normally, start the machine tool to perform trial cutting processing on the workpiece and observe the stability of the workpiece during the processing. If any abnormality occurs, adjust the locking pressure and clamping position of the hydraulic rotary cylinder, or adjust the processing state of the machine tool to ensure that the locking state is stable and reliable during the workpiece processing. S4: Batch processing: After the trial processing is confirmed to be qualified, the batch workpieces are clamped and processed according to the clamping process of steps S2 to S3. During the processing, the locking pressure of each hydraulic rotary cylinder can be adjusted individually according to the processing requirements of the workpiece, or the clamping sequence of each clamping point can be adjusted. Each cylinder can be locked one by one or all cylinders can be controlled to move at the same time to ensure accurate positioning and stable clamping of the workpieces during batch processing, and to ensure consistent processing accuracy.

2. The method for processing a shell-type workpiece according to claim 1, characterized in that, Step S1 further includes the following steps: S11: Mill the mounting base plate to ensure that both sides of the base plate are parallel. Then, machine a mounting groove parallel to the worktable surface of the machining center on the base plate to ensure that the mounting base plate can be reliably and firmly installed parallel to the worktable surface of the equipment. S12: Based on the outer contour dimensions of the workpiece to be processed, design and install the workpiece positioning reference on the mounting base plate. The positioning reference adopts cylindrical positioning or hole positioning to ensure that the workpiece will not deviate after positioning. S13: For parts of the workpiece that are too high relative to the positioning datum, the mounting base plate is adapted to the high point of the workpiece. For the high point area of ​​the workpiece, the base plate is locally thickened by milling and grinding to make the positioning surface fit the workpiece without gaps; S14: Machining a groove parallel to the worktable surface on the base plate to ensure that the base plate can be reliably and securely installed parallel to the worktable surface of the equipment.

3. The method for processing a shell-type workpiece according to claim 2, characterized in that, Two T-shaped mounting slots parallel to the worktable surface of the machining center are machined on the base plate. The spacing between the T-slots matches the spacing between the mounting holes on the worktable, ensuring that the base plate can be parallel to the worktable surface and securely installed when it is fixed to the worktable with bolts.

4. The method for processing a shell-type workpiece according to claim 2, characterized in that, Based on the outline of the workpiece to be processed, two cylindrical locating pins are designed and installed on the mounting base plate as positioning references. The positions of the cylindrical locating pins correspond to the positioning holes on the workpiece to ensure that the workpiece will not deviate after installation.

5. The method for processing a shell-type workpiece according to claim 1, characterized in that, Step S2 further includes the following steps: adjusting the installation support height of the hydraulic rotary cylinder or the height of the hydraulic rotary cylinder locking block according to the height difference of the workpiece clamping part, so that the hydraulic rotary cylinder can be accurately aligned with the workpiece clamping part; configuring a hydraulic station for the hydraulic clamping mechanism, adjusting the pressure of the hydraulic station to meet the pressure required for workpiece processing, configuring a reversing valve and control button for the hydraulic station, and achieving precise control of the working state of the hydraulic rotary cylinder through the hydraulic station, reversing valve and control button; The pressure control adopts an independent proportional pressure regulating valve group to ensure that the locking pressure of each hydraulic rotary cylinder can be adjusted individually; the control logic of the hydraulic clamping mechanism realizes the automated process of "positioning → pre-tightening → clamping → processing → releasing" through PLC programming.

6. The method for processing a shell-type workpiece according to claim 5, characterized in that, Four 90-degree hydraulic rotary cylinders are symmetrically mounted on the mounting base plate, corresponding to the four clamping parts of the workpiece respectively; the hydraulic station is equipped with four directional valves, corresponding to the four hydraulic rotary cylinders respectively, as well as one main control button and four individual control buttons. The main control button controls all cylinders to operate simultaneously, and the individual control buttons enable individual control of each cylinder.

7. The method for processing a shell-type workpiece according to claim 1, characterized in that, The steps in step S3 to confirm that the hydraulic clamping mechanism is clamping normally include: operating the control button to rotate the corresponding hydraulic rotary cylinder to the workpiece clamping part, observing the contact between the cylinder locking block and the workpiece clamping part to ensure tight contact and no deviation; starting the hydraulic system, pressing the release button to control all cylinders to release, and observing whether the workpiece shakes. If the workpiece does not shake, it means that the hydraulic clamping mechanism is clamping normally.

8. The method for processing a shell-type workpiece according to claim 1, characterized in that, The trial cutting process includes milling the end face of the workpiece and drilling the internal cavity.

9. The method for processing a shell-type workpiece according to claim 1, characterized in that, The contact area between the workpiece and the mounting base plate shall not be less than 85% of the effective support surface.

10. A hydraulic clamping system, applied in a machining method for a shell-type workpiece as described in any one of claims 1-9, characterized in that, include: Four sets of double-acting hydraulic rotary cylinders, wherein the rated thrust of the hydraulic rotary cylinder is ≥5kN; An independent proportional pressure regulating valve assembly allows for individual adjustment of the pressure at each clamping point within a range of 0.5-10MPa; The PLC control system realizes the automated process of "positioning → pre-tensioning → clamping → processing → releasing", with a response time of ≤0.5 seconds for each action switching. The hydraulic station consists of a variable vane pump, an accumulator, and a cooling system. The working pressure of the hydraulic station is stable at 6-8 MPa, and the flow rate fluctuation is ≤±2%.

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