Aluminum alloy door and window processing corner cutting device

Abstract

This invention relates to the field of metal cutting technology and discloses a corner-cutting device for aluminum alloy doors and windows, including a table, a mounting bracket, a disc cutter, and an MQL nozzle, as well as a micro-lubricant atomization adaptive system. This system includes: a cutting load dynamic calculation module for generating a cutting intensity coefficient by integrating sawing current, temperature, and feed rate; a cutting configuration feature extraction module for generating cutting geometric feature coefficients based on the entry angle and wall thickness; an atomization delivery efficiency evaluation module for obtaining the effective atomization factor; and a system capability degradation evaluation module for calculating the process capability degradation degree by combining tool wear, vibration intensity, and operating condition coefficients, and dynamically adjusting the MQL atomization amount through a lubrication compensation mapping model. This invention can adaptively adjust the lubrication supply according to real-time changes in cutting conditions, effectively solving the problems of insufficient cooling or oil mist contamination caused by fixed-parameter lubrication, and significantly improving machining quality and tool life.

Description

Technical Field

[0001] This invention belongs to the field of metal cutting processing technology, and particularly relates to a corner cutting device for aluminum alloy doors and windows. Background Technology

[0002] In the processing of aluminum alloy doors and windows, the corner cutting process is a core step in ensuring the precision of frame splicing, directly affecting the sealing performance and structural stability of the finished product. Traditional corner cutting devices generally employ wet cutting processes, relying on large amounts of emulsion or cutting oil for cooling and lubrication. While this can suppress high temperatures in the cutting zone and delay tool wear, it also causes multiple drawbacks: the consumption of cutting fluid is enormous, requiring a continuous supply of several liters of liquid per processing run, leading to a significant increase in production costs; the waste liquid treatment process is complex, involving neutralization, sedimentation, and filtration, resulting in high treatment costs and additional labor time; more seriously, the chemicals in the waste liquid can easily pollute soil and water sources, and with increasingly stringent environmental regulations, such problems have become a major obstacle to the sustainable development of the industry. With the popularization of green manufacturing concepts, dry cutting and micro-lubrication technologies are gradually becoming alternative solutions. The principle is to mix and atomize a micro-lubricant with compressed air, forming micron-sized oil mist particles that are precisely delivered to the cutting area, providing effective boundary lubrication while assisting in chip removal, thereby significantly reducing lubricant consumption and eliminating waste liquid emissions. However, current micro-lubrication systems used for chamfering aluminum alloy doors and windows mostly employ open-loop control, with fixed atomization parameters, failing to respond to dynamic changes in actual cutting conditions. The properties of aluminum alloy materials further exacerbate this contradiction: high thermal conductivity leads to rapid heat dissipation but localized overheating is still prone to occur; a large coefficient of linear expansion causes significant dimensional fluctuations in the workpiece after heating; and the tendency of chips to adhere accelerates tool surface damage. Simultaneously, factors such as differences in saw blade entry angles (e.g., oblique versus straight cutting), variations in profile cross-section wall thickness (from thin to thick walls), cumulative saw blade wear, and feed rate adjustments collectively contribute to highly nonlinear and time-varying lubrication requirements. Fixed-parameter systems are prone to imbalance under complex conditions. Insufficient lubrication leads to a sharp increase in friction between the saw blade and the workpiece, causing adhesion, surface roughness deterioration, and abnormal tool breakage; excessive lubrication results in oil mist contaminating the work environment and leaving an oil film on the workpiece surface, affecting subsequent processes. Furthermore, existing devices lack integrated real-time monitoring modules for key parameters such as saw blade temperature, vibration acceleration, and motor load current, and lack multi-source data fusion and analysis capabilities. This results in the cutting process remaining in an open-loop state, making it impossible to achieve closed-loop adaptive adjustment of lubrication parameters. This technological limitation severely restricts the consistency of processing quality and the reliability of equipment operation. Summary of the Invention

[0003] The purpose of this invention is to provide a corner-cutting device for aluminum alloy doors and windows, in order to solve the above-mentioned problems.

[0004] This invention is implemented as follows: an aluminum alloy door and window corner cutting device, comprising a table and a mounting frame. A disc cutter is rotatably connected to the mounting frame, and a saw blade guard is fixed on the mounting frame outside the disc cutter. An MQL nozzle is mounted on the saw blade guard via an adjusting bracket. The device further includes: a rotating mechanism mounted on the mounting frame for driving the disc cutter to rotate; a moving mechanism mounted on the table for driving the mounting frame to move along the length of the table; and a micro-lubricant atomization adaptive system, comprising: a cutting load dynamic calculation module for acquiring the saw motor load current, saw feed speed, and saw blade temperature, and calculating the cutting intensity. The system includes: a cutting geometry coefficient; a cutting configuration feature extraction module, used to obtain the saw blade entry angle and profile cross-sectional wall thickness, and calculate the cutting geometry coefficient; an atomization delivery efficiency evaluation module, used to obtain the compressed air pressure at the MQL system inlet, and calculate the atomization effective coefficient; a system capability degradation evaluation module, used to obtain the cumulative sawing times and saw blade vibration acceleration, and calculate the process capability degradation degree by combining the cutting intensity coefficient and the cutting geometry coefficient; and an atomization quantity calculation and adjustment module, used to obtain the target micro-lubricant atomization quantity and adjust the current value based on the baseline atomization quantity, process capability degradation degree, and atomization effective coefficient through a lubrication compensation mapping model.

[0005] A further technical solution involves calculating the cutting intensity coefficient as follows: The sawing motor load current, sawing feed speed, and saw blade temperature are obtained; the difference between the current sawing motor load current and the saw blade's stable idle current is compared with the difference between the motor's rated current and the saw blade's stable idle current, and this ratio is limited to a maximum of 1 to obtain the sawing motor load current index; the current sawing feed speed is compared with the equipment's maximum feed speed to obtain the sawing feed speed index; the difference between the current saw blade temperature and the workshop ambient temperature is compared with the difference between the allowable aluminum alloy sawing temperature and the workshop ambient temperature, and this ratio is limited to a maximum of 1 to obtain the saw blade temperature index; the sawing motor load current index, sawing feed speed index, and saw blade temperature index are weighted and fused to generate a cutting intensity coefficient that comprehensively characterizes the severity of the thermo-mechanical-speed coupling in the cutting process; wherein the value of the cutting intensity coefficient is positively correlated with the sawing motor load current index, sawing feed speed index, and saw blade temperature index.

[0006] A further technical solution involves the following calculation process for the cutting geometric characteristic coefficient: obtaining the saw blade entry angle and the profile cross-section wall thickness; comparing the absolute value of the difference between the current saw blade entry angle and the neutral reference angle with the neutral reference angle to obtain the angle characteristic index; comparing the current sawing profile cross-section wall thickness with the maximum wall thickness that the equipment can process to obtain the wall thickness characteristic index; summing the angle characteristic index and the wall thickness characteristic index to generate a composite constraint factor that characterizes the total strength of geometric constraints within the cutting area; and performing continuous nonlinear transfer mapping on the composite constraint factor to generate the output range. The cutting geometric characteristic coefficients of the interval; wherein, as the composite constraint factor increases, the cutting geometric characteristic coefficients monotonically increase, and their increasing slope shows a monotonically decreasing trend as the composite constraint factor increases, so that the cutting geometric characteristic coefficients asymptotically converge to 1 when the composite constraint factor approaches infinity.

[0007] A further technical solution involves calculating the effective atomization coefficient as follows: obtaining the compressed air pressure at the MQL system inlet; and then comparing the current MQL system inlet compressed air pressure with the optimal atomization setting pressure to obtain the effective atomization factor. , , A value close to 0 indicates a complete failure of the delivery process. A value close to 1 indicates an ideal delivery state.

[0008] A further technical solution involves calculating the process capability degradation as follows: First, obtain the cumulative number of sawing operations and the saw blade vibration acceleration. Then, compare the current cumulative number of sawing operations and the saw blade vibration acceleration with the reference service life of the saw blade under standard working conditions and the maximum allowable vibration acceleration of the sawing process, respectively. After limiting the ratio to an upper limit of 1, obtain the tool wear factor and vibration intensity influence factor. Finally, substitute the tool wear factor, vibration intensity influence factor, cutting intensity coefficient, and cutting geometric characteristic coefficient into the formula. Degradation of the acquisition process capability ,in, This is the cutting intensity coefficient. These are the cutting geometric characteristic coefficients. For tool wear factor, The vibration intensity influencing factor, and All are weights related to the difficulty of the working conditions. It is a very small positive number.

[0009] A further technical solution is that the lubrication compensation mapping model is:

[0010] in, The target is the amount of micro-lubricant atomization. As the baseline atomization amount, For process capability degradation, As an effective atomizing agent, It is a very small positive number.

[0011] In a further technical solution, the moving mechanism includes two guide shafts fixed along the length direction on the table surface, the mounting bracket is slidably connected to the guide shafts via guide sleeves, a lead screw is rotatably connected to the bottom of the table surface, the lead screw is threadedly connected to the mounting bracket, a feed motor is fixed at one end of the table surface, and the rotating end of the feed motor is connected to the lead screw.

[0012] In a further technical solution, the rotating mechanism includes a rotating shaft rotatably connected to a mounting frame, a rotary motor fixedly mounted on the mounting frame, the rotating end of the rotary motor being connected to the rotating shaft, and the rotating shaft being connected to the disc cutter via a synchronous belt and a synchronous pulley.

[0013] Compared with the prior art, the beneficial effects of the present invention are as follows: 1. This invention establishes a multi-dimensional process capability degradation assessment model that includes cutting load, geometric constraints, tool wear, and vibration intensity, and combines it with atomization delivery efficiency for feedforward compensation. This achieves closed-loop adaptive control of micro-lubricant atomization amount, effectively solving the problem that traditional MQL systems cannot respond to time-varying cutting conditions due to fixed parameters, and significantly reducing machining defects such as saw blade adhesion, tooth breakage, and workpiece surface roughness.

[0014] 2. This invention utilizes a nonlinear saturation function and a multi-factor multiplicative coupling algorithm to accurately quantify the cutting state, enabling the lubrication supply to precisely match the tribological requirements of the actual cutting area. This avoids abnormal tool wear caused by insufficient lubrication and eliminates workshop oil mist pollution and waste liquid treatment burden caused by excessive lubrication, thus meeting the development requirements of green manufacturing.

[0015] 3. The device of the present invention has a compact structure. Through the coordinated work of integrated sensors and controllers, it can automatically cope with the working condition fluctuations throughout the entire life cycle of bevel cutting, thick walls, and saw blades without manual intervention, which greatly improves the stability and consistency of the aluminum alloy door and window corner cutting process and reduces the overall production cost. Attached Figure Description

[0016] Figure 1 A schematic diagram of the structure of an aluminum alloy door and window processing corner cutting device provided by the present invention; Figure 2 Provided by the present invention Figure 1 A structural schematic diagram of the platform surface viewed from below. Figure 3 The flowchart of the micro-lubricant atomization amount adaptive system provided by the present invention.

[0017] In the attached diagram: 1. Tabletop; 2. Cutting clearance groove; 3. Mounting bracket; 4. Circular blade; 5. Saw blade guard; 6. MQL nozzle; 7. Rotary motor; 8. Guide shaft; 9. Guide sleeve; 10. Lead screw; 11. Feed motor; 12. Rotating shaft. Detailed Implementation

[0018] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0019] The specific implementation of the present invention will be described in detail below with reference to specific embodiments.

[0020] like Figures 1-3 As shown, an aluminum alloy door and window processing corner cutting device according to an embodiment of the present invention includes a table 1 and a mounting bracket 3. A disc cutter 4 is rotatably connected to the mounting bracket 3. A saw blade guard 5 is fixed on the mounting bracket 3 outside the disc cutter 4. An MQL nozzle 6 is mounted on the saw blade guard 5 via an adjusting bracket. The MQL nozzle 6 is connected to a micro-lubrication system. A cutting clearance groove 2 is provided on the table 1. The saw blade guard 5 surrounds the outside of the disc cutter 4, and its main function is to protect the operator from injury by the high-speed rotating saw blade and to collect the chips generated during the cutting process. It also provides a mounting position for the MQL nozzle 6. The MQL nozzle 6 is one of the core components of the micro-lubrication (MQL) system. It is used to mix a very small amount of lubricant with compressed air to form an oil mist and spray it precisely onto the cutting area of ​​the disc cutter 4 to achieve lubrication, cooling, and auxiliary chip removal. The micro-lubrication system is an integrated system including a lubricant tank, a compressed air source, a mixing device, the MQL nozzle 6, and a control unit. It is used to achieve micro-lubrication of the cutting area and also includes: A rotating mechanism, mounted on the mounting bracket 3, is used to drive the disc cutter 4 to rotate; A moving mechanism, installed on the table 1, is used to drive the mounting frame 3 to move along the length of the table 1; Micro-lubrication atomization adaptive system, comprising: The dynamic cutting load calculation module is used to acquire the load current of the sawing motor, the sawing feed speed, and the saw blade temperature, and calculate the cutting intensity coefficient. Specifically, the load current can be acquired by connecting a current sensor in series in the sawing motor circuit; the sawing feed speed can be acquired by installing a photoelectric encoder or magnetic scale on the moving mechanism; and the saw blade temperature can be acquired by installing an infrared temperature sensor or thermocouple near the saw blade. After acquiring these parameters, a simple weighted average algorithm or a preset lookup table method can be used to map these parameters into a coefficient reflecting the degree of cutting intensity. For example, when the load current, feed speed, and saw blade temperature increase, the value of the cutting intensity coefficient will increase accordingly.

[0021] The cutting configuration feature extraction module is used to obtain the saw blade entry angle and the profile cross-section wall thickness, and calculate the cutting geometric feature coefficients. The saw blade entry angle can be obtained through an angle sensor mounted on mounting bracket 3, or through preset machining program parameters. The profile cross-section wall thickness can be measured non-contactly using a laser rangefinder, or manually input by the operator according to the profile specifications. After obtaining these geometric parameters, simple proportional relationships or piecewise functions can be used to convert these parameters into cutting geometric feature coefficients. For example, when the entry angle deviates significantly from the vertical direction or the profile wall thickness increases, the value of the cutting geometric feature coefficient will increase accordingly.

[0022] The atomization delivery efficiency evaluation module is used to acquire the compressed air pressure at the MQL system inlet and calculate the effective atomization coefficient. This can be achieved by installing a pressure sensor at the MQL system inlet. After acquiring the pressure value, it can be compared with a preset minimum working pressure. If the current pressure is lower than the minimum working pressure, the effective atomization coefficient is zero; if it is higher than the minimum working pressure, the effective atomization coefficient can be calculated linearly or nonlinearly based on the ratio of the pressure value to the ideal pressure.

[0023] The system capability degradation assessment module is used to acquire the cumulative number of sawing operations and the saw blade vibration acceleration, and calculate the process capability degradation degree by combining the cutting intensity coefficient and the cutting geometric characteristic coefficient. The cumulative number of sawing operations can be recorded by a counter inside the device. The saw blade vibration acceleration can be acquired by installing an acceleration sensor on the saw blade guard 5 or the mounting bracket 3. After acquiring these parameters, a simple weighted summation or product method can be used to combine the cumulative number of sawing operations, the saw blade vibration acceleration, the cutting intensity coefficient, and the cutting geometric characteristic coefficient to calculate a process capability degradation degree that reflects the degree of saw blade wear and deterioration of working conditions. For example, when the cumulative number of sawing operations increases, the vibration acceleration increases, and the cutting intensity coefficient and geometric characteristic coefficient are higher, the process capability degradation degree will increase accordingly.

[0024] The atomization quantity calculation and adjustment module is used to obtain the target micro-lubrication (MQL) atomization quantity and adjust the current value based on the baseline atomization quantity, process capability degradation degree, and atomization effectiveness coefficient through a lubrication compensation mapping model. The baseline atomization quantity can be an initial value preset based on experience. The lubrication compensation mapping model can be a multi-dimensional lookup table. Based on the input process capability degradation degree and atomization effectiveness coefficient, the corresponding compensation factor is looked up in the table, and then multiplied by the baseline atomization quantity to obtain the target atomization quantity. Alternatively, the model can be a simple linear or nonlinear function, using the above parameters as input to directly calculate the target atomization quantity. Based on the calculated target atomization quantity, the MQL system dynamically adjusts the lubricant atomization quantity by adjusting the flow control valve or air pressure regulating valve inside the MQL nozzle 6.

[0025] In this embodiment of the invention, in an aluminum alloy door and window processing workshop, a batch of aluminum alloy profiles with varying thicknesses and different cutting angle requirements need to be cut. The operator places and fixes the profile to be processed on the worktable 1. By adjusting the fixing angle of the profile, the cutting angle of the disc cutter 4 can be adjusted. The rotating mechanism drives the disc cutter 4 to rotate at high speed, preparing for cutting. The moving mechanism drives the mounting bracket 3 to move the disc cutter 4 for feed cutting. The micro-lubricant atomization adaptive system, based on a preset benchmark atomization amount and combined with real-time calculated cutting intensity coefficient, cutting geometric characteristic coefficient, atomization effective action coefficient, and process capability degradation degree, dynamically calculates the target micro-lubricant atomization amount required under the current working conditions through a lubrication compensation mapping model. For example, if the cutting intensity coefficient, cutting geometric characteristic coefficient, and process capability degradation degree are all high, and the atomization effective action coefficient is low, the system will calculate a target atomization amount significantly higher than the benchmark atomization amount. The MQL nozzle 6 adjusts according to the target atomization amount, precisely spraying oil mist onto the cutting area of ​​the disc cutter 4. Therefore, even under complex and varied working conditions such as heavy loads, thick walls, large angle cutting, or saw blade wear, the MQL system can provide appropriate lubrication to ensure smooth cutting.

[0026] This application further proposes the following calculation process for the cutting intensity coefficient: The load current of the sawing motor, the sawing feed speed, and the saw blade temperature are obtained. The load current of the sawing motor can be monitored in real time by connecting a current sensor or a Hall sensor in series in the power supply circuit of the sawing motor. The sawing feed speed can be obtained by an encoder or a linear displacement sensor installed on the moving mechanism. The saw blade temperature can be measured by a non-contact infrared temperature sensor or a thermocouple sensor. The sensor can be installed inside the saw blade guard 5, close to the cutting area of ​​the saw blade 4.

[0027] The difference between the current load current of the sawing motor and the stable idle current of the saw blade is compared with the difference between the rated current on the motor nameplate and the stable idle current of the saw blade. After using a min function to limit the ratio to an upper limit of 1, the load current index of the sawing motor is obtained. This processing method can convert the actual load current into a relative value between 0 and 1, effectively reflecting the degree of motor load, while avoiding the excessive influence of abnormal values ​​caused by instantaneous overload on the evaluation results.

[0028] The sawing feed rate index is obtained by comparing the current sawing feed rate with the maximum feed rate of the equipment. The sawing feed rate index directly reflects the proportion of the current feed rate to the maximum capacity of the equipment.

[0029] The difference between the current saw blade temperature and the ambient temperature in the workshop is compared with the difference between the allowable temperature for aluminum alloy sawing and the ambient temperature in the workshop. The ratio is then limited to 1 using a min function to obtain the saw blade temperature index. This quantifies the degree of increase in saw blade temperature relative to ambient temperature and limits its upper limit to prevent extreme high temperature data from having an unreasonable impact on the index.

[0030] Parameters such as the stable current of the saw blade during idle, the rated current on the motor nameplate, the maximum feed speed of the equipment, the ambient temperature of the workshop, and the allowable temperature for sawing aluminum alloys can be obtained in advance through experiments, by consulting the equipment manual or industry standards, and stored in the database of the control system.

[0031] The load current index of the sawing motor, the sawing feed rate index, and the saw blade temperature index are weighted and fused to generate a cutting intensity coefficient that comprehensively characterizes the severity of the thermo-mechanical-speed coupling in the cutting process. The value of the cutting intensity coefficient is positively correlated with all three indices. The specific weighted fusion formula is as follows:

[0032] in, This is the cutting intensity coefficient. , A value close to 0 indicates light load and low temperature. A value close to 1 indicates overheating under heavy load. The load current index of the sawing motor. This refers to the saw blade temperature index. This refers to the sawing feed rate index. , and All are cutting intensity weights ranging from 0 to 1, and By using this weighted summation method, the effects of motor load, saw blade temperature, and feed speed on cutting intensity can be comprehensively considered, and the weights can be adjusted accordingly. , and The importance of various factors in the cutting intensity assessment can be flexibly adjusted according to different processing requirements or material characteristics. These weights can be set and adjusted based on actual processing experience, material characteristics, or optimization algorithms.

[0033] This application's solution addresses the inaccuracy of traditional methods by providing a standardized calculation process for cutting intensity coefficients. The process first acquires key parameters reflecting the cutting state in multiple dimensions and in real-time, including the saw motor load current, saw feed rate, and saw blade temperature. These parameters are collected in real-time by sensors, providing a data foundation for subsequent accurate calculations. Next, through a series of carefully designed ratio processing and min-function limiting operations, the original physical quantities are transformed into normalized exponents within the range of 0 to 1. This normalization process not only eliminates the influence of different physical dimensions, making the various indicators comparable, but also ensures the stability and rationality of the exponents through limiting, avoiding interference from extreme data in the evaluation results. For example, the load current index reflects the relative relationship between the actual working load of the motor and the rated load, the temperature index quantifies the degree of increase in saw blade temperature relative to the ambient temperature, and the feed rate index reflects the relative level of the current processing speed. Finally, these normalized exponents are substituted into a weighted average model, using preset cutting intensity weights. , and A comprehensive calculation is performed to obtain the final cutting intensity coefficient. This coefficient precisely quantifies the intensity of the current cutting condition with a single value; the closer its value is to 1, the more severe the condition. This comprehensive evaluation method makes the quantification results of cutting intensity more reliable and consistent, providing solid data support for the subsequent precise adjustment of the micro-lubricant atomization adaptive system. When the cutting intensity coefficient... A higher lubrication level indicates a severe cutting condition, requiring increased lubrication; conversely, a lower lubrication level indicates a more severe cutting condition. When the temperature is low, the amount of lubrication can be reduced appropriately, thereby achieving precise adaptive control of the MQL atomization amount.

[0034] As a specific implementation, in the aluminum alloy door and window corner cutting device, corresponding sensors and controllers can be configured to calculate the aforementioned cutting intensity coefficient. For example, a current transformer is installed on the power supply line of the sawing motor to collect the load current of the sawing motor in real time; a photoelectric encoder is installed on the moving mechanism to measure the feed speed; and an infrared temperature sensor is installed inside the saw blade guard 5, near the cutting edge of the saw blade 4, to measure the surface temperature of the saw blade 4 non-contactly. The analog signals collected by these sensors can be converted into digital signals by an A / D converter and transmitted to an industrial controller (such as a PLC or embedded controller). This controller has pre-stored the saw blade idle stable current, the motor nameplate rated current, the maximum feed speed of the equipment, the workshop ambient temperature, the allowable temperature for aluminum alloy sawing, and the cutting intensity weight. , and Parameters such as current, speed, and temperature are processed by the controller according to preset calculation logic. First, the controller performs ratio processing and minimum function limiting on the real-time collected current, speed, and temperature data to calculate the load current index of the sawing motor. Sawing feed rate index and saw blade temperature index Then, these exponents are substituted into the formula. The current cutting intensity coefficient is calculated. For example, when the sawing motor load current is close to the rated current, the saw blade temperature rises significantly, and the feed speed is high, the calculated... A value close to 1 indicates extremely harsh cutting conditions; conversely, a value close to 1 indicates that the cutting conditions are very severe. The value will approach 0, indicating a relatively easy cutting condition. This calculated cutting intensity coefficient It will serve as an important input parameter for the micro-lubrication atomization adaptive system, used for subsequent lubrication volume adjustment.

[0035] Through the above technical solution, this application provides a standardized and accurate method for calculating the cutting intensity coefficient, effectively solving the problem of inconsistent or inaccurate assessments of cutting intensity by traditional corner cutting devices. This method comprehensively considers multiple key factors such as saw motor load, saw blade temperature, and feed speed, and employs normalization and weighted summation to ensure that the cutting intensity coefficient accurately and in real-time reflects the true intensity of the current cutting condition. This provides a reliable input for the micro-lubricant atomization adaptive system, enabling the MQL nozzle 6 to dynamically adjust the atomization amount of lubricant according to changes in actual cutting conditions. When the cutting intensity is high, the system can promptly increase the lubrication amount, effectively suppressing saw blade adhesion, reducing tool wear, and lowering the surface roughness of the machined surface; when the cutting intensity is low, the system can appropriately reduce the lubrication amount, avoiding lubricant waste and excessive workpiece contamination. Therefore, this solution significantly improves the adaptive control capability and lubrication effect of the MQL system, optimizes the processing quality of aluminum alloy doors and windows, and reduces lubricant consumption, meeting the requirements of green manufacturing.

[0036] This application further proposes the following calculation process for the cutting geometric characteristic coefficients: The saw blade entry angle (the angle between the saw blade plane and the profile axis) and the profile cross-section wall thickness are obtained. The saw blade entry angle can be obtained in real time by detecting the tilt angle of the saw blade relative to the profile through an angle sensor (e.g., a rotary encoder or tilt sensor) mounted on the mounting bracket 3, or by reading the set angle of the current machining program through the CNC system. The profile cross-section wall thickness can be queried from a preset profile database, or measured before cutting using non-contact measuring devices such as laser rangefinders or ultrasonic sensors.

[0037] The absolute value of the difference between the current saw blade approach angle and the neutral reference angle is compared with the neutral reference angle to obtain the angle characteristic index. The neutral reference angle is a preset ideal cutting angle, typically 90 degrees, where the saw blade plane is perpendicular to the profile axis. This value can be stored in the parameter table of the control system. This step aims to quantify the degree to which the saw blade approach angle deviates from the ideal straight-cut state. This ratio processing standardizes the angle deviation, allowing for comparison of the geometric constraint strength at different angles. For example, when the saw blade approach angle matches the neutral reference angle, the angle characteristic index is 0, indicating minimal angle constraint; when the deviation is large, the index value increases, indicating stronger angle constraint. This calculation can be performed by the device's controller (e.g., an industrial PC, PLC, or embedded microcontroller).

[0038] The wall thickness characteristic index is obtained by comparing the current wall thickness of the cut profile section with the maximum wall thickness that the equipment can process. The maximum wall thickness that the equipment can process is a design parameter of the corner cutting device, representing the maximum profile thickness it can effectively cut. This value can also be stored in the parameter table of the control system. This step aims to quantify the impact of profile thickness on cutting difficulty. By comparing the actual wall thickness with the maximum capacity of the equipment, the impact of wall thickness can be standardized, allowing the system to assess the degree of "thickness challenge" of the current cutting task. For example, the wall thickness characteristic index is small when cutting thin-walled profiles; when cutting profiles close to the maximum wall thickness of the equipment, the index value is close to 1, indicating a large wall thickness constraint. This calculation can also be performed by the device's controller.

[0039] The angular characteristic index and the wall thickness characteristic index are summed to generate a composite constraint factor that characterizes the total strength of geometric constraints within the cutting region. This composite constraint factor is then subjected to continuous nonlinear transfer mapping to generate the output range. The cutting geometric characteristic coefficients of the interval; wherein, as the composite constraint factor increases, the cutting geometric characteristic coefficients monotonically increase, and their increasing slope shows a monotonically decreasing trend as the composite constraint factor increases, so that the cutting geometric characteristic coefficients asymptotically converge to 1 when the composite constraint factor approaches infinity; the specific formula for the continuous nonlinear transfer mapping is:

[0040] in, These are the cutting geometric characteristic coefficients. , It is an angular characteristic index. Let be the wall thickness characteristic index. This formula uses an exponential function, such that when both the angular characteristic index and the wall thickness characteristic index are small, A value close to 0 indicates the ideal straight-cut thin-walled working condition with minimal geometric constraints; as these two exponents increase, The value gradually approaches 1, representing the extreme oblique cutting of thick walls under maximum geometric constraints. This nonlinear mapping can more accurately reflect the comprehensive influence of geometric constraints on the cutting process, providing a precise basis for subsequent lubrication adjustment. The calculation of this formula can be completed by the mathematical processing unit in the device's controller.

[0041] The proposed solution systematically acquires key geometric parameters such as the saw blade entry angle and the profile cross-section wall thickness, and then standardizes these parameters by combining a neutral reference angle and the maximum machinable wall thickness of the equipment, thereby obtaining angular characteristic indices and wall thickness characteristic indices. These indices are then substituted into a nonlinear exponential formula to comprehensively calculate the cutting geometric characteristic coefficients. This series of steps provides a precise method for quantifying cutting geometry constraints, solving the problem that traditional MQL systems cannot dynamically adjust lubrication based on actual geometric conditions. By quantifying the deviation between the saw blade's entry angle and the neutral reference angle, as well as the ratio of the profile cross-section wall thickness to the maximum processing wall thickness of the equipment, this solution can accurately capture changes in cutting geometry. This quantification allows the system to distinguish various degrees of geometric constraints, from ideal straight-cutting thin-walled conditions to extreme oblique-cutting thick-walled conditions, thus providing a key input parameter for the micro-lubrication atomization adaptive system. Cutting geometry characteristic coefficients The introduction of this technology enables the entire micro-lubrication atomization adaptive system to more comprehensively consider the complexity of the cutting process. Working together with other parameters such as the sawing motor load current, sawing feed speed, and saw blade temperature, it achieves precise adaptive adjustment of the MQL atomization amount, significantly improving the lubrication effect and processing quality.

[0042] In one specific implementation, in the aluminum alloy door and window processing corner cutting device, the saw blade cutting angle can be obtained in real time by an angle sensor (e.g., a high-precision absolute rotary encoder) mounted on the end of the rotary motor 7 shaft or on the mounting bracket 3 of the rotating mechanism. This sensor transmits the angle signal to the central controller of the device. The profile cross-section wall thickness can be read from the production order database of the processing task, or pre-scanned by a laser scanner integrated on the table 1 before the profile is fed, and the measurement data is sent to the controller. The neutral reference angle and the maximum wall thickness that the equipment can process are fixed parameters and are pre-stored in the controller's memory. After receiving these data, the controller first calculates the absolute value of the difference between the current saw blade cutting angle and the neutral reference angle, and compares it with the neutral reference angle to obtain the angle characteristic index. Then, it compares the current profile cross-section wall thickness with the maximum wall thickness that the equipment can process to obtain the wall thickness characteristic index. Finally, the controller substitutes these two indices into a preset index formula. Calculations are performed to obtain the cutting geometric characteristic coefficients in real time. The calculation result was then fed into the micro-lubrication atomization adaptive system as the basis for adjusting the atomization amount of the MQL nozzle 6.

[0043] Through the above technical solution, this application can accurately quantify the impact of cutting geometry on lubrication requirements, solving the problem that traditional MQL systems cannot accurately adjust the lubrication amount when faced with different saw blade entry angles and profile cross-sectional wall thicknesses. This allows the micro-lubrication atomization adaptive system to more accurately assess the geometric difficulty of the cutting conditions, thereby achieving refined and adaptive adjustment of the MQL atomization amount. This precise quantification of geometric constraints helps avoid saw blade adhesion and rough machined surfaces caused by insufficient lubrication, as well as oil mist waste and workpiece contamination caused by excessive lubrication, significantly improving the efficiency, processing quality, and tool life of aluminum alloy door and window corner cutting.

[0044] This application further proposes the following calculation process for the effective atomization coefficient: Obtain the compressed air pressure at the MQL system inlet. The MQL system inlet compressed air pressure refers to the actual compressed air pressure measured at the inlet of the Micro-Lubrication (MQL) system. Its function is to serve as a key input parameter for the normal operation and atomization effect of the MQL system. This pressure can be monitored and acquired in real time using a pressure sensor installed on the MQL system's inlet pipeline. For example, a piezoresistive pressure sensor or a capacitive pressure sensor can be used to convert the air pressure signal into an electrical signal for the control system to read.

[0045] The ratio of the current MQL system inlet compressed air pressure to the optimal atomization setting pressure is used to obtain the effective atomization factor. The optimal atomization setting pressure refers to the ideal compressed air pressure value that enables the MQL system to achieve the best lubricant atomization effect under specific operating conditions. This value is usually determined through experimental calibration, equipment manufacturer recommendations, or experience. For example, an optimal pressure range or specific value can be determined by conducting atomization tests at different pressures and observing the atomized particle size, distribution uniformity, and lubrication effect. Ratio processing involves mathematically comparing the real-time MQL system inlet compressed air pressure with the preset optimal atomization setting pressure to quantify the deviation between the current air pressure and the ideal air pressure. This ratio processing can be performed by a microprocessor or dedicated calculation module in the control system, for example, by performing a simple division operation. Atomization Effectiveness Factor This is a dimensionless parameter obtained after ratio processing, used to characterize the effectiveness of the MQL system's atomization effect under the current compressed air pressure. Its value ranges from 0 to 1, where a value close to 0 indicates severely insufficient air pressure leading to almost complete atomization failure, while a value close to 1 indicates sufficient air pressure and ideal atomization performance. This factor provides a basis for quantifying the current atomization effect in the subsequent lubrication compensation mapping model.

[0046] This application's solution improves the overall performance of the micro-lubricant atomization adaptive system by precisely quantifying the impact of the MQL system's inlet compressed air pressure on atomization. Specifically, the system first acquires the MQL system's inlet compressed air pressure in real time, which is a key factor affecting lubricant atomization and delivery efficiency. Simultaneously, the system presets an optimal atomization setting pressure as a benchmark. Subsequently, by comparing the real-time pressure with the optimal setting pressure, the effective atomization factor is calculated. This factor directly reflects the MQL system's ability to achieve effective atomization under current atmospheric pressure conditions. A value closer to 1 indicates a more ideal atomization effect; conversely, a value closer to 0 indicates a poorer atomization effect, or even potential failure. This atomization effectiveness factor... As a crucial input parameter in the adaptive micro-lubricant atomization system, it works in conjunction with other parameters such as the cutting intensity coefficient, cutting geometry coefficient, and process capability degradation degree in the lubrication compensation mapping model. In this way, the system can comprehensively consider the severity of cutting conditions, tool wear, and the operating status of the MQL system itself, thereby achieving precise and dynamic adjustment of the target micro-lubricant atomization amount. This mechanism effectively solves the problem of poor lubrication performance caused by air pressure fluctuations in traditional MQL systems, ensuring adequate lubrication under various operating conditions and avoiding insufficient or excessive lubrication.

[0047] The following is a specific example. As a concrete implementation, the compressed air pressure at the MQL system inlet can be acquired in real time using a high-precision digital pressure sensor installed on the MQL system's inlet pipeline. For example, a pressure sensor with a range of 0-1 MPa and an accuracy of 0.5%FS can be selected. The optimal atomization setting pressure is determined to be 0.6 MPa based on the characteristics of the MQL nozzle 6 and the lubricant through preliminary experiments. The microprocessor in the control system, such as an industrial-grade PLC or embedded controller, periodically reads the data from the pressure sensor. When the current compressed air pressure at the MQL system inlet is obtained to be 0.45 MPa, the microprocessor performs a ratio calculation: 0.45 MPa / 0.6 MPa = 0.75, thereby obtaining the effective atomization factor. The value is 0.75. This factor is then input into the lubrication compensation mapping model, where it, along with other calculated cutting intensity coefficients, cutting geometry coefficients, and process capability degradation, jointly determines the final target micro-lubricant atomization amount. For example, if the model calculates that an increase in lubrication is needed under the current operating conditions, but the atomization effectiveness factor is [not specified], the target micro-lubricant atomization amount may be [not specified]. If the value is low (e.g., 0.75), the system may further increase the lubricant supply based on the baseline atomization amount to compensate for the decrease in atomization efficiency caused by insufficient air pressure, ensuring that the total amount of lubricant actually reaching the cutting area reaches the expected level.

[0048] Through the above technical solution, this application can accurately quantify the impact of the inlet compressed air pressure of the MQL system on the lubricant atomization effect. This is achieved by introducing an effective atomization factor. The system can evaluate the operating status of the MQL system in real time, thus providing a key parameter reflecting the actual atomization efficiency for the micro-lubricant atomization adaptive system. This allows the lubrication compensation mapping model to more comprehensively consider the MQL system's own operating conditions when calculating the target micro-lubricant atomization amount, avoiding insufficient or excessive lubrication caused by air pressure fluctuations. Therefore, this application significantly improves the accuracy of lubrication compensation and the system's adaptability, ensuring that the MQL system provides optimal lubrication under different air pressure conditions, thereby improving the cutting quality and tool life in aluminum alloy door and window machining.

[0049] This application further proposes the following calculation process for process capability degradation: The system acquires the cumulative number of sawing operations and the saw blade vibration acceleration. The cumulative number of sawing operations refers to the total number of sawing operations completed by the saw blade since it was put into use. This can be accumulated in real time by setting a counter in the control system of the device, or by reading the number of operation commands of the sawing motor 7. The saw blade vibration acceleration refers to the vibration intensity generated by the saw blade during the cutting process. It is usually monitored and collected in real time by an acceleration sensor installed near the mounting bracket 3 or the saw blade guard 5.

[0050] The current cumulative sawing count and saw blade vibration acceleration are compared with the reference service life of the saw blade under standard working conditions and the maximum allowable vibration acceleration of the sawing process, respectively. After using a min function to limit the ratio to an upper limit of 1, the tool wear factor and vibration intensity influence factor are obtained. The reference service life of the saw blade under standard working conditions is the expected service life of a specific model of saw blade under ideal or standard cutting conditions. This value can be obtained from technical parameters provided by the saw blade manufacturer, historical experience data, or through previous experimental calibration. The maximum allowable vibration acceleration of the sawing process is an upper limit value set according to process requirements and equipment safety operation standards. Exceeding this value may lead to a decrease in processing quality or equipment damage. This value can be determined through process specifications or experiments. The aim is to standardize the degree of tool wear to a tool wear factor between 0 and 1, avoiding excessive distortion of the factor value due to the cumulative number of cuts exceeding the reference service life. Similarly, the vibration intensity influence factor is also between 0 and 1, reflecting the degree of influence of vibration on cutting stability. These ratio processing and limiting operations are usually implemented through software algorithms in the control unit or calculation module within the device.

[0051] Substituting the tool wear factor, vibration intensity influence factor, cutting intensity coefficient, and cutting geometric characteristic coefficient into the formula Degradation of the acquisition process capability , , A value close to 0 indicates that the equipment has ample capacity, the cutting conditions are easy, and it is in a highly matched and ideal state. A value close to 1 indicates that the equipment is overstretched, the cutting conditions are harsh, and the equipment is in a severe mismatch alarm state. This is the cutting intensity coefficient. These are the cutting geometric characteristic coefficients. For tool wear factor, The vibration intensity influencing factor, and All are work condition difficulty weights ranging from 0 to 1, and , To ensure the denominator is a very small positive number, and to prevent the denominator from being zero, such as... Difficulty weight of working conditions and It is used to adjust the cutting intensity coefficient. and cutting geometric characteristic coefficients Process capability degradation The parameter for contribution level has a value range of 0-1 and a sum of 1. It can be set by expert experience or optimized and adjusted based on historical data through machine learning algorithms.

[0052] The tool wear factor, vibration intensity influence factor, and cutting intensity coefficient obtained above, along with the micro-lubricant atomization adaptive system, are used to... and cutting geometric characteristic coefficients Substituting into the preset formula, the process capability degradation degree is calculated. This formula comprehensively considers tool wear, vibration intensity, and the difficulty of the cutting conditions, and can quantify the degree of matching between the current equipment capabilities and the cutting conditions. The smallest positive number in the formula... The introduction of , for example, a value of 0.001, is to prevent calculation errors when the denominator is zero, and to ensure the stability and robustness of the calculation.

[0053] This application's solution comprehensively acquires key parameters such as the cumulative number of sawing cuts and the saw blade vibration acceleration, and standardizes these parameters by combining the saw blade's reference service life under standard working conditions and the maximum allowable vibration acceleration of the sawing process. This allows for precise quantification of the tool wear factor and vibration intensity influence factor. Based on this, these factors are then correlated with the cutting intensity coefficient. and cutting geometric characteristic coefficients By combining these methods organically, the process capability degradation degree can be calculated using a specific mathematical model. This multi-dimensional and comprehensive evaluation method overcomes the problem of traditional methods lacking precise quantification of tool wear, vibration intensity, and cutting condition difficulty. By comprehensively considering these key factors, this solution can dynamically and accurately reflect the degree of matching between equipment capabilities and current cutting conditions, providing more precise input parameters for the micro-lubricant atomization adaptive system, thereby making the adjustment of micro-lubricant (MQL) atomization more intelligent and adaptive.

[0054] As a specific implementation method, in the aluminum alloy door and window corner cutting device, the above-mentioned process capability degradation degree can be calculated in the following way: A counting module is integrated into the device's control system to record the cumulative number of sawing operations in real time; a high-precision acceleration sensor is installed on the mounting bracket 3 or inside the saw blade guard 5 to collect saw blade vibration acceleration data in real time. Parameters such as the saw blade's service life and the maximum allowable vibration acceleration under standard working conditions can be pre-stored in the device's database or configured through a human-machine interface. Working condition difficulty weight. and It can also be set as a configurable parameter. When the device is performing sawing operations, the control system reads the cumulative number of sawing operations and the saw blade vibration acceleration in real time, and compares and limits these values ​​with preset reference values ​​and maximum allowable values ​​to generate tool wear factors and vibration intensity influence factors. Subsequently, the control system compares these factors with the cutting intensity coefficient calculated by the micro-lubricant atomization adaptive system. and cutting geometric characteristic coefficients Substitute these values ​​into a preset formula, and the built-in calculation program will calculate the process capability degradation degree in real time. For example, when the cumulative number of sawing operations reaches 80% of the reference life and the saw blade vibration acceleration is close to the maximum allowable value, the calculated tool wear factor and vibration intensity influence factor will be high, leading to a deterioration in process capability. An increase indicates that the equipment is under high load or in a sub-healthy state.

[0055] Through the above technical solution, this application can provide a precise quantification of process capability degradation. This degradation level comprehensively reflects tool wear, vibration intensity, and the difficulty of the cutting conditions. This allows the adaptive micro-lubrication atomization system to more accurately assess the lubrication requirements of the current cutting state, thereby achieving precise adaptive adjustment of the micro-lubrication (MQL) atomization. This precise degradation level assessment avoids the problems of insufficient or excessive lubrication caused by fixed parameters under traditional open-loop control, effectively reducing the occurrence of adverse phenomena such as saw blade adhesion and rough machined surfaces, while reducing lubricant waste and workpiece contamination, significantly improving the quality and efficiency of aluminum alloy door and window processing.

[0056] This application further proposes a lubrication compensation mapping model as follows:

[0057] in, For the target micro-volume lubrication (MQL) atomization amount, As the baseline atomization amount, For process capability degradation, As an effective atomizing agent, It is a very small positive number.

[0058] Reference atomization volume This refers to the preset MQL atomization level required to ensure effective lubrication and cooling under standard or ideal cutting conditions. It serves as the initial reference point for dynamic system adjustments. This reference atomization level... An optimal initial atomization level can be determined experimentally, for example, by observing the machined surface quality, tool wear, and cutting temperature under specific material, tool, feed rate, and depth of cut conditions. As another approach, a baseline atomization level can be established. Alternatively, it can be set based on empirical values ​​or manufacturer recommendations, such as a pre-set universal reference value based on common machining parameters of aluminum alloy profiles and the performance parameters of the MQL system. Target Micro-Lubrication (MQL) Atomization Amount This refers to the actual MQL atomization amount dynamically calculated and output by the system based on real-time operating parameters (such as process capability degradation and atomization effectiveness factor). It is the final output of the system's adaptive adjustment. This target micro-lubrication (MQL) atomization amount... The atomization amount can be adjusted via a flow controller or proportional valve in a Minimum Mass Lubrication (MQL) system. This controller receives a calculated target atomization amount signal and adjusts the lubricant-compressed air mixing ratio and injection volume accordingly. Alternatively, the target MQL atomization amount... Alternatively, the volume and frequency of lubricant sprayed each time can be precisely controlled by a micro-pump or solenoid valve integrated on the MQL nozzle 6, based on control signals, thereby achieving the target atomization amount. Process capability degradation. It is an indicator that comprehensively reflects the wear and tear of equipment (such as saw blades) and the severity of cutting conditions. A higher value indicates more severe equipment deterioration and more difficult cutting conditions. In the lubrication compensation mapping model, As a numerator, its increase directly leads to an increase in the target atomization amount, compensating for the increased lubrication demand caused by equipment degradation or harsh operating conditions. Process capability degradation degree The calculation, as described in the above scheme, is obtained by comprehensively calculating parameters such as the cumulative number of sawing cuts, saw blade vibration acceleration, cutting intensity coefficient, and cutting geometric characteristic coefficient. Atomization effective action factor. This is an indicator reflecting the actual atomization effect and delivery efficiency of the MQL system. A higher value indicates better atomization and more ideal lubricant delivery. In the lubrication compensation mapping model, As a denominator term, a decrease in its value (i.e., a worsening of atomization effect) leads to a smaller denominator, thereby increasing the compensation term and prompting an increase in the target atomization amount to compensate for the insufficient atomization efficiency. Atomization Effectiveness Factor The calculation, as described in the above scheme, is obtained by processing the ratio of the compressed air pressure at the MQL system inlet to the optimal atomization setting pressure. Minimal positive number. It is a preset, very small positive value used to prevent the denominator from being zero in mathematical calculations, ensuring the stability and reliability of the model. In the lubrication compensation mapping model, when the atomization effective factor... When it is close to 0 (e.g., when compressed air completely fails). The presence of this variable avoids division-by-zero errors, allowing the model to output a reasonable (usually large) target atomization amount to indicate a serious system problem or the need for maximum lubrication compensation. Minimal positive numbers. It is usually set to a fixed, tiny value during system design, such as 0.001.

[0059] This application's solution achieves precise adaptive adjustment of minute lubrication atomization amount by introducing a lubrication compensation mapping model. This model uses a reference atomization amount... Based on this, through process capability degradation and atomization effective factors The baseline value is dynamically adjusted. Specifically, when the process capability deteriorates... An increase in this value indicates increased saw blade wear or deterioration of cutting conditions. In this case, the model will correspondingly increase the target micro-lubricant (MQL) atomization amount. This provides enhanced lubrication and cooling, compensating for any decline in equipment performance. Simultaneously, when the atomized effective action factor... When the value decreases, it indicates a decline in the atomization efficiency or delivery capacity of the MQL system. The model then... Placing it in the denominator increases the compensation term, thereby improving the atomization amount of the target micro-lubricant (MQL). This is to compensate for insufficient lubricant actually reaching the cutting area. Minimal positive number. The introduction of this method effectively avoids the mathematical problem of zero denominator, ensuring the stability and reliability of the model under extreme working conditions. This model, combined with the aforementioned technical solution for acquiring parameters such as sawing motor load current, sawing feed speed, saw blade temperature, saw blade entry angle, profile cross-section wall thickness, MQL system inlet compressed air pressure, cumulative sawing cycles, and saw blade vibration acceleration, and calculating the cutting intensity coefficient, cutting geometric characteristic coefficient, atomization effective coefficient, and process capability degradation degree, enables the entire micro-lubrication atomization adaptive system to sense the cutting state in real time and intelligently adjust the lubricant supply according to complex working condition changes, thereby achieving closed-loop control.

[0060] The following is a concrete example to illustrate this. Assume a baseline atomization amount. The flow rate was set to 10 ml / min. Under ideal cutting conditions, the process capability degradation was... The effective atomization factor is 0.1. The value is 0.9. According to the lubrication compensation mapping model, the target micro-lubrication (MQL) atomization amount... =11.1 ml / min. At this point, the MQL system will output an atomization rate of approximately 11.1 ml / min, slightly higher than the baseline value, to address minor degradation. Under another heavy-load condition with severe saw blade wear, the process capability degradation... It may reach 0.8, while the MQL system has sufficient compressed air pressure at the intake port, resulting in an effective atomization factor. It remains at 0.9. At this point, the target micro-lubrication (MQL) atomization amount... =18.8 ml / min. The MQL system will significantly increase the atomization rate to approximately 18.8 ml / min to compensate for severe equipment degradation and harsh cutting conditions. For example, under a light load condition, the process capability degradation... The value is 0.1, but the compressed air pressure at the MQL system's inlet is insufficient, resulting in a decrease in the effective atomization factor. It drops to 0.2. At this point, the target micro-volume lubrication (MQL) atomization amount... =15ml / min. The MQL system will increase the atomization rate to approximately 15ml / min to compensate for the decrease in atomization efficiency caused by insufficient air pressure. Through the above calculations, the MQL system can adjust the atomization rate based on the target micro-lubrication (MQL) atomization volume calculated in real time. Precisely adjust the lubricant output of the MQL nozzle 6 to ensure optimal lubrication under various operating conditions.

[0061] Through the above technical solution, this application provides a precise and adaptive lubrication compensation mapping model, effectively solving the problems of inaccurate lubrication, low efficiency, and inability to effectively compensate for equipment degradation and atomization efficiency changes caused by the lack of dynamic adjustment mechanism in traditional MQL systems during aluminum alloy door and window processing. This model can adjust the lubrication based on real-time acquired process capability degradation... and atomization effective factors It intelligently adjusts the target micro-lubrication (MQL) atomization amount to ensure proper lubrication under different cutting conditions, avoiding tool sticking and rough machined surfaces caused by insufficient lubrication, as well as oil mist waste and workpiece contamination caused by excessive lubrication. This significantly improves the stability and efficiency of cutting processes, extends saw blade life, and reduces lubricant consumption and waste liquid treatment costs.

[0062] like Figure 1 and Figure 2 As shown, in a preferred embodiment of the present invention, the moving mechanism includes two guide shafts 8 fixed along the length direction on the table 1, the mounting frame 3 is slidably connected to the guide shafts 8 through guide sleeves 9, a lead screw 10 is rotatably connected to the bottom of the table 1, the lead screw 10 is threadedly connected to the mounting frame 3, and a feed motor 11 is fixed at one end of the table 1, the rotating end of the feed motor 11 is connected to the lead screw 10.

[0063] In this embodiment of the invention, the motor 11 drives the lead screw 10 to rotate. Under the guidance of the guide shaft 8, the rotating lead screw 10 drives the mounting frame 3 to move through the threaded transmission. The mounting frame 3 drives the disc cutter 4 to move.

[0064] Specifically, the guide shaft 8 is a mechanical component that provides a linear motion trajectory. It is fixed to the platform 1, providing a basis for the precise movement of the mounting bracket 3. Two guide shafts 8 are arranged in parallel, forming a stable guide plane, effectively limiting the vertical and horizontal sway of the mounting bracket 3 and ensuring its movement along a preset straight path. The guide shaft 8 can be a high-strength, high-hardness linear shaft, such as a carbon steel or stainless steel shaft that has been quenched and precision ground. It can be fixed to the side or bottom of the platform 1 by bearing seats and bolts, or pressed into a specific groove in the platform 1 by pressure plates and screws. The guide sleeve 9 is a sliding bearing that mates with the guide shaft 8. It has a low-friction material or structure inside, allowing the mounting bracket 3 to slide smoothly and easily on the guide shaft 8. This connection method reduces motion resistance, lowers wear, and further improves the smoothness and accuracy of movement. The guide sleeve 9 can use self-lubricating bearing materials, such as oil-impregnated bearings, polymer bearings, or composite material bearings, to reduce friction and wear. Another implementation method is to use linear bearings, which contain balls or rollers inside, achieving low-resistance sliding through rolling friction, further improving motion accuracy and load-bearing capacity. The lead screw 10 is a transmission element that converts rotary motion into linear motion. It is connected to the mounting bracket 3 via threads to achieve precise position control. It is rotatably connected to the bottom of the table 1, enabling stable rotation and driving the movement of the mounting bracket 3. The lead screw 10 can be a trapezoidal lead screw or a ball screw. Trapezoidal lead screws have a simple structure and lower cost, suitable for medium-to-low precision and medium-load applications; ball screws have higher transmission efficiency, lower frictional resistance, higher positioning accuracy, and longer service life, suitable for applications requiring high precision and speed. The threads of the lead screw 10 mesh with a nut (or threaded hole) on the mounting bracket 3. When the lead screw 10 rotates, the nut (and mounting bracket 3) moves along the axis of the lead screw. This threaded transmission method has self-locking properties (under certain conditions), can provide a large thrust, and achieves high-precision linear positioning. The threaded drive connection can be achieved by integrating a nut, such as a bronze nut, plastic nut, or ball nut, onto the mounting bracket 3 to match the thread of the lead screw 10. The feed motor 11, the actuator providing the power source, is fixed at one end of the platform 1. Its rotating end drives the lead screw 10 to rotate, thereby causing the mounting bracket 3 to perform linear feed motion. The feed motor 11 can be a stepper motor or a servo motor. The connection between the rotating end of the feed motor 11 and the lead screw 10 ensures that the rotational power of the feed motor 11 is effectively transmitted to the lead screw 10, causing it to rotate. The connection method needs to ensure smooth, backlash-free transmission and be able to withstand a certain torque. The rotating end of the feed motor 11 and the lead screw 10 can be connected via a coupling, such as a flexible coupling, a rigid coupling, or a diaphragm coupling.

[0065] like Figure 1 and Figure 2As shown, in a preferred embodiment of the present invention, the rotating mechanism includes a rotating shaft 12 rotatably connected to a mounting frame 3, a rotary motor 7 fixedly mounted on the mounting frame 3, the rotating end of the rotary motor 7 being connected to the rotating shaft 12, and the rotating shaft 12 being connected to the disc cutter 4 via a synchronous belt and a synchronous pulley.

[0066] In this embodiment of the invention, the rotary motor 7 drives the rotating shaft 12 to rotate, and the rotating shaft 12 drives the disc cutter 4 to rotate via a synchronous belt and a synchronous pulley.

[0067] A rotating shaft 12 is rotatably connected to the mounting bracket 3. The rotating shaft 12 is the core component for transmitting rotational motion and torque, serving as support and power input for the rotation of the disc cutter 4. The rotating shaft 12 can be rotatably connected to the mounting bracket 3 via precision bearings (e.g., deep groove ball bearings or angular contact ball bearings) to ensure low friction and high-precision rotation. Alternatively, the rotating shaft 12 can be fixed to the inner ring of the bearing using a tapered fit or key connection, while the outer ring of the bearing is fixed within the bearing housing hole of the mounting bracket 3. A rotary motor 7 is fixed to the mounting bracket 3. The rotary motor 7 is the power-providing actuator, supplying rotational power to the rotating shaft 12 and the disc cutter 4. The rotary motor 7 can be directly fixed to the reserved mounting surface of the mounting bracket 3 using fasteners such as bolts and pins. Alternatively, the rotary motor 7 can be mounted on an adjustable motor mount, which is then fixed to the mounting bracket 3 for subsequent tension adjustment of the synchronous belt. The rotating end of the rotary motor 7 is connected to the rotating shaft 12, a connection designed to transmit the power of the rotary motor 7 to the rotating shaft 12. The rotating end (i.e., output shaft) of the rotary motor 7 can be connected to the rotating shaft 12 via a coupling (e.g., a flexible coupling or a rigid coupling). Alternatively, the rotating end of the rotary motor 7 can be directly rigidly connected to one end of the rotating shaft 12 via a keyway, spline, or other means to achieve more direct power transmission. The rotating shaft 12 is connected to the disc cutter 4 via a synchronous belt and synchronous pulley. The synchronous belt and synchronous pulley are a precise mechanical transmission method, whose function is to transmit the rotational motion of the rotating shaft 12 to the disc cutter 4 at a precise speed ratio and maintain a high degree of synchronization. Specifically, a synchronous pulley is mounted on the rotating shaft 12, and another synchronous pulley is mounted on the center hole of the disc cutter 4 or its connecting structure; the two are connected by a synchronous belt. The synchronous belt is usually a toothed belt, and the synchronous pulley has a corresponding tooth profile to achieve slip-free transmission. The synchronous belt can be made of different materials (e.g., rubber or polyurethane), and different tooth profiles (e.g., trapezoidal teeth or circular arc teeth) can be selected according to the power transmission and accuracy requirements.

[0068] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A corner-cutting device for aluminum alloy doors and windows, comprising a table and a mounting bracket, wherein a disc cutter is rotatably connected to the mounting bracket, and a saw blade guard is fixedly mounted on the mounting bracket outside the disc cutter, and an MQL nozzle is mounted on the saw blade guard via an adjusting bracket, characterized in that, Also includes: The rotating mechanism, mounted on the mounting bracket, is used to drive the disc cutter to rotate; The moving mechanism, installed on the table, is used to move the mounting bracket along the length of the table. Micro-lubrication atomization adaptive system, comprising: The dynamic calculation module for cutting load is used to obtain the load current of the sawing motor, the sawing feed speed and the saw blade temperature, and to calculate the cutting intensity coefficient. The cutting configuration feature extraction module is used to obtain the saw blade entry angle and the profile cross-section wall thickness, and to calculate the cutting geometric feature coefficients. The atomization delivery efficiency evaluation module is used to obtain the compressed air pressure at the inlet of the MQL system and calculate the effective atomization coefficient. The system capability degradation assessment module is used to obtain the cumulative number of sawing operations and the vibration acceleration of the saw blade, and calculate the process capability degradation degree by combining the cutting intensity coefficient and the cutting geometric characteristic coefficient. The atomization quantity calculation and adjustment module is used to obtain the target micro-lubricant atomization quantity and adjust the current value based on the baseline atomization quantity, process capability degradation degree and atomization effective coefficient through the lubrication compensation mapping model.

2. The aluminum alloy door and window processing corner cutting device according to claim 1, characterized in that, The calculation process for the cutting intensity coefficient is as follows: Obtain the sawing motor load current, sawing feed speed, and saw blade temperature; The difference between the current load current of the sawing motor and the stable idle current of the saw blade is compared with the difference between the rated current on the motor nameplate and the stable idle current of the saw blade. After limiting the upper limit of the ratio to 1, the load current index of the sawing motor is obtained. The current sawing feed speed is compared with the maximum feed speed of the equipment to obtain the sawing feed speed index. The saw blade temperature index is obtained by comparing the difference between the current saw blade temperature and the ambient temperature of the workshop with the difference between the allowable temperature for aluminum alloy sawing and the ambient temperature of the workshop, and then limiting the upper limit of the ratio to 1. The load current index of the sawing motor, the sawing feed speed index, and the saw blade temperature index are weighted and fused to generate a cutting intensity coefficient that comprehensively characterizes the severity of the thermo-mechanical-speed coupling in the cutting process. The cutting intensity coefficient is positively correlated with the load current index of the sawing motor, the sawing feed speed index, and the saw blade temperature index.

3. The aluminum alloy door and window processing corner cutting device according to claim 1, characterized in that, The calculation process for the cutting geometric feature coefficients is as follows: Obtain the saw blade entry angle and the profile cross-section wall thickness; The absolute value of the difference between the current saw blade cutting angle and the neutral reference angle is compared with the neutral reference angle to obtain the angle characteristic index; The wall thickness characteristic index is obtained by comparing the current wall thickness of the sawn profile section with the maximum wall thickness that the equipment can process. The angular characteristic index and the wall thickness characteristic index are summed to generate a composite constraint factor that characterizes the total strength of geometric constraints within the cutting region. This composite constraint factor is then subjected to continuous nonlinear transfer mapping to generate the output range. Cutting geometric characteristic coefficients of the interval; Among them, as the composite constraint factor increases, the cutting geometric feature coefficient increases monotonically, and its increasing slope shows a monotonically decreasing trend as the composite constraint factor increases, so that the cutting geometric feature coefficient asymptotically converges to 1 when the composite constraint factor approaches infinity.

4. The aluminum alloy door and window processing corner cutting device according to claim 1, characterized in that, The calculation process for the effective atomization coefficient is as follows: Obtain the compressed air pressure at the MQL system inlet; The ratio of the current MQL system inlet compressed air pressure to the optimal atomization setting pressure is used to obtain the effective atomization factor. , , A value close to 0 indicates a complete failure of the delivery process. A value close to 1 indicates an ideal delivery state.

5. The aluminum alloy door and window processing corner cutting device according to claim 1 or 2, characterized in that, The calculation process for the process capability degradation is as follows: Obtain the cumulative number of saw cuts and the vibration acceleration of the saw blade; The current cumulative number of sawing operations and the vibration acceleration of the saw blade are compared with the reference service life and the maximum vibration acceleration allowed by the sawing process under standard working conditions for this specification of saw blade, and the upper limit of the ratio is limited to 1 to obtain the tool wear factor and vibration intensity influence factor. Substituting the tool wear factor, vibration intensity influence factor, cutting intensity coefficient, and cutting geometric characteristic coefficient into the formula Degradation of the acquisition process capability ,in, This is the cutting intensity coefficient. These are the cutting geometric characteristic coefficients. For tool wear factor, The vibration intensity influencing factor, and All are weights related to the difficulty of the working conditions. It is a very small positive number.

6. The aluminum alloy door and window processing corner cutting device according to claim 1, characterized in that, The lubrication compensation mapping model is as follows: ； in, The target is the amount of micro-lubricant atomization. As the baseline atomization amount, For process capability degradation, As an effective atomizing agent, It is a very small positive number.

7. The aluminum alloy door and window processing corner cutting device according to claim 1, characterized in that, The moving mechanism includes two guide shafts fixed along the length of the table surface. The mounting bracket is slidably connected to the guide shafts via guide sleeves. A lead screw is rotatably connected to the bottom of the table surface. The lead screw is threadedly connected to the mounting bracket. A feed motor is fixed at one end of the table surface. The rotating end of the feed motor is connected to the lead screw.

8. The aluminum alloy door and window processing corner cutting device according to claim 1, characterized in that, The rotating mechanism includes a rotating shaft rotatably connected to a mounting frame, a rotary motor fixedly mounted on the mounting frame, the rotating end of the rotary motor being connected to the rotating shaft, and the rotating shaft being connected to the disc cutter via a synchronous belt and a synchronous pulley.

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