A diamond tool machining method, system and apparatus

Abstract

The application belongs to the technical field of digital twin tool machining, and particularly relates to a diamond tool machining method, system and equipment, the method comprising: establishing a space coordinate system in a real space and a three-dimensional coordinate system in a corresponding digital twin, modeling a metal body and determining the actual central angle position of each slot, and modeling a diamond tool bit; obtaining basic welding parameters, simulating the welding process of the metal body and the diamond tool bit through the digital twin; obtaining the position error of each diamond tool bit after simulation welding compared with a design drawing; according to the position error, performing attribution analysis, and adjusting the welding sequence and the preset posture according to the analysis result; until the error meets a preset convergence condition, the welding sequence and the preset posture are converted into instructions and sent to a production line to perform diamond tool machining. The application reduces the welding error of the diamond tool, and avoids the occurrence of tool bit splashing and damage.

Description

Technical Field

[0001] This invention belongs to the field of digital twin tool processing technology, specifically relating to a diamond tool processing method, system and equipment. Background Technology

[0002] In the existing technology of diamond circular saws, the manufacturing of diamond cutting heads has become increasingly mature. The welding of diamond cutting heads to the metal body mainly adopts laser welding, high-frequency induction brazing and traditional brazing technology. Chinese invention patent publication number CN117621269A discloses a diamond circular saw blade base for cutting stone. The circular saw blade base includes a saw blade mother body for support and several saw blade sub-body for embedding in the circumference of the mother body. The saw blade mother body is provided with several embedding grooves for embedding the saw blade sub-body along the circumference. Each saw blade sub-body includes a tooth for welding diamond cutting heads and a connecting part for embedding in the embedding groove on the saw blade mother body. The connecting part of each saw blade sub-body is embedded in the embedding groove of the saw blade mother body and is connected and fixed to the saw blade mother body by brazing to form a complete circular saw blade base.

[0003] In the existing welding process, due to the significant differences in the thermal expansion coefficients of the diamond cutting tip, the metal substrate, and the brazing filler metal, uneven thermal stress and thermal deformation will be generated during the welding heating and cooling process. The deformation leads to a significant deviation between the actual position of the cutting tip after welding and the design drawing, which directly affects the geometric accuracy, dynamic balance characteristics, and cutting quality of the tool.

[0004] In recent years, digital twin technology has been attempted to be applied to welding process simulation, but existing solutions mostly remain at the simulation level, without establishing error attribution models, making it impossible to determine the source of errors, let alone adjust and improve them. Summary of the Invention

[0005] The purpose of this invention is to provide a method, system and equipment for machining diamond tools.

[0006] A method for machining diamond tools, applicable to diamond circular saws, includes the following steps: S1. Establish a spatial coordinate system in the real space and a corresponding three-dimensional coordinate system in the digital twin. Obtain the coordinates of N sampling points on the metal body in the real space. Calculate the center coordinates and radius using the least squares method. For each slot on the metal body in the real space, measure the feature points on its two side walls to determine the actual center angle position of each slot. At the same time, model the diamond cutting head. S2. Obtain basic welding parameters and simulate the welding process between the metal body and the diamond cutting head using digital twin technology; S3. Obtain the positional error of each diamond cutting tip after simulated welding compared to the design drawing. The positional error includes at least the center of gravity displacement distance error, the center of gravity displacement direction error, and the cutting tip pointing angle error. Based on the positional error, an attribution analysis was performed, and the welding sequence and preset posture were adjusted according to the analysis results. S4. Repeat steps S2 to S3 until the error meets the preset convergence condition. Then, convert the welding sequence and preset posture into instructions and send them to the production line to perform diamond tool processing.

[0007] In S3, based on the positional error, an attribution analysis is performed, and the welding sequence and preset posture are adjusted according to the analysis results. Specifically: Based on the current digital twin simulation results, the center of gravity displacement distance error and the pointing angle error of each diamond cutter head are obtained. Outliers are detected and eliminated. The proportion of the main direction of the center of gravity displacement direction error of each slot is calculated. If the proportion of the main direction exceeds the preset ratio and the average center of gravity displacement distance error is greater than the preset threshold, it is determined that the overall torsional deformation is dominant. The welding sequence is adjusted to alternate slots with opposite center of gravity displacement directions. The preset attitude includes a preset translation amount and a preset pointing angle. For each slot, if the center of gravity displacement distance error of the slot is greater than a preset threshold, the preset translation amount is adjusted by the absolute value of the center of gravity displacement distance error, and the adjustment direction is opposite to the center of gravity displacement direction. If the tool pointing angle error of the slot is greater than a preset threshold, the preset pointing angle is adjusted by the absolute value of the tool pointing angle error, and the adjustment direction is opposite to the tool pointing error direction.

[0008] The detection and removal of outliers are as follows: For any position error, sort all slots by position error from smallest to largest, calculate the first quartile and the third quartile, subtract the first quartile from the third quartile to obtain the interquartile range, calculate the reasonable range based on the interquartile range, and list the position error that exceeds this range as an outlier and remove it.

[0009] S3 also includes adjustment amount verification: whether the welding parameter adjustment amount obtained from the verification is within the process allowable range. If so, it is output; otherwise, the adjustment amount is limited to the process boundary.

[0010] In S1, a spatial coordinate system in real space and a corresponding three-dimensional coordinate system in the digital twin are established. Specifically, a cylindrical coordinate system is established with the intersection of the axis of the central hole of the metal body and the upper surface as the origin, the direction perpendicular to the upper surface upward as the positive Z-axis, and the direction of the reference feature on the metal body as the radial zero-degree reference line. At the same time, a Cartesian coordinate system is established in the digital twin, with its origin coinciding with the origin of the cylindrical coordinate system. The X-axis points to the radial zero-degree reference line, the Z-axis is perpendicular to the upper surface upward as positive, and the Y-axis is determined by the right-hand rule.

[0011] In S2, the welding process between the metal body and the diamond cutting head is simulated using a digital twin, specifically as follows: The metal body and the cutting tool are locally refined into a hexahedral mesh, and a fixed constraint on the center hole and an ambient temperature boundary are set. A double ellipsoidal moving heat source model is used, and heat sources are applied sequentially according to the actual welding sequence. The temperature-related material properties of the diamond, the metal body, and the brazing filler metal are defined. The transient heat conduction equation is solved first to obtain the temperature field, and then the temperature load is applied to the thermo-elastic-plastic mechanical model to solve for the displacement field and stress field. After cooling to room temperature, the final offset of the cutting tool is extracted as the position error output.

[0012] The specific convergence conditions preset in S4 are: the absolute value of the position error of all slots is less than the threshold, or the error improvement rate calculated in two consecutive iterations is less than the improvement threshold.

[0013] Error improvement rate = (total error of the previous round - total error of this round) / total error of the previous round × 100%.

[0014] A diamond tool machining system for implementing a diamond tool machining method, comprising: The modeling module establishes a spatial coordinate system in the real space and a corresponding three-dimensional coordinate system in the digital twin. It obtains the coordinates of N sampling points on the metal body in the real space, calculates the center coordinates and radius of the circle using the least squares method, measures the feature points on both sides of each slot on the metal body in the real space, and then determines the actual center angle position of each slot. At the same time, it models the diamond cutting head. The simulation module acquires basic welding parameters and simulates the welding process between the metal body and the diamond cutting head through digital twin technology. The attribution analysis module obtains the positional error of each diamond cutting tip after simulated welding compared to the design drawing. The positional error includes at least the center of gravity displacement distance error, the center of gravity displacement direction error, and the cutting tip pointing angle error. Based on the positional error, an attribution analysis was performed, and the welding sequence and preset posture were adjusted according to the analysis results. The instruction sending module converts the welding sequence and preset posture into instructions and sends them to the production line to execute diamond tool processing when the error meets the preset convergence conditions.

[0015] A diamond tool machining apparatus includes a processor and a memory, wherein the processor executes a computer program stored in the memory to implement a diamond tool machining method.

[0016] Compared to existing technologies, the advantages of this application are as follows: This application deconstructs complex welding errors into two independent dimensions: overall torsional deformation and individual slot deviation, employing two adjustment methods: adjusting the welding sequence and adjusting the preset attitude of the cutting head. Compared to existing technologies that require simultaneous adjustment of multiple parameters such as heat input, dwell time, preset offset, and side clearance, the adjustment logic of this invention is greatly simplified, allowing operators to quickly understand and execute it.

[0017] The welding sequence adjustment rules of this application can cancel out the thermal effects of positive and negative deflection slots, or distribute the welding heat source in a circumferential direction, thereby reducing residual torque caused by heat accumulation at the source. Compared with the prior art, which only uses indirect means such as reducing heat input or adjusting dwell time, the sequence optimization method of this invention has zero cost, zero risk, and direct effect.

[0018] This invention performs an iterative cycle of simulation, measurement, attribution, adjustment, and re-simulation within a digital twin environment until the error meets the target or improvement stagnates. Two exit conditions are met: all slot errors are less than a threshold, and improvement stagnation converges. The former ensures that machining accuracy meets requirements, while the latter prevents infinite iteration due to insufficient error improvement, achieving a good balance between accuracy and efficiency. Attached Figure Description

[0019] Figure 1 shows the diamond circular saw described in the embodiment. Detailed Implementation

[0020] To further understand the content of this invention, the invention will be described in detail with reference to the embodiments.

[0021] This invention relates to a diamond tool machining method, applicable to diamond circular saws, such as... Figure 1 As shown, it includes the following steps: S1. Establish a spatial coordinate system in the real space and a corresponding three-dimensional coordinate system in the digital twin. Obtain the coordinates of N sampling points on the metal body in the real space. Calculate the center coordinates and radius using the least squares method. For each slot on the metal body in the real space, measure the feature points on its two side walls to determine the actual center angle position of each slot. At the same time, model the diamond cutting head.

[0022] Specifically, a spatial coordinate system in real space and a corresponding three-dimensional coordinate system in the digital twin are established. Specifically, a cylindrical coordinate system is established with the intersection of the axis of the central hole of the metal body and the upper surface as the origin, the direction perpendicular to the upper surface upward as the positive Z-axis, and the direction of the reference feature on the metal body as the radial zero-degree reference line. At the same time, a Cartesian coordinate system is established in the digital twin, with its origin coinciding with the origin of the cylindrical coordinate system. The X-axis points to the radial zero-degree reference line, the Z-axis is perpendicular to the upper surface upward as positive, and the Y-axis is determined by the right-hand rule.

[0023] Furthermore, the fundamental reason for establishing two coordinate systems in this application is that there is a contradiction between the practical convenience of measurement and the theoretical rigor of simulation calculation, which cannot be perfectly satisfied by a single coordinate system.

[0024] If only a cylindrical coordinate system is used, the geometric features of the circular saw are naturally circularly symmetrical, making the description of the slot position very intuitive and requiring no conversion. However, mainstream finite element software, such as ANSYS, Abaqus, and COMSOL, all use the Cartesian coordinate system as their native coordinate system. Therefore, measurements taken in the cylindrical coordinate system must be converted to the Cartesian coordinate system after measurement.

[0025] Therefore, a cylindrical coordinate system is used in the spatial coordinate system to facilitate the intuitive description of the angle and position of the slot and the error of the tool head; the three-dimensional coordinate system in the digital twin adopts a Cartesian coordinate system to be compatible with the thermo-mechanical coupling solver of mainstream finite element simulation software; the two are mapped through coordinate transformation formulas to ensure the theoretical rigor of the simulation calculation and maintain the intuitiveness of the error evaluation results.

[0026] Preferably, after modeling, a slot is randomly selected as the starting slot and numbered 1, and then each slot is numbered in a clockwise order.

[0027] S2. Obtain basic welding parameters and simulate the welding process between the metal body and the diamond cutting head using digital twin technology.

[0028] Furthermore, the basic welding parameters include one or more of the following categories: Heat source parameters: welding torch power, thermal efficiency coefficient, heat source radius, heat source ellipsoid shape factor, moving speed, dwell time in each slot, welding torch centering position and welding sequence; Preset position parameters: design center of gravity, design center angle, preset radial offset of the cutter head, preset tangential offset, preset yaw angle, preset Z-axis offset, and single-sided clearance of the slot. Material properties: thermal conductivity, specific heat capacity, coefficient of thermal expansion, yield strength, and elastic modulus.

[0029] Among them, the heat source parameters determine the welding process, defining the intensity, distribution shape, movement trajectory and timing of the moving heat source, which serve as the thermal load input for thermal analysis. Preferably, the welding sequence of the slot is represented by the number in S1. The preset posture parameters define the initial position and attitude of the cutter head in the slot, serving as the initial conditions for mechanical analysis. The material property parameters define the coefficients in the heat conduction equation and the thermo-elastic-plastic constitutive equation, determining the evolution of the temperature field and stress field.

[0030] The welding process between the metal body and the diamond cutting tip is simulated using a digital twin, specifically as follows: The metal body and the cutting tool are locally refined into a hexahedral mesh, and a fixed constraint on the center hole and an ambient temperature boundary are set. A double ellipsoidal moving heat source model is used, and heat sources are applied sequentially according to the actual welding sequence. The temperature-related material properties of the diamond, the metal body, and the brazing filler metal are defined. The transient heat conduction equation is solved first to obtain the temperature field, and then the temperature load is applied to the thermo-elastic-plastic mechanical model to solve for the displacement field and stress field. After cooling to room temperature, the final offset of the cutting tool is extracted as the position error output.

[0031] Furthermore, the localized refinement of the hexahedral mesh for the metal body and the cutting head can be achieved in the following ways, which are merely examples and not intended to be limiting: Import the geometric model, including the metal body, diamond cutting head, and brazing filler layer thickness. Mesh the cutting head independently with a unit size of 0.2mm. Mesh the brazing filler layer independently with at least two layers in the thickness direction to prevent shear locking. Locally refine the metal body slot area: select all inner surfaces of the slot, set the volume control size to 0.2mm, select "close to surface" for the influence range, and set the influence depth to 5mm. Add a transition mesh control: grow 3-5 layers outward from the slot surface at a growth rate of 1.2 to smoothly transition the fine mesh to the coarse mesh. Check the mesh quality: skewness <0.85, orthogonality >0.15. If unsatisfactory, locally refine the mesh or adjust the mesh parameters. Compared to tetrahedral meshes, hexahedral meshes offer higher computational accuracy, fewer elements, and better convergence. Locally refined meshes can capture large temperature gradients in the heat-affected zone, accurately capturing temperature distribution and stress concentration.

[0032] The fixed constraint position of the center hole is all nodes on the inner surface of the center hole of the metal body. The displacement adopts a completely fixed constraint: UX=0, UY=0, UZ=0. The rotation is not constrained. In the simulation of actual welding, the tooling fixture presses and fixes the metal body on the welding worktable. The center hole is the only positioning reference, constraining all translational degrees of freedom, but not the rotation.

[0033] Before the ambient temperature boundary welding begins, the initial temperature field of the entire model is uniform, and all outer surfaces of the model are set as convective boundaries. At high temperatures, radiation heat dissipation is considered. In thermal analysis, the boundary conditions are used as boundary terms of the heat flow equation to solve the problem. In mechanical analysis, the thermal boundary conditions do not participate directly, but are indirectly affected by the temperature field.

[0034] The double ellipsoid is not two heat sources side by side, but a heat source divided into two asymmetrical hemispheres, with the front hemisphere being shorter and the rear hemisphere longer. During the welding process, the material in front of the heat source is cold, heat conduction is slow, and the temperature gradient is large, so the front hemisphere is narrow. The material behind the heat source has been heated, heat conduction is fast, and the heat diffusion range is large, so the rear hemisphere is wide. The asymmetrical configuration can more realistically simulate the temperature field distribution of the moving heat source.

[0035] For each slot, at the start time of arrival at that slot, the center of the heat source moves from one end of the slot to the other along the center line of the slot for a preset time, then stays in that slot, keeping the position of the heat source unchanged, and continues to heat, before moving to the next slot and repeating the above process to simulate welding.

[0036] S3. Obtain the positional error of each diamond cutting tip after simulated welding compared to the design drawing. The positional error includes at least the center of gravity displacement distance error, the center of gravity displacement direction error, and the cutting tip pointing angle error. Based on the positional error, an attribution analysis was performed, and the welding sequence and preset posture were adjusted according to the analysis results.

[0037] Specifically, after simulated welding, the positional error of each diamond cutting tip relative to the design drawing is obtained, and the positional error includes at least: The center of gravity displacement distance error is the Euclidean distance between the simulated rear tool head center of gravity and the designed center of gravity. The error in the direction of the center of gravity displacement is the angle from the designed center of gravity to the simulated center of gravity. The error of the cutting head pointing angle is the difference between the angle of the center of the circle on which the outer arc surface of the cutting head is located and the designed angle of the center.

[0038] Furthermore, measurement errors and data from individual slots may deviate significantly from the true value due to abnormal reasons, such as the tool tip falling off or vibration during measurement. Direct use of these data could mislead subsequent attribution, so outliers must be detected and removed first.

[0039] For any type of position error, sort all slots by position error from smallest to largest, calculate the first quartile and the third quartile, subtract the first quartile from the third quartile to obtain the interquartile range, calculate the reasonable range based on the interquartile range, and classify the position error that exceeds this range as an outlier and remove it.

[0040] Furthermore, a reasonable range is set from Q1-1.5×IQR to Q3+1.5×IQR, where Q1 is the first quartile, Q3 is the third quartile, and IQR is the quartile.

[0041] Preferably, all positional errors require the above outlier detection and removal steps.

[0042] For the position error count corresponding to the slot, as mentioned above, each slot has at least three position error parameters: center of gravity displacement distance error, center of gravity displacement direction error, and tool pointing angle error. If there are no outliers in the slot, all position error parameters for the slot will be used in the future. If the number of outliers removed from the slot is greater than 2, the data of the batch is considered suspicious and the attribution is stopped. If the number of outliers removed from the slot is ≤ 2, the subsequent steps will continue and the data will be marked for retesting.

[0043] Furthermore, for the positional error of the eliminated slots, the average value of the left and right adjacent slots is used to make up the difference.

[0044] If the total number of outliers exceeds 30% of the total data volume, the entire batch of data is considered suspicious. Attribution should be stopped, and S1 should be re-executed.

[0045] After removing outliers, attribution analysis was performed: Calculate the proportion of the main direction error of the center of gravity displacement direction for each slot. Specifically, divide the 360° circumference into several sectors, select the sector containing the most center of gravity displacement directions as the main direction interval, and calculate the proportion of the main direction error for all slots by dividing the number of slots whose center of gravity displacement direction falls within the main direction interval by the total number of slots.

[0046] This can be understood as follows: if most of the directions in which the cutter head deflects are in the same general direction, it indicates that there is a systematic torsion.

[0047] If the proportion of the main direction exceeds the preset ratio and the average center of gravity displacement distance error is greater than the preset threshold, it is determined that the overall torsional deformation is dominant, and the welding sequence is adjusted to alternate the slots with opposite center of gravity displacement directions.

[0048] This is because the welding process is performed sequentially. Assuming the current welding sequence is [1,2,3,4,5,6,7,8], welding is done in angular order. When welding slot 1, the metal expands locally due to heat, creating a localized heat-affected zone. When welding slot 2, the heat-affected zone of slot 2 overlaps with the residual heat-affected zone of slot 1. The later the slot is welded, the greater the cumulative heat impact from all the preceding slots. This results in an uneven distribution of the heat-affected zone in the circumferential direction. After cooling, uneven contraction occurs, forming a residual torque. This torque causes all the cutting tips to deflect in the same direction, causing overall torsional deformation.

[0049] Welding the positive and negative bias slots alternately allows the heat effects to cancel each other out, thus solving the overall torsion problem first.

[0050] If the main direction has a single proportion, that is, all positive or all negative, a new welding sequence with intervals and jumps is generated, and the slots are selected sequentially according to the interval of N / 2 rounded down. Otherwise, keep the original welding sequence unchanged.

[0051] This invention adjusts the welding sequence based on alternating positive and negative weld positions or intermittently skipping weld positions. This allows the thermal effects of positively and negatively biased weld positions to cancel each other out, or disperses the welding heat source in a circumferential direction, thereby reducing residual torque caused by heat accumulation at its source. Compared to existing technologies that only rely on indirect means such as reducing heat input or adjusting dwell time, the sequence optimization method of this invention is cost-free, risk-free, and directly effective.

[0052] Furthermore, if the proportion of the main direction exceeds the preset ratio and the average center of gravity displacement distance error is not greater than the preset threshold, it indicates that the directions are consistent but the magnitude is small, and the welding sequence is not adjusted. If the proportion of the main direction does not exceed the preset ratio, and the average center of gravity displacement distance error is greater than the preset threshold, it means that the quantity is extremely large but the direction is relatively random. This is not caused by the welding sequence, so the welding sequence should not be adjusted. If the proportion of the main direction does not exceed the preset ratio and the average center of gravity displacement distance error is not greater than the preset threshold, it means there is no problem and the welding sequence does not need to be adjusted.

[0053] Preferably, the preset ratio is recommended to be set to 60%~70%. The more cutters there are, the stronger the statistical significance, and the threshold can be appropriately reduced. The preset threshold for the average center of gravity displacement distance error is recommended to be set to 0.1 mm, or calculated according to the circular saw diameter D at a ratio of 0.001×D (e.g., the threshold is 0.15 mm when D=150 mm).

[0054] The preset attitude includes the preset translation amount and the preset pointing angle.

[0055] For each slot, if the center of gravity displacement distance error of the slot is greater than the preset threshold, the preset translation amount of the cutter head in the slot is adjusted. The adjustment amount of the preset translation amount is equal to the center of gravity displacement distance error, and the adjustment direction is opposite to the center of gravity displacement direction. If the center of gravity displacement distance error of the slot is not greater than the preset threshold, the preset translation amount of the slot will not be adjusted. If the error of the cutting head pointing angle of the slot is greater than the preset threshold, then adjust the preset pointing angle of the cutting head of the slot. The adjustment amount is equal to the error of the cutting head pointing angle. The adjustment direction is the opposite direction of the cutting head pointing angle. Before welding, rotate the cutting head in the opposite direction of the error by the same angle. If the error of the cutting head pointing angle of the slot is not greater than the preset threshold, the preset pointing angle of the slot will not be adjusted.

[0056] After adjustment, the adjustment amount must be reviewed: whether the adjustment amount obtained from the review is within the allowable range of the process. If so, output it; otherwise, limit the adjustment amount to the process boundary.

[0057] The two-layer optimization framework proposed in this application, which combines overall sequential optimization and individual pre-set compensation, is not only applicable to the welding of diamond circular saw blades, but can also be extended to other multi-station welding and assembly scenarios with circumferential symmetrical distribution characteristics, such as gear welding, impeller assembly, and ring structure welding.

[0058] The attribution analysis and adjustment decisions of this invention are completed automatically in a digital twin environment, ultimately outputting control commands to the production line in only two dimensions: welding sequence and preset posture. Operators do not need to understand the complex principles of welding thermodynamics, nor do they need to judge the source of error themselves. They only need to execute clamping and welding operations according to the instructions to obtain high-precision results, significantly reducing quality fluctuations caused by human factors.

[0059] S4. Repeat steps S2 to S3 until the error meets the preset convergence condition. Then, convert the welding sequence and preset posture into instructions and send them to the production line to perform diamond tool processing.

[0060] Furthermore, the welding sequence and preset posture adjustment amount determined in S3 are used as new process parameters, and the digital twin simulation in S2 is re-executed. After the simulation is completed, S3 is executed to obtain the position error of each tool head in the new round, and the error improvement rate of this iteration relative to the previous iteration is calculated.

[0061] Verify that the welding sequence and preset posture adjustment amount are correct until the absolute value of the position error of all slots is less than the threshold, or the error improvement rate calculated in two consecutive iterations is less than the improvement threshold.

[0062] Specifically, the error improvement rate = (total error of the previous round - total error of this round) / total error of the previous round × 100%, which measures how much the error has been reduced compared to the previous round after one round of adjustment.

[0063] The following examples illustrate the operational process during production: Scenario 1: Error meets target, convergence is normal.

[0064] Maximum center of gravity displacement distance = 0.04mm (< center of gravity displacement threshold 0.05mm), maximum pointing angle error = 0.15° (< pointing angle threshold 0.2°) Once convergence is determined, the current parameters are output, and the iteration ends.

[0065] Scenario 2: Error rate not met but improvement stalled.

[0066] In the nth round, the maximum center of gravity displacement distance is 0.08mm (still > 0.05mm). The improvement rate from round n-1 to round n was 2.5%; The improvement rate from round n to round n+1 is 3.0%. The improvement threshold is set at 5%. At this point, the output message reads: "Optimization limit has been reached. It is recommended to manually check the processing quality of the slots or the precision of the equipment." This invention sets two exit conditions: error convergence with all slot errors less than a threshold and improvement stagnation with two consecutive rounds of improvement rate falling below the improvement threshold. The former ensures that the machining accuracy meets the requirements, while the latter prevents infinite iteration due to insufficient error improvement, achieving a good balance between accuracy and efficiency.

[0067] After iterative convergence, the final determined welding sequence and the preset attitude parameters of each slot are converted into control commands that can be executed by the production line: Generate a list of slot welding sequence and preset posture instructions, including generating tool clamping parameters for each slot: preset translation amount and preset pointing angle.

[0068] The above instructions are sent to the production line control system, the welding sequence is sent to the welding torch motion controller, and the preset posture is sent to the tool clamping station. The production line then performs the actual welding process of the diamond tool according to the received instructions.

[0069] A diamond tool machining system for implementing a diamond tool machining method, comprising: The modeling module establishes a spatial coordinate system in the real space and a corresponding three-dimensional coordinate system in the digital twin. It obtains the coordinates of N sampling points on the metal body in the real space, calculates the center coordinates and radius of the circle using the least squares method, measures the feature points on both sides of each slot on the metal body in the real space, and then determines the actual center angle position of each slot. At the same time, it models the diamond cutting head. The simulation module acquires basic welding parameters and simulates the welding process between the metal body and the diamond cutting head through digital twin technology. The attribution analysis module obtains the positional error of each diamond cutting tip after simulated welding compared to the design drawing. The positional error includes at least the center of gravity displacement distance error, the center of gravity displacement direction error, and the cutting tip pointing angle error. Based on the positional error, an attribution analysis was performed, and the welding sequence and preset posture were adjusted according to the analysis results. The instruction sending module converts the welding sequence and preset posture into instructions and sends them to the production line to execute diamond tool processing when the error meets the preset convergence conditions.

[0070] A diamond tool machining apparatus includes a processor and a memory, wherein the processor executes a computer program stored in the memory to implement a diamond tool machining method.

Claims

1. A diamond tool machining method suitable for a diamond disc saw, characterized by, Includes the following steps: S1. Establish a spatial coordinate system in the real space and a corresponding three-dimensional coordinate system in the digital twin. Obtain the coordinates of N sampling points on the metal body in the real space. Calculate the center coordinates and radius using the least squares method. For each slot on the metal body in the real space, measure the feature points on its two side walls to determine the actual center angle position of each slot. At the same time, model the diamond cutting head. S2. Obtain basic welding parameters and simulate the welding process between the metal body and the diamond cutting head using digital twin technology; S3. Obtain the positional error of each diamond cutting tip after simulated welding compared to the design drawing. The positional error includes at least the center of gravity displacement distance error, the center of gravity displacement direction error, and the cutting tip pointing angle error. Based on the positional error, an attribution analysis was performed, and the welding sequence and preset posture were adjusted according to the analysis results. S4. Repeat steps S2 to S3 until the error meets the preset convergence condition. Then, convert the welding sequence and preset posture into instructions and send them to the production line to perform diamond tool processing.

2. The method of claim 1, wherein, In S3, based on the positional error, an attribution analysis is performed, and the welding sequence and preset posture are adjusted according to the analysis results. Specifically: Based on the current digital twin simulation results, the center of gravity displacement distance error and the pointing angle error of each diamond cutter head are obtained. Outliers are detected and eliminated. The proportion of the main direction of the center of gravity displacement direction error of each slot is calculated. If the proportion of the main direction exceeds the preset ratio and the average center of gravity displacement distance error is greater than the preset threshold, it is determined that the overall torsional deformation is dominant. The welding sequence is adjusted to alternate slots with opposite center of gravity displacement directions. The preset attitude includes a preset translation amount and a preset pointing angle. For each slot, if the center of gravity displacement distance error of the slot is greater than a preset threshold, the preset translation amount is adjusted by the absolute value of the center of gravity displacement distance error, and the adjustment direction is opposite to the center of gravity displacement direction. If the tool pointing angle error of the slot is greater than a preset threshold, the preset pointing angle is adjusted by the absolute value of the tool pointing angle error, and the adjustment direction is opposite to the tool pointing error direction.

3. The method of claim 2, wherein, The detection and removal of outliers are as follows: For any position error, sort all slots by position error from smallest to largest, calculate the first quartile and the third quartile, subtract the first quartile from the third quartile to obtain the interquartile range, calculate the reasonable range based on the interquartile range, and list the position error that exceeds this range as an outlier and remove it.

4. The method according to claim 1, characterized in that, S3 also includes adjustment amount verification: whether the welding parameter adjustment amount obtained from the verification is within the process allowable range. If so, it is output; otherwise, the adjustment amount is limited to the process boundary.

5. The method according to claim 1, characterized in that, In S1, a spatial coordinate system in real space and a corresponding three-dimensional coordinate system in the digital twin are established. Specifically, a cylindrical coordinate system is established with the intersection of the axis of the central hole of the metal body and the upper surface as the origin, the direction perpendicular to the upper surface upward as the positive Z-axis, and the direction of the reference feature on the metal body as the radial zero-degree reference line. At the same time, a Cartesian coordinate system is established in the digital twin, with its origin coinciding with the origin of the cylindrical coordinate system. The X-axis points to the radial zero-degree reference line, the Z-axis is perpendicular to the upper surface upward as positive, and the Y-axis is determined by the right-hand rule.

6. The method according to claim 1, characterized in that, In S2, the welding process between the metal body and the diamond cutting head is simulated using a digital twin, specifically as follows: The metal body and the cutting tool are locally refined into a hexahedral mesh, and a fixed constraint on the center hole and an ambient temperature boundary are set. A double ellipsoidal moving heat source model is used, and heat sources are applied sequentially according to the actual welding sequence. The temperature-related material properties of the diamond, the metal body, and the brazing filler metal are defined. The transient heat conduction equation is solved first to obtain the temperature field, and then the temperature load is applied to the thermo-elastic-plastic mechanical model to solve for the displacement field and stress field. After cooling to room temperature, the final offset of the cutting tool is extracted as the position error output.

7. The method according to claim 1, characterized in that, The specific convergence conditions preset in S4 are: the absolute value of the position error of all slots is less than the threshold, or the error improvement rate calculated in two consecutive iterations is less than the improvement threshold.

8. The method according to claim 7, characterized in that, Error improvement rate = (total error of the previous round - total error of this round) / total error of the previous round × 100%.

9. A diamond tool machining system for implementing the diamond tool machining method according to any one of claims 1-8, characterized in that, include: The modeling module establishes a spatial coordinate system in the real space and a corresponding three-dimensional coordinate system in the digital twin. It obtains the coordinates of N sampling points on the metal body in the real space, calculates the center coordinates and radius of the circle using the least squares method, measures the feature points on both sides of each slot on the metal body in the real space, and then determines the actual center angle position of each slot. At the same time, it models the diamond cutting head. The simulation module acquires basic welding parameters and simulates the welding process between the metal body and the diamond cutting head through digital twin technology. The attribution analysis module obtains the positional error of each diamond cutting tip after simulated welding compared to the design drawing. The positional error includes at least the center of gravity displacement distance error, the center of gravity displacement direction error, and the cutting tip pointing angle error. Based on the positional error, an attribution analysis was performed, and the welding sequence and preset posture were adjusted according to the analysis results. The instruction sending module converts the welding sequence and preset posture into instructions and sends them to the production line to execute diamond tool processing when the error meets the preset convergence conditions.

10. A diamond tool processing equipment, characterized in that, It includes a processor and a memory, wherein the processor executes a computer program stored in the memory to implement a diamond tool machining method as described in any one of claims 1-8.

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