Automatic control method and system for grinding wheel piece in continuous isobath rotary cutting process

Abstract

This invention discloses an automated control method and system for an abrasive wheel during continuous equal-depth rotary cutting. The method includes: obtaining the volumetric wear ratio constant 'a' of the abrasive wheel cutting the master alloy material, the rotary cutting radius 'r1' of the master alloy, and the abrasive wheel radius 'R' before the nth cut. n ; Calculate the feed rate ΔC for the nth cut according to the formula. n The invention controls the grinding wheel to perform the nth uniform depth rotary cut according to the feed rate. It also determines whether the radius of the grinding wheel after cutting is less than the allowable value and issues a replacement prompt. After the first cut with the new grinding wheel, the normal value 'a' is corrected in reverse based on the actual feed rate. This invention achieves adaptive and precise calculation of the feed rate, avoiding manual secondary correction, improving the automation level and processing efficiency of the continuous cutting process, and is especially suitable for precision weight cutting of difficult-to-cut materials such as high-temperature alloys.

Description

Technical Field

[0001] This invention relates to the field of master alloy material processing, and in particular to an automated control method and system for grinding wheels during continuous equal-depth rotary cutting. Background Technology

[0002] High-temperature alloy master alloys are the core basic materials for manufacturing high-temperature alloy components. They are prepared by adding alloying elements such as chromium, molybdenum, titanium, tungsten, aluminum, tantalum, niobium, hafnium, and rhenium to the base metal, through processes such as smelting and casting. With their excellent high-temperature strength, oxidation resistance, corrosion resistance, and structural stability, they are key materials for ensuring the stable operation of high-end equipment under high-temperature and high-pressure conditions, and are widely used in high-end equipment manufacturing fields such as aerospace, energy and power, petrochemicals, and nuclear industry.

[0003] After the high-temperature alloy master alloy is prepared, weight-controlled cutting is a crucial process connecting the master alloy ingot with subsequent component manufacturing. Its core objective is to precisely cut the master alloy ingot into billets of a predetermined weight, providing raw materials with controllable dimensions, weight, purity, and cleanliness for subsequent processes such as precision casting and powder preparation. This directly affects component quality, material utilization, and production costs. Currently, the most advanced machining technology is rotary cutting with abrasive wheels (patents CN210081416U and CN110103124B). This technology uses a multi-blade rotary cutting method on the entire master alloy bar. During the entire cutting process, the "secondary shrinkage cavity" is not exposed to the dust splashing environment during cutting, thus avoiding processing contamination caused by abrasive wheel dust entering the shrinkage cavity.

[0004] During continuous rotary cutting with equal depth, the diameter of the grinding wheel changes constantly. How to accurately control the depth of cut for each cut to ensure high-precision cuts with equal depth multiple times, while also improving production efficiency by eliminating the need for the spindle to return to the origin after each cut to measure the diameter of the grinding wheel, has become a key issue restricting the full automation control of cutting equipment.

[0005] To ensure precise cutting depth, previous techniques involved retracting the spindle to its origin after each cut to measure the remaining diameter of the grinding wheel and determine the spindle stroke for the next cut. However, because the reduction in the grinding wheel diameter is unpredictable, the cutting depth would vary with each cut. During continuous cutting, the diameter of the worn grinding wheel needs to be measured manually or using laser ranging to calculate the cutting feed. With a fixed laser beam position, overcutting or undercutting can occur due to varying wear on individual grinding wheels. Measurement errors and other factors contribute to decreased cutting accuracy, making precise control of continuous, automated, equal-depth cutting impossible. Summary of the Invention

[0006] The technical solution of this invention to solve the above-mentioned technical problems is to provide an automated control method for grinding wheels during continuous equal-depth rotary cutting, comprising the following steps: Step S10: Obtain the volume wear ratio constant a, the rotatable radius r1 of the master alloy material cut by the grinding wheel, and the radius R of the grinding wheel before the nth cut. n ; Step S20, according to the formula Calculate the feed rate ΔC for the nth cut. n , where R n+1 The radius of the grinding wheel after the nth cut; Step S30, based on the calculated feed rate ΔC n Control the grinding wheel to perform the nth equal-depth rotary cut.

[0007] Furthermore, the radius R of the grinding wheel after the nth cut... n+1 The relationship between the volume wear proportional constant a and the shear radius r1 of the master alloy is as follows: The radius of the central reserved core is r0 .

[0008] Furthermore, the automated control method for the grinding wheel during continuous equal-depth rotary cutting also includes a judgment step: The feed rate ΔC for the nth cut is calculated. n Then, determine the radius R of the grinding wheel after the nth cut. n+1 Is it smaller than the preset allowable grinding wheel radius [R]? If R n+1 If < [R], a prompt or instruction will be issued to replace the grinding wheel before the nth rotary cut.

[0009] Furthermore, after replacing the grinding wheel, step S40 is also included: After the new grinding wheel completes the first cut, the value of the volume wear ratio constant 'a' is calculated and corrected in reverse based on the actual feed rate of the cut and the change in the grinding wheel radius before and after the cut, and used for the feed rate calculation of subsequent cuts.

[0010] This invention also proposes an automated control system for the grinding wheel during continuous equal-depth rotary cutting, comprising: One or more processors; Memory, used to store one or more programs; When the one or more programs are executed by the one or more processors, the one or more processors implement the automated control method as described above.

[0011] The beneficial effects provided by this invention are as follows: By introducing a volume wear proportionality constant 'a' and establishing an accurate mathematical model between the feed rate and the change in the radius of the grinding wheel, adaptive and accurate calculation of the feed rate is achieved during continuous constant-depth rotary cutting. This avoids the problems of poor accuracy and inconsistent operation caused by relying on manual measurement and secondary correction in traditional methods, significantly improving the automation level and processing efficiency of the cutting process. At the same time, by setting a step to judge the allowable radius of the grinding wheel, timely warnings or prompts for replacing the grinding wheel can be provided to prevent the decline in cutting quality or equipment damage caused by excessive wear of the grinding wheel. In addition, by reverse-correcting the volume wear proportionality constant 'a' after the first cut with a new grinding wheel, the influence of material differences between different batches of grinding wheels on the calculation accuracy is effectively eliminated, enhancing the robustness and engineering applicability of the system, especially suitable for precision weight cutting scenarios of difficult-to-cut materials such as high-temperature alloys. Attached Figure Description

[0012] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0013] Figure 1 This is a schematic diagram of the rotary cutting process of the automated control method for the grinding wheel in the continuous equal-depth rotary cutting process described in this invention. Detailed Implementation

[0014] This invention proposes an automated control method and system for the grinding wheel during continuous equal-depth rotary cutting, aiming to improve the automation level and processing efficiency of the cutting process.

[0015] The automated control method and system for the grinding wheel in the continuous equal-depth rotary cutting process proposed in this invention will be described below in specific embodiments: Example 1

[0016] An automated control method for grinding wheels during continuous equal-depth rotary cutting, such as... Figure 1 As shown, when the same grinding wheel cuts metal of the same material, the ratio of the volume lost by the metal cutting edge to the volume consumed by the grinding wheel is approximately constant, denoted as 'a'. This value depends on the specific materials of the master alloy and the grinding wheel. The radius of the master alloy being rotary-cut is denoted as r1, and the radius of the central pre-reserved core is r0. The radius of the grinding wheel before the nth cut is R. n The radius after cutting is R. n+1 The steps include: Step S10: Obtain the volume wear ratio constant a, the rotatable radius r1 of the master alloy material cut by the grinding wheel, and the radius R of the grinding wheel before the nth cut.n ; Step S20, according to the formula Calculate the feed rate ΔC for the nth cut. n , where R n+1 The radius of the grinding wheel after the nth cut; Step S30, based on the calculated feed rate ΔC n Control the grinding wheel to perform the nth equal-depth rotary cut.

[0017] Furthermore, the radius R of the grinding wheel after the nth cut... n The relationship between +1 and the volume wear proportional constant a and the shear radius r1 of the master alloy is as follows: The radius of the central reserved core is r0.

[0018] Furthermore, the automated control method for the grinding wheel during continuous equal-depth rotary cutting also includes a judgment step: The feed rate ΔC for the nth cut is calculated. n Then, determine the radius R of the grinding wheel after the nth cut. n+1 Is it smaller than the preset allowable grinding wheel radius [R]? If R n+1 If < [R], a prompt or instruction will be issued to replace the grinding wheel before the nth rotary cut.

[0019] Furthermore, after replacing the grinding wheel, step S40 is also included: After the first cut with a new grinding wheel, the value of the volumetric wear proportional constant 'a' is calculated and corrected based on the actual feed rate and the change in wheel radius before and after the cut. This correction is then used to calculate the feed rate for subsequent cuts. In engineering applications, even grinding wheel manufacturers cannot guarantee consistent quality across batches. Therefore, after each grinding wheel replacement, the value of 'a' needs to be corrected after the first cut to improve the accuracy of subsequent cut calculations. This process can also be automated.

[0020] Taking the fixed-weight cutting of DZ125 high-temperature alloy master alloy as an example: If the diameter of the master alloy is 80mm, then the radius r1 = 40mm; To ensure that the secondary shrinkage cavity does not open during cutting, the reserved core diameter is set at 20mm, then the radius r0 = 10mm; The grinding wheel has a diameter of 400mm, an allowable diameter of 100mm, R1=200mm, and [R]=50mm. The value of a for the newly replaced grinding wheel is unknown and needs to be calculated by the change in the diameter of the grinding wheel after the first cut. At this time, the change in the diameter of the grinding wheel is the smallest, and the error of the obtained value of a is the smallest. R2=189.6mm, the feed amount of the first rotary cut ΔC1=10.4mm, and the value of a for the grinding wheel can be calculated to be a≈0.3702. Without this calculation method, the feed rate for the second rotary cut is preset to ΔC2=10.4mm, and then manually measured and corrected after cutting. This results in poor accuracy and discontinuous operation, which is not conducive to automated control. With the calculation of this method, the feed rate for the second rotary cut can be accurately calculated in advance as ΔC2=11.005mm, which greatly improves accuracy and eliminates the need for manual correction. This enables fully automated control and improves processing efficiency. Example 2

[0021] This invention also proposes an automated control system for the grinding wheel during continuous equal-depth rotary cutting, comprising: One or more processors; Memory, used to store one or more programs; When the one or more programs are executed by the one or more processors, the one or more processors implement the automated control method as described in Embodiment 1.

[0022] The above description is merely a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. An automated control method for a grinding wheel during continuous equal-depth rotary cutting, characterized in that, Includes the following steps: Step S10: Obtain the volume wear ratio constant a, the rotatable radius r1 of the master alloy material cut by the grinding wheel, and the radius R of the grinding wheel before the nth cut. n ; Step S20, according to the formula Calculate the feed rate ΔC for the nth cut. n , where R n+1 The radius of the grinding wheel after the nth cut; Step S30, based on the calculated feed rate ΔC n Control the grinding wheel to perform the nth equal-depth rotary cut.

2. The automated control method according to claim 1, characterized in that, The radius R of the grinding wheel after the nth cut n+1 The relationship between the volume wear proportional constant a and the shear radius r1 of the master alloy is as follows: The radius of the central reserved core is r0.

3. The automated control method according to claim 1, characterized in that, It also includes a judgment step: The feed rate ΔC for the nth cut is calculated. n Then, determine the radius R of the grinding wheel after the nth cut. n+1 Is it smaller than the preset allowable grinding wheel radius [R]? If R n+1 If < [R], a prompt or instruction will be issued to replace the grinding wheel before the nth rotary cut.

4. The automated control method according to claim 1 or 3, characterized in that, After replacing the grinding wheel, step S40 is also included: After the new grinding wheel completes the first cut, the value of the volume wear ratio constant 'a' is calculated and corrected in reverse based on the actual feed rate of the cut and the change in the grinding wheel radius before and after the cut, and used for the feed rate calculation of subsequent cuts.

5. An automated control system for a grinding wheel during continuous equal-depth rotary cutting, characterized in that, include: One or more processors; Memory, used to store one or more programs; When the one or more programs are executed by the one or more processors, the one or more processors implement the automated control method as described in any one of claims 1 to 4.

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