A superfinishing pressure self-adaptive control method

Abstract

The application relates to the technical field of grinding and superfinishing control, and discloses a superfinishing pressure self-adaptive control method; the method first establishes a machining initial reference by acquiring workpiece incoming feature and oil stone use state, synchronously collects pressure, acoustic emission, spindle power, displacement, vibration, cooling liquid pressure, cooling liquid flow and workpiece rotation angle information after the oil stone contacts the workpiece, identifies the sharpness of the oil stone, the pore blockage degree, the contact area change and the machining stage, and combines the circumferential state change and the oil stone wear state linkage to adjust the oil stone pressure, the oscillation parameter and the cooling liquid supply parameter, and meanwhile, the method executes degradation, rollback, pause, abnormal record and parameter write-back on abnormal working conditions; the method improves the matching of superfinishing pressure control and contact state.

Description

Technical Field

[0001] This invention relates to the field of grinding and ultra-precision grinding control technology, specifically to an adaptive control method for ultra-precision grinding pressure. Background Technology

[0002] After grinding, the raceways of rolling bearing rings typically require ultra-precision grinding to remove the grinding-degraded layer, improve the surface roughness of the raceways, and correct raceway shape errors. During ultra-precision grinding, an oilstone presses against a rotating workpiece under pressure and performs high-frequency reciprocating oscillations in a predetermined direction. As the machining process progresses, the sharpness of the oilstone abrasive grains gradually decreases, the pores of the oilstone become easily clogged, and the actual contact area between the oilstone and the workpiece continuously changes. Furthermore, differences in machining allowance, hardness, and initial surface condition among different workpieces result in a significant dynamic change in the actual contact state between the oilstone and the workpiece. For example, the published invention patent application CN100484715C discloses the use of communication technology to realize online operation of an ultra-precision grinding machine. The monitoring and control system determines the end of the idle stroke of the honing stone by monitoring the load current of the workpiece motor and switches the work steps accordingly. This scheme is mainly used to identify the contact start point between the honing stone and the workpiece, but it is difficult to adjust the honing stone pressure in real time according to the wear of the honing stone, pore blockage, and changes in contact area during the ultra-precision grinding process. For example, the published invention patent application CN106141892B discloses a composite ultra-precision grinding machine for bearing raceways and flanges, which can complete the composite ultra-precision grinding of raceways and flanges on the same machine and can preset the oscillation frequency, workpiece speed, and pressure parameters. The pressure parameters in this scheme still mainly rely on process experience for preset, and it is difficult to reflect the real-time changes in the contact state in different processing stages such as cutting, semi-cutting, and finishing. Therefore, existing ultra-precision grinding equipment generally suffers from insufficient identification of the interface state between the grinding stone and the workpiece, resulting in the grinding stone pressure not being adjusted in a timely manner according to the processing stage and the state of the grinding stone. Consequently, in the cutting stage, insufficient pressure can easily lead to incomplete removal of excess material; in the semi-cutting stage, excessive pressure can easily cause burns or subsurface damage to the workpiece surface; and in the finishing stage, untimely pressure reduction can easily cause surface scratches and uneven texture, ultimately affecting the consistency of raceway roughness, waviness, roundness error, and residual stress distribution. To address this, it is necessary to provide an adaptive pressure control method for ultra-precision grinding, which identifies the processing stage and the state of the grinding stone through multi-source signal fusion and dynamically adjusts the grinding stone pressure based on the identification results. This solves the problem of mismatch between contact pressure and processing state, thereby improving the stability of raceway surface quality and batch processing consistency. Summary of the Invention

[0003] To address the shortcomings of existing technologies, this invention provides an adaptive control method for ultra-precision grinding pressure, which solves the problems mentioned in the background section.

[0004] To achieve the above objectives, the present invention provides the following technical solution: An adaptive control method for ultra-precision grinding pressure includes: S1. Obtain the incoming material characteristics and current usage status of the workpiece to be processed, and determine the initial processing reference based on the incoming material characteristics and usage status; S2. After the honing stone establishes contact with the workpiece, synchronously collect information on honing stone pressure, acoustic emission, spindle power, honing stone displacement, vibration, coolant pressure, coolant flow rate, and workpiece rotation angle. S3. Based on the characteristics of the incoming material, the usage status, and the information collected synchronously, identify the sharpness of the whetstone, the degree of blockage of the whetstone pores, the change in the contact area between the whetstone and the workpiece, and the current processing stage. S4. Based on the current processing stage, the circumferential state change corresponding to the workpiece rotation angle, and the wear state of the honing stone, adjust the honing stone pressure and simultaneously adjust the honing stone oscillation parameters and coolant supply parameters. S5. When the sensor signal is interrupted, the pressure tracking is abnormal, the honing stone oscillation is abnormal, or the coolant supply is abnormal, execute the process of degraded processing, honing stone retraction, processing suspension, abnormal record, and process parameter write-back.

[0005] Furthermore, the incoming material characteristics of the workpiece to be processed and the current usage status of the oilstone are obtained, and the initial processing reference is determined based on the incoming material characteristics and usage status, including: After the workpiece is stably clamped, the raceway profile, roughness, waviness, groove error, single-sided allowance, hardness and batch information are collected according to the circumferential partition and multiple cross sections to form a workpiece feature table. The workpiece category and circumferential disturbance are determined based on the unilateral allowance, hardness, and unilateral allowance dispersion. Read the oilstone particle size, binder, zero position, number of processed parts, wear amount and dressing record, and complete the oilstone zero position calibration; Based on the workpiece category identifier, circumferential disturbance identifier, and oilstone wear state, the pressure candidate range and pressure offset are determined, and an initial processing record is generated.

[0006] Furthermore, after the honing stone establishes contact with the workpiece, information on honing stone pressure, acoustic emission, spindle power, honing stone displacement, vibration, coolant pressure, coolant flow rate, and workpiece rotation angle is simultaneously collected, including: Once the pressure feedback exceeds the contact judgment value and remains stable, the corresponding moment will be recorded as the zero point of the processing time. Each acquisition channel is checked for range, recorded for no-load reference and time alignment, and data frames are generated according to the preset frame length. A frame index is formed based on the data frame, which includes workpiece rotation angle, spindle net power, displacement change, acoustic emission characteristics, and validity identifier. A circumferential data table is formed according to the workpiece corner partitions, and the collected data and abnormal channel screening results are written into a circular buffer.

[0007] Furthermore, the range of each acquisition channel is confirmed, the idle reference is recorded, and the time is aligned. Data frames are then generated according to the preset frame length, including: Set the sampling range and sampling frequency for pressure, acoustic emission, spindle power, displacement, vibration, coolant pressure, and coolant flow channels respectively; Record the spindle idle power as the no-load reference; Align the sampling times of each channel using a unified clock or software compensation method; The acoustic emission characteristics and statistics of each channel are written into the data frame with the same frame length.

[0008] Furthermore, based on the characteristics of the incoming material, its usage status, and synchronously collected information, the sharpness of the oilstone, the degree of blockage in the oilstone pores, changes in the contact area between the oilstone and the workpiece, and the current processing stage are identified, including: The status determination is initiated after the valid data frame and valid channel meet the preset conditions, taking the frame index, circumferential data table and initial processing record as inputs. The oilstone state vector is generated based on the energy ratio of the acoustic emission radio frequency band, the power consumption per unit pressure, and the displacement response per unit pressure. Determine the status threshold based on the first piece trial cutting data or historical qualified processing records; By combining the matching relationship of consecutive frames, the trend of spindle power, vibration stability and the difference in rotation angle intervals, a state feature table is formed that includes the recording stage identifier, the circumferential state change identifier and the data reliability.

[0009] Furthermore, an oilstone state vector is generated based on the energy ratio of the acoustic emission radio frequency band, the power consumption per unit pressure, and the displacement response per unit pressure, including: The ratio of high-frequency energy to low-frequency energy is extracted from the acoustic emission signal and normalized according to the initial cutting reference of the first qualified workpiece to determine the sharpness index. The unit pressure power consumption is calculated based on the spindle net power and average pressure, and the pore blockage index is determined by combining the number of parts processed by the oilstone and the amount of wear. Contact compliance is calculated based on the change in oilstone displacement and the average pressure, and then normalized according to the light contact benchmark to determine the contact area index.

[0010] Furthermore, based on the current processing stage, the circumferential state changes corresponding to the workpiece rotation angle, and the wear state of the honing stone, the honing stone pressure is adjusted, and the honing stone oscillation parameters and coolant supply parameters are adjusted simultaneously, including: Select the corresponding baseline parameters based on the stage identifier, and perform pressure correction and amplitude limiting based on the incoming material type, data reliability, and oilstone state vector; During the semi-cutting stage, the honing stone pressure and coolant supply parameters are adjusted based on the combined amount of low-frequency acoustic emission energy and radial vibration acceleration. During the finishing stage, the pressure of the oilstone is gradually reduced based on the oil film formation indicator and the acoustic emission stability threshold. Generate a circumferential compensation command with phase advance according to the workpiece rotation angle range, and update the process parameter table according to the wear of the oilstone.

[0011] Furthermore, a circumferential compensation command with phase advance is generated according to the workpiece rotation angle range, and the process parameter table is updated according to the wear of the oilstone, including: During the cutting stage or in the early stage of the transition from cutting to semi-cutting, the angle range to be compensated is determined based on the circumferential state change indicator. The command advance angle is determined based on the spindle speed, the response time of the pressurizing mechanism, and the contact position of the oilstone, and pressure fine-tuning commands are generated for the range where the margin is too large or the hardness is too high. The cumulative wear is updated based on the change in the zero position of the oilstone. The reference pressure for each stage is corrected according to the range of the cumulative wear. The pressure fine-tuning command and wear correction results are written into the process parameter table.

[0012] Furthermore, in the event of sensor signal interruption, pressure tracking anomaly, hoist oscillation anomaly, or coolant supply anomaly, a process of downgraded processing, hoist retraction, processing suspension, anomaly recording, and process parameter write-back is executed, including: The input includes data validity indicators, data credibility, stage indicators, stress commands, and parameter update records; The exception types are divided into degradeable exceptions, exceptions that need to be rolled back, and exceptions that need to be paused. Perform a self-test on the sensor channels, and select either degradation identification or pressure increase limit based on critical channel failure or short-term failure of non-critical channels; For pressure tracking abnormalities, oscillation abnormalities, and cooling abnormalities, at least one of the following actions should be selected: retry, parameter locking, backup fluid supply, oilstone retraction, or processing suspension. Based on the status characteristic table, pressure execution curve and in-machine detection results, the root cause of the abnormality is determined, an abnormality record is generated and the process parameters are written back.

[0013] Furthermore, based on the status characteristic table, pressure execution curve, and in-machine detection results, the root cause of the anomaly is determined, an anomaly record is generated, and process parameters are written back, including: Based on the processing stage, the abnormal root causes are classified into categories such as insufficient removal of residual material, signs of burn, unstable oil film, or pore blockage. Establish an exception record based on the workpiece number, occurrence time, exception type, handling action, and write-back content; Adjust the pressure benchmark, observation time, cooling benchmark, or smoothing pressure reduction step size according to the root cause of the abnormality. If the same type of anomaly occurs repeatedly, stop automatic write-back and mark it as a manual review status.

[0014] Compared with the prior art, the present invention provides an adaptive control method for ultra-precision grinding pressure, which has the following beneficial effects: 1. This invention establishes an initial processing benchmark by acquiring the incoming material characteristics of the workpiece and the usage status of the honing stone. After the honing stone and workpiece establish contact, it synchronously collects process information such as honing stone pressure, acoustic emission, spindle power, honing stone displacement, vibration, coolant status, and workpiece rotation angle. Then, based on the acoustic emission radio frequency band energy, unit pressure power consumption, and unit pressure displacement response, it identifies the honing stone sharpness, pore blockage degree, contact area change, and current processing stage. Furthermore, it combines the processing stage, circumferential state changes, and honing stone wear state to adjust the honing stone pressure, oscillation parameters, and coolant supply parameters in a coordinated manner. In case of signal abnormalities, pressure tracking abnormalities, oscillation abnormalities, or cooling abnormalities, it executes a downgrade, rollback, pause, abnormality recording, and parameter write-back process. This solves the problem that existing ultra-precision grinding pressure mainly relies on experience-based presets and is difficult to match the contact state in a timely manner, thereby improving the sufficiency of material removal in the cutting stage, the ability to suppress surface damage in the semi-cutting stage, the stability of the oil film in the finishing stage, and the consistency of batch processing.

[0015] 2. This invention continuously monitors sensor signals, pressure tracking, honing stone oscillation, and coolant supply status during processing. It also classifies anomalies based on data validity indicators, data reliability, processing stage indicators, and pressure commands. When critical channels fail, pressure tracking is abnormal, oscillation deviates, or coolant supply is insufficient, it executes actions such as downgrade identification, pressure limit, retry, parameter locking, backup coolant supply, honing stone retraction, or processing suspension. Simultaneously, it associates data frames before and after the anomaly, handling actions, on-machine detection results, and write-back content to form an anomaly record. Furthermore, it adjusts the pressure reference, observation time, cooling reference, or finishing pressure reduction step size of subsequent workpieces according to the root cause of the anomaly, thereby reducing the interference of anomaly control actions on the processing process and improving the traceability of anomaly handling, the targeted nature of process parameter correction, and the safety of continuous equipment operation. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the ultra-precision grinding pressure adaptive control method of the present invention; Figure 2 This is a schematic diagram illustrating the establishment of the initial processing reference for this invention; Figure 3 This is a schematic diagram of multi-channel synchronous framing and circumferential data table generation according to the present invention; Figure 4 This is a schematic diagram illustrating the identification of oilstone state and processing stage in this invention; Figure 5 This is a schematic diagram of the closed-loop regulation of pressure, oscillation, and coolant in this invention; Figure 6 This is a schematic diagram of the abnormal operating condition classification and parameter write-back of the present invention; Figure 7 This is a schematic diagram illustrating the ultra-precision grinding process of the inner ring raceway of the deep groove ball bearing according to the present invention. Figure 8 This is a schematic diagram of the raceway circumferential partition detection and circumferential compensation of the present invention. Detailed Implementation

[0017] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0018] Example 1: Figures 1-6 An adaptive control method for ultrafine grinding pressure is presented, including: S1. Obtain the incoming material characteristics and current usage status of the workpiece to be processed, and determine the initial processing reference based on the incoming material characteristics and usage status; S2. After the honing stone establishes contact with the workpiece, synchronously collect information on honing stone pressure, acoustic emission, spindle power, honing stone displacement, vibration, coolant pressure, coolant flow rate, and workpiece rotation angle. S3. Based on the characteristics of the incoming material, the usage status, and the information collected synchronously, identify the sharpness of the whetstone, the degree of blockage of the whetstone pores, the change in the contact area between the whetstone and the workpiece, and the current processing stage. S4. Based on the current processing stage, the circumferential state change corresponding to the workpiece rotation angle, and the wear state of the honing stone, adjust the honing stone pressure and simultaneously adjust the honing stone oscillation parameters and coolant supply parameters. S5. When the sensor signal is interrupted, the pressure tracking is abnormal, the honing stone oscillation is abnormal, or the coolant supply is abnormal, execute the process of degraded processing, honing stone retraction, processing suspension, abnormal record, and process parameter write-back.

[0019] This method is applicable to the ultra-precision grinding process of rolling bearing raceways after grinding, and is particularly suitable for the precision machining of rotating surface workpieces such as the inner raceway of deep groove ball bearings, the outer raceway of tapered roller bearings, the raceway of self-aligning roller bearings, and the peach-shaped raceway of four-point contact ball bearings. The method uses the workpiece to be machined, the honing stone, the workpiece spindle, the honing stone pressurization mechanism, the honing stone oscillation mechanism, the coolant supply unit, the workpiece incoming material detection device, and the machining process sensors as the control objects. It utilizes the characteristics of the incoming workpiece, the usage status of the honing stone, and multi-source process signals during the machining process to identify the real-time state of the contact interface between the honing stone and the workpiece. The output includes at least the initial machining reference, machining stage identifier, honing stone status identification result, honing stone pressure adjustment command, honing stone oscillation parameters, coolant supply parameters, abnormal handling records, and subsequent workpiece machining correction parameters. The method operates in the order of establishing the initial machining reference, synchronous acquisition after contact, contact status identification, dynamic adjustment of machining parameters, and abnormal retreat handling. The data tables, status identifiers, and parameter records formed in the preceding process serve as inputs for the subsequent process, enabling the honing stone pressure to be adaptively adjusted according to the machining stage and honing stone status, rather than relying solely on fixed time or empirical pressure settings.

[0020] Specifically, such as Figure 2 As shown: Before the workpiece enters the ultra-precision grinding station, the incoming material feature acquisition process is triggered. This process is initiated when the workpiece reaches the pre-detection position and is stably held by the positioning fixture. The acquired incoming material features include at least the raceway generatrix profile, initial raceway roughness, initial raceway waviness, raceway groove error, workpiece single-sided allowance, workpiece hardness, and workpiece batch information. The raceway generatrix profile is acquired along the raceway circumference by an eddy current displacement sensor, a contact profile measurement device, or an equivalent profile detection device. For bearing rings of standard sizes, the workpiece can be... The circumference is divided into 24 equal-angle sampling intervals, each corresponding to a 15° central angle. This division method is based on the fact that the 24 sampling intervals can cover the allowance fluctuations in the circumferential direction of the raceway and can establish a correspondence with the subsequent workpiece corner partitions, without significantly increasing the incoming material inspection cycle. For miniature bearings, due to the small workpiece diameter and narrow raceway width, the sampling intervals can be reduced to 12. For large-size bearings or workpieces with large fluctuations in the previous grinding process, the sampling intervals can be increased to 36 to improve the accuracy of circumferential allowance identification. Initial roughness and initial waviness of the raceway are measured at three equidistant cross-sections along the circumference. The positions of these three cross-sections correspond to the vicinity of 0°, 120°, and 240°, respectively. This arrangement can reflect the surface condition differences along the circumference of the raceway without significantly increasing the detection time. When the workpiece outer diameter is large, the raceway width is wide, or there are obvious circumferential fluctuations in the previous grinding process, the measurement cross-sections can be expanded to six to improve the ability to identify local waviness and roughness anomalies. The workpiece hardness is measured at no less than two points on the outer diameter reference surface or in the non-working load-bearing area. The average hardness value is used to characterize the overall cutting difficulty of the workpiece, and the hardness difference is used to characterize the workpiece in the circumferential direction or in local areas. The workpiece has uneven hardness; the single-sided allowance is calculated based on the measured profile of the raceway, the nominal design profile, and the previous grinding datum, and the average single-sided allowance, maximum single-sided allowance, minimum single-sided allowance, and standard deviation of single-sided allowance are generated; after the incoming material features are collected, the relevant data are written into the workpiece feature table, which includes at least the workpiece number, batch number, inspection time, average single-sided allowance, standard deviation of single-sided allowance, average initial roughness, average initial waviness, average hardness, hardness difference, and groove error; among them, the workpiece number is used as the main index and the batch number is used as the auxiliary index so that the allowance fluctuation and hardness fluctuation of different workpieces in the same batch can be called by the subsequent processing control. Under the conditions of ultra-precision grinding of P4 grade deep groove ball bearing rings, the conventional machining window for single-sided allowance can be selected as 8μm to 15μm. The basis for determining this window is that ultra-precision grinding after grinding mainly undertakes the tasks of removing the grinding-modified layer, improving surface roughness, and correcting raceway shape errors. 8μm to 15μm can cover the conventional finishing allowance while avoiding excessive material removal during ultra-precision grinding. When the average single-sided allowance is between 8μm and 15μm and the standard deviation of the single-sided allowance is no greater than 2μm, the workpiece is marked as a conventional workpiece; when the average single-sided allowance is greater than 15μm but no greater than 25μm, the workpiece is marked as a heavy-cut workpiece; when the average single-sided allowance is less than... At 8μm, the workpiece is marked as a lightly cut workpiece; when the standard deviation of the single-sided allowance is greater than 4μm, a circumferential disturbance mark is added; 2μm is used to distinguish the dispersion of the regular allowance within the same batch, and 4μm is used to identify obvious allowance fluctuations that may cause uneven distribution of circumferential contact pressure; for miniature bearings, due to the small raceway width and low allowable removal allowance, the regular machining window can be adjusted to 5μm to 12μm; for large-size tapered roller bearings, due to the large raceway contact length and usually high previous grinding allowance, the regular machining window can be adjusted to 10μm to 20μm; the above window adjustments are based on the workpiece type, previous grinding allowance, honing stone grit size, and workpiece hardness. After the incoming material characteristics are collected, the current usage status of the honing stone is read. The honing stone usage status includes at least the following fields: honing stone model, honing stone grit size, binder type, initial height, current zero position, cumulative number of processed parts, cumulative wear, last dressing time, quality feedback after the previous workpiece processing, average pressure during the previous workpiece processing, and stage switching time. After a new honing stone is installed or dressed, the honing stone zero position calibration is performed first. During calibration, the pressurizing mechanism pushes the honing stone close to the standard workpiece or calibration surface with a light touch pressure below 0.15 MPa. When the pressure feedback first stably exceeds 0.05 MPa and remains stable for more than 100 ms, the honing stone displacement is read as the current zero position, and then the honing stone is moved back to a safe distance. 0.05 MPa is used as the light touch judgment value, and its setting is based on... This pressure is higher than the slight fluctuations that may be caused by mechanical clearance and sensor noise, but significantly lower than the pressure during normal cutting, thus avoiding significant wear on the end face of the honing stone during the calibration process. When the cumulative number of parts processed by the honing stone reaches 500 or the cumulative wear reaches 0.5mm, the honing stone is determined to enter the replacement warning range. This replacement warning range is applicable to the scenario of processing conventional bearing steel rings with W7 to W10 particle size ceramic bond honing stones. In actual use, it can be adjusted according to the wear of the end face of the honing stone, the stability of stage switching, and the workpiece quality feedback. When using a softer bond or processing high-hardness workpieces, the cumulative number of parts processed threshold can be lowered to 300 to 400. When using a honing stone with higher wear resistance or adding an online dressing process, it can be appropriately increased according to the first test cut results and batch quality feedback. After associating the workpiece's incoming material characteristics with the oilstone's usage status, the initial machining datum is determined. The initial machining datum includes at least the initial contact position, initial pressure candidate range, datum pressure for each machining stage, initial oscillation frequency, initial amplitude, coolant inlet pressure, and stage observation window data. For the scenario of machining the inner raceway of a P4 grade deep groove ball bearing using a W7 alumina ceramic bond oilstone, the initial pressure candidate range is determined based on the oilstone grit size, bond type, bearing steel hardness, and single-sided allowance after grinding, and recorded in the initial machining record. When the workpiece is a heavy-cut workpiece, the initial pressure candidate range is offset upwards by 0.03 MPa to 0.08 MPa; when the workpiece is a light-cut workpiece, the initial pressure candidate range is offset downwards by 0.03 MPa. The range is from 0.06 MPa to 0.06 MPa. When the average hardness is greater than Rockwell hardness 62, the range is increased by 0.02 MPa to 0.05 MPa from the current candidate range. When the average hardness is less than Rockwell hardness 59, the range is decreased by 0.02 MPa to 0.05 MPa from the current candidate range. Rockwell hardness 59 to 62 is the effective hardness range of common bearing steel after heat treatment. When it exceeds this range, the workpiece cutting response and surface plastic deformation tendency will change. Therefore, it serves as the basis for determining the pressure offset. After the initial machining reference is formed, the workpiece feature table and the oilstone usage status table are combined into the initial machining record. This initial machining record enters the machining station with the workpiece and serves as the data basis for subsequent time calibration, status identification, and pressure correction.

[0021] Specifically, such as Figure 3 As shown: After the honing stone establishes contact with the workpiece, the synchronous acquisition process is initiated; the contact establishment is judged by the pressure feedback exceeding 0.1MPa for the first time after the honing stone feed mechanism performs the approach action and maintaining it continuously for no less than 100ms; 0.1MPa is higher than the light touch pressure during the honing stone zero position calibration process, which can eliminate false triggering caused by mechanical clearance and sensor noise, and is lower than the normal working pressure during the cutting stage, making it suitable as the contact judgment value for initiating multi-source acquisition before formal loading; the moment when the pressure feedback meets the above conditions is recorded as the zero point of the machining time, and each acquisition channel uses this zero point of the machining time as a common time reference; the synchronous acquisition objects include at least honing stone pressure, acoustic emission, spindle power, honing stone displacement, honing stone vibration, coolant pressure, coolant flow rate, and workpiece rotation angle information, and each acquired data is written into the machining process data frame according to a unified time reference; Before synchronous acquisition, the range of each acquisition channel is confirmed and no-load reference is recorded. The effective range of the pressure acquisition channel can be selected from 0MPa to 2MPa, with a resolution of not less than 0.001MPa. This range can cover the pressure variation range during the cutting, semi-cutting, and finishing stages, and reserves a margin for abnormal pressure identification. The frequency range of the acoustic emission acquisition channel can be selected from 20kHz to 1MHz, where 20kHz to 100kHz is used to characterize changes related to friction, low-frequency impact, and mechanical vibration, and 100kHz to 500kHz is used to characterize high-frequency elastic wave changes related to abrasive cutting. The spindle power acquisition channel records the instantaneous current, voltage, and power of the motor. The sampling frequency should be no less than 10,000 times / s; the resolution of the oilstone displacement acquisition channel should be no less than 0.1μm; the vibration acquisition channel should at least acquire radial acceleration and tangential acceleration, and acquire axial acceleration if necessary; the sampling frequency of coolant pressure and coolant flow rate should be no less than 100 times / s; the workpiece rotation angle information is provided by the spindle encoder, and the preferred resolution of the spindle encoder is no less than 10,000 pulses per revolution; the above sampling frequencies are determined according to the rate of change of each physical quantity, among which pressure and coolant are relatively low-frequency control quantities, acoustic emission is a high-frequency elastic wave signal, and the workpiece rotation angle is used to establish a circumferential mapping relationship, so it needs to have sufficient angular resolution; To enable multi-source information to participate in state judgment at the same processing moment, a unified timestamp alignment method is adopted in the acquisition process; each acquisition channel is connected to a unified clock, and the hardware synchronization error is controlled within 100μs; when the equipment conditions cannot achieve hardware synchronization, a software timestamp compensation method is adopted to resample the data of each channel to a unified time axis according to the sampling time, and reduce the reliability of the corresponding data in subsequent state recognition; the reference period of the unified time axis can be selected as 1ms, 5ms or 10ms, preferably 1ms, to meet the real-time requirements of pressure closed loop and stage recognition; the high-frequency data of acoustic emission is not directly entered into the main control loop, but the energy, root mean square value, peak factor and frequency band energy ratio are extracted within a 200ms data frame, and then the extracted feature quantities are written into the unified time axis; the spindle power, pressure, displacement, vibration, coolant pressure and coolant flow rate are statistically analyzed according to the same frame length to generate the mean, maximum value, minimum value, standard deviation and slope of each frame; The data frame length is set to 200ms. This value is based on the fact that the spindle speed of the workpiece during ultra-precision grinding is usually between 600 rpm and 1500 rpm, which corresponds to 10 to 25 revolutions per second. 200ms can cover the workpiece rotation process of about 2 to 5 revolutions, which can contain sufficient contact status information without causing significant lag in stage switching judgment. An overlap segment of 10ms to 20ms is set between adjacent data frames to reduce feature abrupt changes caused by frame switching. The synchronously acquired data is written to a circular buffer, which stores the raw data and preprocessed data within the most recent 30s. The 30s buffer length can cover the ultra-precision grinding process of a single workpiece, which is usually 6s to 12s, and retain traceability data before and after the occurrence of anomalies. After each frame of data is generated, a corresponding frame index is established. The frame index includes at least the following fields: workpiece number, processing time, workpiece rotation angle range, pressure statistics, acoustic emission radio frequency band energy, spindle net power, hoist displacement change, vibration acceleration characteristics, coolant pressure and flow status, and acquisition validity identifier. The spindle net power is obtained by subtracting the no-load power at the current speed from the current spindle power. The no-load power is collected after the spindle has been idle for more than 10 seconds before processing, or determined by calling the historical no-load curve at the same speed. The coolant pressure and flow status records the inlet pressure, flow rate, and their corresponding relationship. When the inlet pressure is normal but the flow rate is lower than the rated value, it is marked as a suspected pipe blockage. When the flow rate is normal but the pressure fluctuates abnormally, it is marked as a suspected unstable supply pump or valve. The workpiece rotation angle information is established in 15° or 5° intervals. Regular workpieces are divided into 15° intervals, and workpieces with circumferential disturbance identifiers are divided into 5° to 10° intervals. The rotation angle intervals are bound to the pressure, acoustic emission, and displacement frame characteristics to form a circumferential data table. During synchronous acquisition, data validity filtering is set. If any acquisition channel experiences single-frame over-range, communication interruption, timestamp reversal, or continuous repetition, that acquisition channel is marked as invalid in the current data frame. If a single acquisition channel is temporarily invalid, processing is not stopped immediately, but data compensation judgment is initiated. If the pressure channel is invalid, pressure increase is paused, and only the previous safe pressure is maintained or the hoist is retracted. If the acoustic emission channel is invalid, stage identification is performed by downgrading the spindle power, hoist displacement, and vibration characteristics. If the workpiece corner channel is invalid, circumferential disturbance compensation is paused, and only staged pressure adjustment is retained. If the coolant pressure or coolant flow channel is invalid, the pressure upper limit is reduced and the frequency of cooling anomaly monitoring is increased. The data validity identifier is written into the circular buffer along with the frame index and serves as the data condition for subsequent contact state identification.

[0022] Specifically, such as Figure 4As shown: The status recognition process is executed based on the aforementioned frame index, circumferential data table, and initial machining record. The start condition for status recognition is that no less than 5 valid data frames are continuously formed in the circular buffer, and at least 3 channels of pressure, spindle power, hoist displacement, and workpiece rotation angle are in a valid state. Status recognition does not use single pressure feedback as the basis for judgment, but instead incorporates material characteristics, hoist usage status, acoustic emission frequency band energy, spindle net power, hoist displacement changes, and vibration characteristics, so that the hoist status and workpiece status are associated within the same time window. The status recognition results are written into the status feature table, which is saved in chronological order and includes at least the machining stage identifier, hoist status vector, circumferential status change identifier, and data reliability fields, and serves as the data basis for subsequent pressure adjustment, oscillation parameter adjustment, and anomaly handling. The sharpness identification of the abrasive stone is based on the combined analysis of acoustic emission signals and spindle power variations. The acoustic emission signal is divided into low-frequency and high-frequency bands within each 200ms data frame. The low-frequency band can be selected from 20kHz to 100kHz, and the high-frequency band from 100kHz to 500kHz. The ratio of high-frequency energy to low-frequency energy is used as the initial sharpness index F1. When the abrasive stone is relatively sharp, the cutting edge micro-cuts the workpiece surface peaks, increasing the proportion of high-frequency elastic waves. When the abrasive stone becomes dull, the cutting action weakens, the friction action strengthens, the high-frequency component decreases, and the low-frequency component increases. To avoid misjudgment caused by single-frame impact noise, F1 is averaged over the time window corresponding to one revolution of the workpiece to obtain the sharpness stability index F. If the workpiece speed is 1200 rpm, one revolution is approximately 50ms. Each 200ms data frame contains approximately 4 revolutions of information, and the intra-frame average can be used. If the workpiece rotation speed is low, data corresponding to 1 to 2 revolutions can be taken across frames. F is normalized according to the ratio of the current high-low frequency acoustic emission energy ratio to the reference high-low frequency acoustic emission energy ratio. The reference high-low frequency acoustic emission energy ratio is the median value of multiple data frames within the initial 1 second of cutting the first qualified workpiece after the oilstone has been freshly trimmed. The normalization result is between 0 and 1, with 0 being taken when the result is less than 0 and 1 being taken when it is greater than 1. When F is greater than 0.65, it is marked as high sharpness. When F is between 0.40 and 0.65, it is marked as median sharpness attenuation. When F is less than 0.40, it is marked as low sharpness. The settings of 0.40 and 0.65 are based on the range of acoustic emission energy ratio changes when the oilstone transitions from cutting-dominant to polishing-dominant, and are calibrated using the first piece trial cutting data. The identification of honing stone pore blockage degree is based on spindle net power, pressure feedback, and honing stone usage status. In each data frame, spindle net power is obtained by subtracting the no-load power at the current speed from the actual power, and power consumption per unit pressure is obtained by dividing the average spindle net power by the average pressure. When the honing stone pores are unobstructed, the number of effective cutting edges of the abrasive grains is large, and the material removal work is more sufficient under unit pressure. When the honing stone pores gradually become blocked, chips and passivation products fill the chip space, and the material removal capacity decreases under the same pressure. The reference power consumption for unblocked honing stone is taken as the median value of the power consumption per unit pressure within 1 second of the initial cutting of the first qualified workpiece after honing stone dressing. The degree of pore blockage B is determined according to the ratio of the difference between the reference power consumption and the current power consumption per unit pressure to the reference power consumption. The calculation is corrected based on the cumulative number of parts processed by the oilstone and the cumulative wear. The value of B ranges from 0 to 1, with 0 being taken when the result is less than 0 and 1 being taken when it is greater than 1. When B is less than 0.35, it is marked as a good porosity state. When B is between 0.35 and 0.65, it is marked as an intermediate transition state. When B is greater than 0.65, it is marked as a high-level blockage state. The basis for setting 0.35 and 0.65 is the initial power consumption after oilstone dressing, the stable processing power consumption, and the power consumption distribution range before and after pore blockage during the first piece trial cutting process. If the noise in the spindle power channel is large, the low-frequency acoustic emission energy and tangential vibration component are introduced as correction values. When the net spindle power decreases and the low-frequency acoustic emission and tangential vibration increase, the reliability of the pore blockage judgment is improved. The change in the contact area between the honing stone and the workpiece is identified through honing stone displacement, pressure feedback, and the initial contact reference. Within each data frame, the change in honing stone displacement and the average pressure are read, and the displacement response under unit pressure is calculated as an indicator of contact compliance. When the contact area is small, the local indentation and fretting of the honing stone are more pronounced under the same pressure, resulting in higher contact compliance. As the contact area expands, the load per unit area decreases, the overall indentation of the honing stone decreases, and the contact compliance decreases. The reference compliance is the median value of compliance within 1 second of stable contact under light contact pressure after the honing stone is calibrated at zero position. The contact area index A is determined based on the ratio of the reference compliance to the current contact compliance, and normalized by combining the contact state during the initial light contact stage of the honing stone. The value of A ranges from 0 to 1; a value less than 0 is taken as 0, and a value greater than 1 is taken as 1. When A is less than 0.40, it is judged as a small contact area state; when A is between 0.40 and 0.65, it is judged as a contact area expansion state; when A is greater than 0.40, it is judged as a small contact area state. At a value of 0.65, the contact area is considered to be in a high-level state. This zone corresponds to the changes in contact state during the three processing stages: cutting, semi-cutting, and finishing. After the honing stone is repaired or replaced, the reference compliance is re-collected to avoid the old honing stone reference affecting the judgment of the new honing stone. When the workpiece is a conical raceway or a peach-shaped groove, the contact area index can be converted into an equivalent contact length index, but the pressure and displacement response relationship is still used as the identification basis. The stage thresholds of F, B, and A are not used as fixed industry constants, but are determined by the distribution of state characteristics in the initial cutting stage, stage transition zone, and final finishing stage during the first piece trial cutting under the selected workpiece, honing stone, and cooling conditions. The initial cutting stage state characteristics are used as the cutting side reference, the final finishing stage state characteristics are used as the finishing side reference, and the stage transition zone is taken as the boundary between the two. If the first piece trial cutting workpiece is unqualified, the above thresholds are determined by calling the historical qualified processing records of the same type of workpiece, the same type of honing stone, and the same cooling conditions. The current processing stage identification adopts multi-feature consistency judgment; each frame in the state feature table includes at least the following fields: sharpness F, degree of pore blockage B, contact area index A, acoustic emission high-frequency fluctuation value, spindle net power trend, and vibration stability; the acoustic emission high-frequency fluctuation value is characterized by the standard deviation of high-frequency energy or the difference between adjacent frames, the spindle net power trend is characterized by the slope of consecutive frames, and the vibration stability is characterized by the standard deviation of radial and tangential acceleration; the cutting stage corresponds to a high level of sharpness, good pore condition, and small contact area, and is confirmed by a relatively high acoustic emission high-frequency fluctuation value and a rising or high-level stable spindle net power; the semi-cutting stage corresponds to a mid-level attenuation of sharpness, an intermediate transition state of pores, and an expansion state of contact area, and is confirmed by a decrease in acoustic emission high-frequency fluctuation value and a slow decrease in spindle net power; the finishing stage corresponds to a low level of sharpness, a high level of pore blockage, and a high level of contact area, and is confirmed by a stable overall acoustic emission energy and a spindle net power close to an unloaded state. In the most recent 5 consecutive data frames, if 4 or more frames meet the same processing stage rule, the corresponding processing stage identifier is output; if 2 or more frames match in both processing stages, a stage transition identifier is output and the previous processing stage is maintained, waiting for the next set of data frames to re-evaluate; 5 frames correspond to an observation window of approximately 1 second, which can cover multiple rotations of the workpiece, reducing the interference of local allowances or local hardness differences on stage judgment, while not causing significant control lag; for miniature bearings or high-speed electric spindle equipment, the observation window can be shortened to 3 to 4 frames; for large-size low-speed bearings, the observation window can be extended to 6 to 8 frames; the above window lengths are determined according to the workpiece speed, single-piece processing cycle time, and stage switching response requirements; Circumferential state changes are identified based on workpiece rotation angle information. A circumferential data table records pressure, acoustic emission energy, and displacement changes according to rotation angle intervals. During identification, changes in adjacent rotation angle intervals and within the same rotation angle interval over multiple rotations are compared. When a rotation angle interval exhibits a deviation of more than 15% from the average of adjacent rotation angle intervals in acoustic emission high-frequency energy or hoist displacement response over two or more consecutive rotations, and the deviation direction remains consistent, a circumferential state change identifier is generated. Specifically, when the acoustic emission high-frequency energy and hoist displacement response are lower than adjacent intervals, it is marked as an interval with high hardness or large allowance. When pressure fluctuations are small but the displacement response is higher than adjacent intervals, it is marked as an interval with small allowance or small local contact area. 15% is used as the circumferential disturbance identification threshold to exclude sensor noise and normal circumferential fluctuations. For workpieces with large fluctuations in the previous grinding process, this threshold can be increased to 20%; for miniature bearings, this threshold can be reduced to 10%. The identification result is not directly used as the final pressure command, but rather generates a circumferential state change identifier for subsequent determination of whether to apply circumferential compensation based on the current processing stage. Data reliability C is obtained by weighting channel validity, time synchronization consistency, and stage matching consistency. Channel validity is the ratio of the number of valid acquisition channels to the number of channels that should be acquired. Time synchronization consistency is determined by the ratio of the maximum time synchronization deviation to the allowable synchronization deviation. Stage matching consistency is determined by the number of data frames matching the same processing stage in the last 5 data frames. The weights of channel validity, time synchronization consistency, and stage matching consistency can be 0.4, 0.2, and 0.4, respectively. A C value below 0.6 is marked as a low reliability state, and a C value above 0.8 is marked as a high reliability state. 0.6 and 0.8 are used to distinguish between data missing or unstable stage states and states with high consistency of multi-source data, respectively. After the state identification is completed, the processing stage identifier, oilstone abrasive sharpness index, pore blockage index, contact area index, circumferential state change identifier, and data reliability are output as the data basis for subsequent pressure adjustment and anomaly handling.

[0023] Specifically, such as Figure 5As shown: The dynamic adjustment process starts after obtaining the processing stage identifier, honing stone state vector, circumferential state change identifier, and data reliability. This process first determines the basic parameters based on the current processing stage, then corrects the basic parameters based on the incoming material characteristics, honing stone wear state, honing stone abrasive sharpness, pore blockage degree, and circumferential state changes. It then outputs control actions for honing stone pressure, honing stone oscillation frequency, honing stone amplitude, coolant inlet pressure, and coolant flow rate through pressure tracking and parameter limiting rules. The dynamic adjustment process performs an adjustment judgment once for each new set of state characteristic table data received. The adjustment judgment period can be selected as 200ms, which is consistent with the length of the processing data frame, ensuring that the state identification results and parameter adjustment actions remain synchronized. The pressure closed-loop execution period can be selected from 1ms to 10ms, determined based on the pressurization mechanism's response speed, pressure sensor sampling capability, and pressure command smoothing tracking requirements. When the processing stage is identified as the cutting stage, the reference pressure for the cutting stage is selected as the base pressure. For the scenario of machining the inner raceway of a P4 grade deep groove ball bearing using a W7 alumina ceramic bonded honing stone, the reference pressure for the cutting stage can be selected as 0.35MPa to 0.45MPa, preferably 0.40MPa. The basis for determining this pressure range is the honing stone grit size, bond type, workpiece hardness, and previous grinding allowance, so that the honing stone can remove the grinding-modified layer and initial allowance during the cutting stage, while reducing the risk of workpiece surface damage. When the incoming material is marked as a heavy-cutting workpiece, the base pressure is increased by 0.03MPa to 0.08MPa; when the incoming material is marked as a light-cutting workpiece, the base pressure is decreased by 0.03MPa to 0.06MPa; when the average hardness is greater than Rockwell hardness 62, the base pressure is further increased by 0.02MPa to 0.05MPa. The above correction amounts are determined based on the allowance deviation, the common hardness range of bearing steel, and the cutting ability of the honing stone, and are used to compensate for the changes in material removal load caused by individual differences in the workpiece. During the cutting stage, pressure compensation is also performed based on the sharpness of the abrasive grains in the whetstone. If the sharpness F of the whetstone grains decreases by more than 10% relative to the initial cutting value, the whetstone pressure is increased by 0.01 MPa for every 10% decrease, with the cumulative compensation not exceeding 30% of the reference pressure during the cutting stage. This compensation method is based on the fact that the cutting depth of a single abrasive grain decreases after the whetstone is passivated, and it is necessary to maintain the material removal capacity by appropriately increasing the contact pressure. The upper limit of the cutting stage pressure is set within 0.7 MPa. This upper limit is determined based on the compressive strength, end face wear test, and rated pressurization capacity of the same type of whetstone, and is used to reduce the risk of abnormal end face wear of the whetstone, local whetstone collapse, and workpiece surface damage. When the strength grade, grain size, or binder type of the whetstone changes, the upper limit of the pressure is recalibrated using the first piece test cut data. When the data reliability C is lower than 0.6, even if the cutting stage is currently underway, the pressure is not increased, but only the previous safe pressure is maintained or slowly reduced to the safe pressure. When the machining stage is marked as the semi-cutting stage, the honing stone pressure is smoothly reduced from the cutting stage pressure to the semi-cutting stage reference pressure. The semi-cutting stage reference pressure can be selected from 0.20MPa to 0.30MPa, preferably 0.25MPa. The pressure reduction is completed by a ramp method, and the ramp time can be selected from 200ms to 500ms, with a pressure change rate not exceeding 0.5MPa / s. This change rate is determined based on the contact stiffness between the honing stone and the workpiece, the response speed of the pressurizing mechanism, and the requirement to avoid sudden pressure changes, and is used to reduce the impact load during stage switching. In the semi-cutting stage, the burn precursor is monitored by the combined change of acoustic emission low-frequency energy and radial vibration acceleration. The first piece safety benchmark is the median value of the product of low-frequency acoustic emission energy and radial vibration acceleration during the stable period when the pressure tracking of the first qualified workpiece in this batch is normal, no burns occur, and the in-machine inspection is qualified. If the first piece in this batch is unqualified, the historical qualified machining records of the same type of workpiece, the same type of honing stone, and the same cooling conditions are used to determine the first piece safety benchmark. When the product of low-frequency acoustic emission energy and radial vibration acceleration exceeds 1.2 times the first-piece safety benchmark and persists for more than two data frames, the oilstone pressure is reduced by 0.03 MPa to 0.05 MPa, while the coolant inlet pressure is increased by 15% to 20% and the coolant flow rate is increased by 10% to 15%. The 1.2 times benchmark is used to identify heat accumulation and enhanced friction phenomena that are significantly higher than normal semi-cutting conditions, and two data frames are used to eliminate misjudgments caused by single-frame impact noise. If the burn precursor does not decrease to below 1.05 times the first-piece safety benchmark within 2 seconds after adjustment, a semi-cutting anomaly marker is generated, and the anomaly handling process is initiated. The combined judgment of low-frequency acoustic emission and radial vibration is used because surface heat accumulation and enhanced friction will simultaneously change elastic wave energy and mechanical vibration, which can reduce the probability of misjudgment by a single indicator. When the processing stage is marked as the finishing stage, the oilstone pressure is reduced to the finishing stage reference pressure. The finishing stage reference pressure can be selected from 0.08MPa to 0.12MPa, preferably 0.10MPa. If the pore blockage degree B is greater than 0.65 and the contact area index A is greater than 0.65, and the pressure curve shows a small stable fluctuation, then it is determined that the oil film has begun to form. The oil film formation indicator serves as the trigger condition for further fine pressure reduction. At this time, the oilstone pressure is reduced step by step in increments of 0.005MPa, and the reduction interval can be selected as 500ms. The 0.005MPa step size is determined based on the characteristic that the critical state of the oil film in the finishing stage is sensitive to pressure changes. If the step size is too large, the oilstone may detach from the workpiece, and if the step size is too small, the finishing cycle will be prolonged. The completion indicator is confirmed by the overall acoustic emission energy stability. The completion stability threshold is the average of the overall acoustic emission energy of the first qualified workpiece in this batch during the last second of the completion period, plus 10% as the judgment threshold. If there is no data for the first qualified workpiece in this batch, historical qualified processing data of the same type of workpiece, the same type of oilstone, and the same cooling conditions are used to determine the threshold. When the overall acoustic emission energy drops below the completion stability threshold and remains below it for more than 1 second, the oilstone pressure is stopped from being lowered further, and the completion indicator is output. During the completion stage, the coolant inlet pressure drops back to 0.15MPa to 0.20MPa, and the coolant flow rate is maintained above the minimum stable flow rate covering the grinding zone to reduce the disturbance of the oil film by excessive liquid flow. When using oil-air mixed cooling, because the oil film formation conditions are different from pure oil cooling, the reference pressure during the completion stage can be increased by 0.02MPa to 0.03MPa, and the downward adjustment step can be reduced to 0.003MPa. The circumferential state change corresponding to the workpiece rotation angle only participates in pressure correction during the cutting stage or the early stage of the transition from cutting to semi-cutting. When there is an indication of excessive allowance or high hardness in a certain rotation angle range, a pressure fine-tuning command is generated before the workpiece passes through the whetstone action area in that rotation angle range. The phase advance is determined according to the spindle speed, the response time of the pressurizing mechanism, and the contact position of the whetstone. For example, when the spindle speed is 1200 rpm, the workpiece rotates 20 times per second. When the effective response time of the pressurizing mechanism is 20 ms, the workpiece rotates approximately 144° within 20 ms. Therefore, the pressure fine-tuning command must be issued in advance according to this rotation angle. The circumferential pressure fine-tuning amplitude can be selected from 0.01 MPa to 0.03 MPa, and it can be applied continuously for no more than 3 rotations. If the acoustic emission and displacement difference in the corresponding rotation angle range has not decreased after 3 rotations, the upward adjustment is stopped and a circumferential disturbance anomaly is generated. For the range of insufficient allowance or low hardness, the pressure is reduced by the same amplitude. Circumferential pressure fine-tuning is not performed in the semi-cutting stage and the finishing stage to avoid uneven surface texture caused by rapid pressure fluctuations in the finishing stage. The wear status of the honing stone is involved in the cross-workpiece parameter update. After each workpiece is machined, the cumulative wear of the honing stone is updated according to the change in the zero displacement position. When the cumulative wear increases by 0.05mm, the zero position of the honing stone is refreshed. This refresh interval is determined based on the influence of honing stone wear on the extension of the pressurizing mechanism, which can correct the drift of the pressure application point without significantly increasing the cycle load. When the cumulative wear exceeds 0.2mm but does not reach the replacement threshold, the reference pressure at each stage is slightly increased with the wear, with 0.01MPa compensation for every 0.1mm of wear, and the cumulative compensation not exceeding 0.05MPa. This compensation is used to offset the decrease in equivalent cutting capability caused by the overall passivation of the honing stone. If the cumulative number of machined parts is close to 500 or the cumulative wear is close to 0.5mm, the cutting stage and the semi-cutting stage switch to a conservative pressure strategy, reducing the pressure by 0.05MPa and 0.03MPa respectively, while the pressure in the finishing stage remains low. After dynamic adjustment is completed, the output includes pressure command curve, oscillation frequency and amplitude commands, coolant pressure and flow commands, circumferential compensation commands, and parameter update records. The parameter update records include at least the workpiece number, processing stage identifier, base pressure, pressure correction amount, honing stone wear compensation amount, circumferential compensation range, coolant adjustment amount, oscillation parameter adjustment amount, and data reliability fields. The above outputs are applied to the current processing and written into the process parameter table, serving as the data basis for anomaly handling, parameter write-back, and initial reference correction for the next workpiece.

[0024] Specifically, such as Figure 6 As shown: The anomaly handling process is triggered when there is sensor signal interruption, pressure tracking anomaly, oilstone oscillation anomaly, coolant supply anomaly, status recognition reliability is lower than a set threshold, or quality feedback anomaly. The input to the anomaly handling process includes at least data validity identifier, data reliability, processing stage identifier, pressure command, and parameter update record. Anomaly handling is divided into degradeable anomalies, rollback anomalies, and pause anomalies according to the degree of impact of the anomaly on processing safety and processing quality. Different anomaly types correspond to different handling paths. An anomaly record is generated for each type of anomaly. The anomaly record includes at least the following fields: workpiece number, occurrence time, processing stage, anomaly type, data frames before and after the anomaly, handling action, and parameter write-back content. When a sensor signal is interrupted, a signal self-check is performed first. If any sensor channel has no new data, a timestamp regresses, or a sampled value exceeds the physical range within 200ms, that sensor channel is marked as abnormal in the current data frame. The 200ms threshold is consistent with the length of the machining process data frame, enabling the detection of signal loss within one feature frame and preventing missing data from entering the status identification process. After the signal self-check, it is determined whether the abnormal channel is a critical channel. The pressure channel, hoist displacement channel, and spindle power channel are critical channels; if any critical channel fails, pressure increase is not allowed. If the acoustic emission channel, vibration channel, or workpiece corner channel fails temporarily, degraded machining is allowed. During degraded machining, the stage identification switches from complete multi-source rules to remaining valid feature rules. For example, acoustic emission... When the launch channel fails, the machining stage is determined by the spindle net power trend, honing stone displacement change, and pressure response. When the workpiece corner channel fails, circumferential compensation is canceled, and only staged pressure control is performed. When the coolant pressure signal fails but the flow rate is normal, the supply status is determined by the flow rate and pump status. Degraded machining is only allowed to continue until the current workpiece is finished. Before the next workpiece enters the machine, the abnormal channel needs to be restored or manual confirmation is required to continue machining. During the degradation period, if 3 out of the last 5 frames meet the same machining stage rules, the corresponding machining stage identifier is output, but the pressure limit is reduced by 10% to 20% simultaneously. The basis for this pressure limit reduction is that some signals are missing in the degradation state, and reducing the pressure limit can reduce the risk of scratches, burns, or abnormal honing stone wear in the misjudgment state. When pressure tracking malfunctions, a retry and rollback are executed. The criteria for judging pressure tracking malfunctions are: the pressure feedback during the cutting stage fails to reach 90% of the target pressure within 3 seconds; or the pressure feedback during the semi-cutting and finishing stages fails to follow the target pressure reduction within 1 second; or the pressure deviation exceeds 0.01 MPa and remains continuously for more than 500 ms. The 3-second threshold corresponds to the allowable response time for pressure establishment and allowance removal during the cutting stage, the 1-second threshold corresponds to the pressure drop response requirements during the semi-cutting and finishing stages, and the 0.01 MPa deviation matches the pressure sensor resolution and closed-loop control accuracy. After an malfunction is triggered, the current pressure increase command is frozen, and the target pressure is reduced back to the safe pressure of the current machining stage. Limit; then perform the first retry, that is, clear the pressure command to zero and reissue the safe pressure for the current processing stage, and observe whether the pressure feedback enters the allowable deviation range within 500ms; if the first retry fails, perform the second retry, that is, reset the control signal of the proportional pressure regulating valve or servo pressurizing mechanism, and then re-establish the pressure closed loop; if both retry fail, immediately perform honing stone retraction, so that the honing stone leaves the workpiece raceway, and suspend the current processing; the allowable deviation range is taken as the larger of 5% of the target pressure or 0.01MPa, in order to take into account the tracking and judgment of the low-pressure finishing stage and the high-pressure cutting stage; abnormal pressure tracking data is written into the abnormal record, and the pressure change rate of the next workpiece in the same stage is reduced when writing back the parameters; When abnormal honing stone oscillation occurs, downgrade or revert based on the degree of deviation. An abnormal oscillation is defined as a deviation of more than 10% from the target value in the honing stone oscillation frequency or amplitude feedback, lasting for more than 500ms. The 10% deviation is used to identify oscillation deviations that may affect the uniformity of the honing stone contact trajectory, and the 500ms duration is used to eliminate short-term control jitter. If the deviation is less than 20% and the pressure, acoustic emission, and vibration status are still within safe ranges, the pressure is reduced by 10%, and the current workpiece processing continues, while the oscillation parameters are locked near the actually achievable stable value. If the deviation exceeds 20%, or there is a sudden increase in vibration acceleration, the honing stone pressure is immediately reduced to below 0.05MPa, and the honing stone is reverted. 0.05MPa is used to maintain safe unloading under light-touch conditions, preventing further effective material removal. After reverting from the abnormal oscillation, the current workpiece is marked for review and does not proceed directly to the next process. If the abnormal oscillation occurs during the finishing stage and processing is nearing completion, a short-term finishing can be added based on the in-machine inspection results. If it occurs during the cutting or semi-cutting stage, the current workpiece exits the normal processing flow. When coolant supply is abnormal, first determine the relationship between coolant pressure and coolant flow rate. A cooling anomaly is triggered when the coolant inlet pressure or flow rate is below 80% of the rated value for the current machining stage and remains below this level for more than 5 seconds. The 80% threshold is set based on the minimum stable supply capacity required for cooling and chip removal in the grinding zone. The 5-second threshold is suitable for conventional ultra-precision grinding cycles and can filter short-term pump pressure fluctuations. For high-speed spindle bearings or high-hardness workpieces, the duration of the cooling anomaly can be shortened to 2-3 seconds to improve thermal risk response speed. After a cooling anomaly is triggered, the backup coolant should be switched on first. Reset the fluid supply path or valve opening; if the backup path returns to normal, continue processing and write the anomaly record; if it cannot be restored, reduce the pressure by 30% and increase the oscillation frequency by 10% during the cutting and semi-cutting stages; if the coolant is still insufficient, suspend processing and return the oilstone; if insufficient cooling occurs during the finishing stage, stop increasing the pressure or extend the processing, and switch to surface quality inspection, because insufficient cooling may damage the stability of the oil film; the parameter writeback for cooling anomalies should at least include increasing the coolant pressure reference for the next workpiece's corresponding processing stage, reducing the pressure upper limit, or prompting a check for nozzle blockage, etc. The root cause of the anomaly is determined by combining the processing stage identifier, status characteristic table, pressure execution curve, and in-machine inspection results. Insufficient material removal during the cutting stage corresponds to the cumulative change of the honing stone displacement at the end of the cutting stage being less than 70% of the reference value of the single-sided material allowance, and in-machine inspection showing that the roughness or roundness exceeds the limit. The 70% is used as the judgment ratio, and its basis is that the cutting stage usually undertakes the main material removal task. The pre-burning signs during the semi-cutting stage correspond to the product of low-frequency acoustic emission energy and radial vibration acceleration exceeding the first piece safety benchmark. The unstable oil film during the finishing stage corresponds to the contact area index A being at a high level, but the overall acoustic emission energy not decreasing to the finishing stability threshold. The anomaly caused by honing stone pore blockage corresponds to the pore blockage degree B being at a high level, and having a time correlation with the abnormal pressure execution curve or surface inspection. The parameter write-back uses small-step corrections, avoiding large-scale changes to the process library all at once. If the root cause of the anomaly is insufficient removal of allowance during the cutting stage, the maximum observation time for the next workpiece's cutting stage is increased by 0.5 seconds, and the base pressure during the cutting stage is increased by 0.01 MPa to 0.03 MPa. If the root cause of the anomaly is a precursor to burns during the semi-cutting stage, the semi-cutting pressure for the next workpiece is decreased by 0.02 MPa, and the coolant inlet pressure is increased by 10%. If the root cause of the anomaly is scratches or unstable oil film during the finishing stage, the pressure reduction step for the next workpiece's finishing stage is reduced from 0.005 MPa to 0.003 MPa, and the coolant level is lowered. The scouring intensity; if the abnormal root cause is high-level blockage of the oilstone pores, the oilstone is prompted to be repaired or replaced, and the cutting pressure is prohibited from being increased until the repair is completed; when three consecutive workpieces have the same quality abnormality, the batch is paused, the automatic write-back is stopped, and manual verification of the workpiece material, oilstone condition and cooling supply conditions is required; through downgraded processing, oilstone retraction, processing pause, abnormal recording and parameter write-back, the abnormal handling process forms a closed loop with the aforementioned processing control process, so that the method can be stably implemented under normal processing and abnormal boundary conditions, and improves the stability of ultra-precision grinding pressure control, batch processing consistency and equipment operation reliability.

[0025] Example 2: Based on Example 1, the specific application process of an adaptive pressure control method for ultra-precision grinding is further explained: Specifically, such as Figure 7 and Figure 8 As shown: The ultra-precision grinding of the inner ring raceway of a P4 grade deep groove ball bearing is taken as the object. The workpiece material is conventional bearing steel. The previous process is raceway grinding. The ultra-precision grinding uses a W7 alumina ceramic bonded oilstone. Before processing, the workpiece is sent to the pre-inspection position by the conveying mechanism and is stably clamped by the positioning fixture. The incoming material inspection device collects information on raceway profile, initial roughness, initial waviness, groove error and hardness along the circumference of the raceway, and writes the collected results into the workpiece feature table. The workpiece feature table includes at least the following fields: workpiece number, batch number, inspection time, mean value of single-sided allowance, standard deviation of single-sided allowance, mean initial roughness, mean initial waviness, mean hardness, hardness difference and groove error. The raceway circumference can be divided into 24 equal-angle sampling intervals, each corresponding to a 15° central angle; the initial roughness and initial waviness of the raceway can be sampled in the vicinity of 0°, 120°, and 240°; the hardness can be sampled at least 2 points in the non-working load-bearing area; if the average single-sided allowance obtained is 13μm, the standard deviation of the single-sided allowance is 1.6μm, and the average hardness is Rockwell hardness 61, then the workpiece is marked as a conventional workpiece; among them, 13μm is within the conventional machining window of 8μm to 15μm, and 1.6μm is lower than the conventional discrete judgment value of 2μm, indicating that the previous grinding allowance is relatively stable; Rockwell hardness 61 is within the effective hardness range of common bearing steel after heat treatment, so no hardness offset compensation is required; if the average single-sided allowance of the same batch of workpieces reaches 18μm, then the workpiece is marked as a heavy-cutting workpiece, and upward offset is performed when the initial pressure is determined. After the incoming material characteristics are collected, the current usage status of the oilstone is read. The usage status of the oilstone includes at least the following fields: oilstone model, oilstone grit size, binder type, current zero position, cumulative number of processed parts, cumulative wear, last dressing time, and quality feedback of the previous workpiece. If the current cumulative number of processed parts is 120, the cumulative wear is 0.12mm, and the on-machine inspection result of the previous workpiece is qualified, then the oilstone is determined to be in the normal usage range. If the oilstone is newly installed or used for the first time after dressing, then zero position calibration is performed first. During calibration, the pressure mechanism pushes the oilstone close to the standard workpiece or calibration surface with a light touch pressure of less than 0.15MPa. When the pressure feedback first stabilizes above 0.05MPa and is maintained for more than 100ms, the oilstone displacement is read as the current zero position. 0.05MPa is higher than the slight fluctuations that may be caused by mechanical clearance and sensor noise, but lower than the normal cutting pressure, so it can be used as the judgment value for oilstone light touch calibration. After the workpiece's incoming material characteristics and the honing stone's usage status are correlated, an initial machining record is generated. The initial machining record includes at least the following fields: workpiece number, honing stone number, workpiece category identifier, honing stone wear status, initial contact position, initial pressure candidate range, initial oscillation parameters, coolant reference parameters, and stage observation window. For the inner raceway of a P4-grade deep groove ball bearing marked as a conventional workpiece, the initial pressure candidate range can be selected as 0.35MPa to 0.45MPa. For workpieces marked as heavy cutting, the initial pressure candidate range is offset upwards by 0.03MPa to 0.08MPa. For workpieces marked as light cutting, the initial pressure candidate range is offset downwards by 0.03MPa to 0.06MPa. The above offsets are determined based on the workpiece's single-sided allowance deviation, the honing stone's cutting capability, and the bearing steel's hardness range, and are used to match the initial pressure with the actual material removal load. After the workpiece enters the ultra-precision grinding station, the workpiece spindle drives the workpiece to rotate, and the honing stone feed mechanism drives the honing stone to approach the raceway surface. When the pressure feedback first exceeds 0.1MPa and is maintained continuously for no less than 100ms, it is determined that a stable mechanical contact has been established between the honing stone end face and the workpiece raceway, and this moment is recorded as the zero point of the machining time. 0.1MPa is higher than the light touch pressure when the honing stone is calibrated at the zero position, which can eliminate false contact and sensor noise. At the same time, it is lower than the normal working pressure during the cutting stage, which is suitable as the contact judgment value for starting multi-source acquisition before formal loading. From the zero point of the machining time, the pressure sensor, acoustic emission sensor, spindle power acquisition channel, honing stone displacement sensor, vibration sensor, coolant pressure sensor, coolant flow sensor, and spindle encoder synchronously acquire machining process data. During the data acquisition process, all acquisition channels are connected to a unified clock. When hardware synchronization is available, the synchronization error is controlled within 100μs. When hardware synchronization is not available, software timestamp compensation is used for resampling. The processing data is framed in 200ms intervals, with an overlap of 10ms to 20ms between adjacent data frames. The 200ms frame length is based on the fact that the spindle speed of the workpiece during ultra-precision grinding is usually between 600 rpm and 1500 rpm, corresponding to 10 to 25 revolutions per second. 200ms can cover about 2 to 5 revolutions of workpiece rotation, which can reflect the circumferential contact state of the raceway without causing significant lag in stage identification. Each data frame includes at least the following fields: processing time, workpiece rotation angle range, pressure statistics, acoustic radio frequency band energy, spindle net power, oilstone displacement change, vibration acceleration characteristics, coolant pressure and flow status, and acquisition validity indicator. Status recognition is initiated after at least 5 valid data frames are continuously generated, and at least 3 channels among pressure, spindle power, honing stone displacement, and workpiece rotation angle are in a valid state. During recognition, the acoustic emission signal extracts energy in the low-frequency band of 20kHz to 100kHz and the high-frequency band of 100kHz to 500kHz respectively. The ratio of high-frequency energy to low-frequency energy is used as the initial index F1 of honing stone abrasive sharpness. F1 is averaged within the time window corresponding to one rotation of the workpiece to obtain the sharpness stability index F, and normalized according to the ratio of the current high-low frequency acoustic emission energy ratio to the reference high-low frequency acoustic emission energy ratio. The reference high-low frequency acoustic emission energy ratio is taken as the median value of multiple data frames within 1 second of the initial cutting stage of the first qualified workpiece after honing stone dressing, and the normalized result is between 0 and 1. Meanwhile, the spindle net power is obtained by subtracting the no-load power from the current spindle power, and the unit pressure power consumption is obtained by dividing the average spindle net power by the average pressure. The reference power consumption for unclogged honing stone is the median value of the unit pressure power consumption within 1 second of the initial cutting stage of the first qualified workpiece after honing stone dressing. The degree of pore clogging B is determined according to the ratio of the difference between the reference power consumption and the current unit pressure power consumption to the reference power consumption, and is corrected in combination with the cumulative number of processed parts and the cumulative wear. The change in the contact area between the honing stone and the workpiece is identified by contact compliance, which is the ratio of the honing stone displacement change to the average pressure. The reference compliance is the median value within 1 second of stable contact with light pressure after the honing stone is calibrated at zero position. The contact area index A is determined according to the ratio of the reference compliance to the current contact compliance. The judgment thresholds of F, B, and A are not used as fixed industry constants, but are determined by the state characteristic distribution of the initial cutting stage, the transition zone, and the final finishing stage during the first test cut. If the first test cut workpiece is unqualified, the historical qualified processing records of the same type of workpiece, the same type of honing stone, and the same cooling conditions are used to determine the criteria. In several data frames after machining begins, if F is greater than 0.65, B is less than 0.35, A is less than 0.40, and the acoustic emission high-frequency fluctuation is high, and the spindle net power is in an upward or high-level stable state, then it is marked as the cutting stage. At this time, the dynamic adjustment process selects 0.35MPa to 0.45MPa as the reference pressure for the cutting stage, preferably 0.40MPa. If the current workpiece is a conventional workpiece, the wear condition of the honing stone is normal, and the data reliability C is higher than 0.8, then a base pressure of around 0.40MPa is used. If the sharpness F of the honing stone abrasive grains decreases by more than 10% relative to the initial cutting value, then the honing stone pressure is increased by 0.01MPa for every 10% decrease, with the cumulative compensation not exceeding 30% of the reference pressure for the cutting stage. If the data reliability C is lower than 0.6, then no pressure increase is performed, only the previous safe pressure is maintained or slowly reduced to the safe pressure to avoid erroneous pressure increase when the signal is unstable. As machining continues, if four out of five consecutive data frames meet the combined conditions of median sharpness decay, intermediate porosity transition, and contact area expansion, and the spindle net power begins to slowly decrease, it is marked as the half-cutting stage. At this time, the honing stone pressure is smoothly reduced from the cutting stage pressure to 0.20MPa to 0.30MPa, preferably 0.25MPa. The pressure reduction is completed using a ramp method, with a ramp time of 200ms to 500ms, and the pressure change rate does not exceed 0.5MPa / s. This change rate is determined based on the contact stiffness between the honing stone and the workpiece, the response speed of the pressurizing mechanism, and the need to avoid sudden pressure changes, which can reduce the impact load during stage switching. During the semi-cutting stage, the product of the low-frequency acoustic emission energy and radial vibration acceleration is continuously monitored. The first-piece safety benchmark is the median value of the first qualified workpiece in this batch during a stable period when the pressure tracking is normal, no burns occur, and the in-machine inspection is qualified. If the product exceeds 1.2 times the first-piece safety benchmark and continues for more than 2 data frames, it is determined that there is a precursor to burns. The oilstone pressure is reduced by 0.03MPa to 0.05MPa, while the coolant inlet pressure is increased by 15% to 20% and the coolant flow rate is increased by 10% to 15%. If the pressure does not drop below 1.05 times the first-piece safety benchmark within 2 seconds after adjustment, a semi-cutting abnormality mark is generated. When further identification shows F < 0.40, B > 0.65, and A > 0.65, and the overall acoustic emission energy stabilizes while the spindle net power approaches no-load, it is marked as the finishing stage. At this time, the honing stone pressure is reduced to 0.08 MPa to 0.12 MPa, preferably 0.10 MPa. If both the pore blockage degree B and the contact area index A are at high levels, and the pressure curve shows a small, stable fluctuation, it is determined that the oil film has begun to form. The honing stone pressure is then gradually reduced in increments of 0.005 MPa. The interval is 500ms; the step size of 0.005MPa is determined based on the characteristic that the critical state of the oil film in the finishing stage is sensitive to pressure changes. If the step size is too large, the oilstone may detach from the workpiece, and if the step size is too small, the finishing cycle will be prolonged; the finishing stability threshold is the average value of the overall acoustic emission energy of the first qualified workpiece in this batch in the last 1 second of the finishing period, and is increased by 10% as the judgment threshold; when the overall acoustic emission energy drops below this threshold and remains below it for more than 1 second, the finishing completion indicator is output, and the oilstone pressure is stopped from being lowered further. During the stage adjustment process, workpiece rotation angle information is used to identify circumferential disturbances. When a certain rotation angle interval exhibits a deviation of more than 15% from the average of acoustic emission high-frequency energy or hoist displacement response relative to adjacent rotation angle intervals for more than two consecutive rotations, and the deviation direction remains consistent, a circumferential state change indicator is generated. If the rotation angle interval is marked as having excessive allowance or high hardness, pressure fine-tuning is only performed during the cutting stage or in the early transition from cutting to semi-cutting. The pressure fine-tuning command is issued in advance based on the spindle speed, the response time of the pressurizing mechanism, and the contact position of the hoist. For example, if the spindle speed is... At 1200 rpm, the workpiece rotates 20 times per second. If the effective response time of the pressurizing mechanism is 20 ms, the workpiece will rotate approximately 144° within 20 ms. Therefore, the pressure fine-tuning command must be issued in advance according to this rotation angle. The circumferential pressure fine-tuning range is 0.01 MPa to 0.03 MPa, and it is applied continuously for no more than 3 rotations. If the acoustic emission and displacement differences in the corresponding rotation angle range have not decreased after 3 rotations, the upward adjustment is stopped and a circumferential disturbance anomaly is generated. Circumferential pressure fine-tuning is not performed in the semi-cutting stage and finishing stage to avoid uneven texture formation in the finishing stage. During processing, cross-workpiece corrections are performed based on the cumulative wear status of the honing stone. For each workpiece completed, the cumulative wear of the honing stone is updated according to the change in the zero displacement position. When the cumulative wear increases by 0.05mm, the zero displacement position of the honing stone is refreshed. When the cumulative wear exceeds 0.2mm but does not reach the replacement threshold, the reference pressure at each stage is slightly increased with the wear amount, with 0.01MPa compensation corresponding to every 0.1mm of wear, and the cumulative compensation not exceeding 0.05MPa. This compensation is used to offset the decrease in equivalent cutting capability caused by the overall passivation of the honing stone. If the cumulative number of processed parts approaches 500 or the cumulative wear approaches 0.5mm, a conservative pressure strategy is adopted in the cutting and semi-cutting stages, reducing the pressure by 0.05MPa and 0.03MPa respectively. The pressure in the finishing stage remains low to reduce the risk of scratches at the end of the honing stone's lifespan. If sensor signal interruption, pressure tracking anomaly, hoist oscillation anomaly, or coolant supply anomaly occurs during processing, anomaly handling will be performed. If a sensor channel has no new data within 200ms, timestamps regress, or sampled values ​​exceed the physical range, it will be marked as an anomaly. Pressure increase is not permitted if the pressure channel, hoist displacement channel, or spindle power channel fails. Degraded processing can be performed if the acoustic emission channel, vibration channel, or workpiece corner channel fails temporarily. During degradation, if 3 out of the last 5 frames meet the same processing stage rules, the corresponding processing stage identifier will be output, but the pressure upper limit will be reduced by 10% to 20% simultaneously. Pressure feedback must reach 90% of the target pressure within 3 seconds of the cutting stage, or must follow the target pressure within 1 second of the semi-cutting or finishing stages. If the pressure is reduced, or the pressure deviation exceeds 0.01 MPa and remains for more than 500 ms, a pressure retry is performed; if both retry attempts fail, the honing stone is retracted and the current processing is paused; if the honing stone oscillation frequency or amplitude feedback deviates from the target value by more than 10% and remains for more than 500 ms, it is judged as an oscillation anomaly; if the deviation exceeds 20% or the vibration acceleration suddenly increases, the honing stone pressure is reduced to below 0.05 MPa and the honing stone is retracted; if the coolant inlet pressure or coolant flow rate is lower than 80% of the rated value of the current processing stage and remains for more than 5 seconds, a cooling anomaly is triggered; if the backup coolant supply path cannot be restored, the pressure is reduced by 30% and the oscillation frequency is increased by 10% during the cutting and semi-cutting stages; if the coolant is still insufficient, processing is paused and the honing stone is retracted. After the current workpiece is machined, the raceway roughness, waviness, and roundness error are inspected in-machine. The inspection results are then correlated with the condition characteristic table, pressure execution curve, coolant supply record, and anomaly record to form a workpiece-level process quality file. The workpiece-level process quality file includes at least the following fields: workpiece number, incoming material characteristics, honing stone condition, machining stage switching time, pressure curves for each stage, changes in honing stone abrasive sharpness, changes in pore blockage degree, changes in contact area index, circumferential compensation record, anomaly handling record, and in-machine inspection results. If the inspection shows insufficient material removal during the cutting stage, the maximum observation time for the next workpiece cutting stage is determined. If the interval is increased by 0.5s, the basic pressure during the cutting stage is increased by 0.01MPa to 0.03MPa; if the detection shows signs of burn during the semi-cutting stage, the semi-cutting pressure of the next workpiece is decreased by 0.02MPa, and the coolant inlet pressure is increased by 10%; if the detection shows scratches or unstable oil film during the finishing stage, the pressure reduction step of the finishing stage of the next workpiece is reduced from 0.005MPa to 0.003MPa, and the coolant flushing intensity is reduced; if three consecutive workpieces show the same quality abnormality, batch pause is triggered, automatic write-back is stopped, and a prompt is made to check the incoming workpiece, oilstone status, and cooling supply conditions. Through this operation process, incoming material inspection, synchronous acquisition after contact, oilstone condition identification, processing stage judgment, dynamic pressure adjustment, circumferential compensation, oilstone wear correction, and abnormal retreat handling form a continuous closed loop. This operation logic enables the cutting stage to maintain sufficient material removal capacity, reduces the risk of burns and subsurface damage in the semi-cutting stage, and enables the finishing stage to stably form an oil film and improve surface texture, thereby improving the consistency of raceway surface roughness, waviness, and roundness errors.

[0026] It should be noted that this invention can be deployed on the device itself to realize embedded applications, or it can run on a PC or other terminal with a user interface, thereby meeting various hardware environments and usage requirements.

[0027] The above embodiments can be implemented in whole or in part by software, hardware, firmware, or any other combination. When implemented in software, the above embodiments can be implemented in whole or in part by a computer program product. The computer program product includes one or more computer instructions or computer programs. When the computer instructions or computer programs are loaded or executed on a computer, the processes or functions of the embodiments of this application are implemented in whole or in part. The computer can be a general-purpose computer, a special-purpose computer, a computer network, or other programmable device. The computer instructions can be stored in a computer-readable storage medium or transmitted from one computer-readable storage medium to another. For example, the computer instructions can be transmitted wirelessly or wiredly from one website, computer, server, or data center to another website, computer, server, or data center. Wired methods include optical fiber, twisted pair, coaxial cable, etc. Wireless methods include infrared, microwave, etc. Available media include any available media that can be accessed by a computer or data storage devices such as servers and data centers that contain one or more sets of available media. Available media can be magnetic media (floppy disks, hard disks, magnetic tapes), optical media (DVDs), or semiconductor media. Semiconductor media can be solid-state drives.

[0028] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

[0029] In conclusion, 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, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An adaptive pressure control method for ultra-precision grinding, characterized in that, include: S1. Obtain the incoming material characteristics and current usage status of the workpiece to be processed, and determine the initial processing reference based on the incoming material characteristics and usage status; S2. After the honing stone establishes contact with the workpiece, synchronously collect information on honing stone pressure, acoustic emission, spindle power, honing stone displacement, vibration, coolant pressure, coolant flow rate, and workpiece rotation angle. S3. Based on the characteristics of the incoming material, the usage status, and the information collected synchronously, identify the sharpness of the whetstone, the degree of blockage of the whetstone pores, the change in the contact area between the whetstone and the workpiece, and the current processing stage. S4. Based on the current processing stage, the circumferential state change corresponding to the workpiece rotation angle, and the wear state of the honing stone, adjust the honing stone pressure and simultaneously adjust the honing stone oscillation parameters and coolant supply parameters. S5. When the sensor signal is interrupted, the pressure tracking is abnormal, the honing stone oscillation is abnormal, or the coolant supply is abnormal, execute the process of degraded processing, honing stone retraction, processing suspension, abnormal record, and process parameter write-back.

2. The ultra-precision grinding pressure adaptive control method according to claim 1, characterized in that, Obtain the incoming material characteristics and current usage status of the workpiece to be processed, and determine the initial processing reference based on the incoming material characteristics and usage status, including: After the workpiece is stably clamped, the raceway profile, roughness, waviness, groove error, single-sided allowance, hardness and batch information are collected according to the circumferential partition and multiple cross sections to form a workpiece feature table. The workpiece category and circumferential disturbance are determined based on the unilateral allowance, hardness, and unilateral allowance dispersion. Read the oilstone particle size, binder, zero position, number of processed parts, wear amount and dressing record, and complete the oilstone zero position calibration; Based on the workpiece category identifier, circumferential disturbance identifier, and oilstone wear state, the pressure candidate range and pressure offset are determined, and an initial processing record is generated.

3. The ultra-precision grinding pressure adaptive control method according to claim 1, characterized in that, After the honing stone establishes contact with the workpiece, information on honing stone pressure, acoustic emission, spindle power, honing stone displacement, vibration, coolant pressure, coolant flow rate, and workpiece rotation angle is collected simultaneously, including: Once the pressure feedback exceeds the contact judgment value and remains stable, the corresponding moment will be recorded as the zero point of the processing time. Each acquisition channel is checked for range, recorded for no-load reference and time alignment, and data frames are generated according to the preset frame length. A frame index is formed based on the data frame, which includes workpiece rotation angle, spindle net power, displacement change, acoustic emission characteristics, and validity identifier. A circumferential data table is formed according to the workpiece corner partitions, and the collected data and abnormal channel screening results are written into a circular buffer.

4. The ultra-precision grinding pressure adaptive control method according to claim 3, characterized in that, Each acquisition channel undergoes range verification, no-load reference recording, and time alignment. Data frames are then generated according to a preset frame length, including: Set the sampling range and sampling frequency for pressure, acoustic emission, spindle power, displacement, vibration, coolant pressure, and coolant flow channels respectively; Record the spindle idle power as the no-load reference; Align the sampling times of each channel using a unified clock or software compensation method; Acoustic emission characteristics and statistics for each channel are written into the data frame with the same frame length.

5. The ultra-precision grinding pressure adaptive control method according to claim 1, characterized in that, Based on the characteristics of the incoming material, its usage status, and synchronously collected information, the system identifies the sharpness of the oilstone, the degree of pore blockage in the oilstone, changes in the contact area between the oilstone and the workpiece, and the current processing stage, including: The status determination is initiated after the valid data frame and valid channel meet the preset conditions, taking the frame index, circumferential data table and initial processing record as inputs. The oilstone state vector is generated based on the energy ratio of the acoustic emission radio frequency band, the power consumption per unit pressure, and the displacement response per unit pressure. Determine the status threshold based on the first piece trial cutting data or historical qualified processing records; By combining the matching relationship of consecutive frames, the trend of spindle power, vibration stability and the difference in rotation angle intervals, a state feature table is formed that includes the recording stage identifier, the circumferential state change identifier and the data reliability.

6. The ultra-precision grinding pressure adaptive control method according to claim 5, characterized in that, The oilstone state vector is generated based on the energy ratio of the acoustic emission radio frequency band, the power consumption per unit pressure, and the displacement response per unit pressure, including: The ratio of high-frequency energy to low-frequency energy is extracted from the acoustic emission signal and normalized according to the initial cutting reference of the first qualified workpiece to determine the sharpness index. The unit pressure power consumption is calculated based on the spindle net power and average pressure, and the pore blockage index is determined by combining the number of parts processed by the oilstone and the amount of wear. Contact compliance is calculated based on the change in oilstone displacement and the average pressure, and then normalized according to the light contact benchmark to determine the contact area index.

7. The ultra-precision grinding pressure adaptive control method according to claim 1, characterized in that, Based on the current processing stage, the circumferential state changes corresponding to the workpiece rotation angle, and the wear state of the honing stone, adjust the honing stone pressure, and simultaneously adjust the honing stone oscillation parameters and coolant supply parameters, including: Select the corresponding baseline parameters based on the stage identifier, and perform pressure correction and amplitude limiting based on the incoming material type, data reliability, and oilstone state vector; During the semi-cutting stage, the honing stone pressure and coolant supply parameters are adjusted based on the combined amount of low-frequency acoustic emission energy and radial vibration acceleration. During the finishing stage, the pressure of the oilstone is gradually reduced based on the oil film formation indicator and the acoustic emission stability threshold. Generate a circumferential compensation command with phase advance according to the workpiece rotation angle range, and update the process parameter table according to the wear of the oilstone.

8. The ultra-precision grinding pressure adaptive control method according to claim 1, characterized in that, Generate a circumferential compensation command with phase advance according to the workpiece rotation angle range, and update the process parameter table according to the wear of the oilstone, including: During the cutting stage or in the early stage of the transition from cutting to semi-cutting, the angle range to be compensated is determined based on the circumferential state change indicator. The command advance angle is determined based on the spindle speed, the response time of the pressurizing mechanism, and the contact position of the oilstone, and pressure fine-tuning commands are generated for the range where the margin is too large or the hardness is too high. The cumulative wear is updated based on the change in the zero position of the oilstone. The reference pressure for each stage is corrected according to the range of the cumulative wear. The pressure fine-tuning command and wear correction results are written into the process parameter table.

9. The ultra-precision grinding pressure adaptive control method according to claim 1, characterized in that, In the event of sensor signal interruption, pressure tracking anomaly, hoist oscillation anomaly, or coolant supply anomaly, the following procedures are executed: degraded processing, hoist retraction, processing suspension, anomaly recording, and process parameter write-back. The input includes data validity indicators, data credibility, stage indicators, stress commands, and parameter update records; The exception types are divided into degradeable exceptions, exceptions that need to be rolled back, and exceptions that need to be paused. Perform a self-test on the sensor channels, and select either degradation identification or pressure increase limit based on critical channel failure or short-term failure of non-critical channels; For pressure tracking abnormalities, oscillation abnormalities, and cooling abnormalities, at least one of the following actions should be selected: retry, parameter locking, backup fluid supply, oilstone retraction, or processing suspension. Based on the status characteristic table, pressure execution curve and in-machine detection results, the root cause of the abnormality is determined, an abnormality record is generated and the process parameters are written back.

10. The ultra-precision grinding pressure adaptive control method according to claim 9, characterized in that, Based on the status characteristic table, pressure execution curve, and in-machine detection results, the root cause of the anomaly is determined, an anomaly record is generated, and process parameters are written back, including: Based on the processing stage, the abnormal root causes are classified into categories such as insufficient removal of residual material, signs of burn, unstable oil film, or pore blockage. Establish an exception record based on the workpiece number, occurrence time, exception type, handling action, and write-back content; Adjust the pressure benchmark, observation time, cooling benchmark, or smoothing pressure reduction step size according to the root cause of the abnormality. If the same type of anomaly occurs repeatedly, stop automatic write-back and mark it as a manual review status.

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