Methods and equipment for rough milling of aluminum alloy workpieces

Abstract

This application relates to the field of CNC milling technology, and particularly to a method and equipment for rough milling of aluminum alloy workpieces. The method includes: acquiring the structural feature data of the keyway corresponding to the aluminum alloy keyway to be machined; determining the theoretical milling deformation of each local area based on the single-sided wall thickness, groove depth, and groove width of each local area; adaptively compensating the preset basic machining allowance based on the theoretical milling deformation of each local area to obtain the dynamic finishing allowance for each local area; generating a rough milling toolpath for the keyway based on the dynamic finishing allowance for each local area; and completing the rough milling of the keyway according to the rough milling toolpath. This method can solve the problems of rough milling processes being unable to adapt to the differentiated deformation characteristics of the groove structure, easily leading to local overcutting, undercutting, and uneven allowance distribution.

Description

Technical Field

[0001] This application belongs to the field of CNC milling technology, and particularly relates to a method and equipment for rough milling of aluminum alloy workpieces. Background Technology

[0002] Aluminum alloys, with their lightweight, high strength, and excellent machinability, are widely used in the keyway structure machining of various precision hardware and structural parts. As the core mating structure of a workpiece, the flatness of the keyway wall, the accuracy of the keyway depth, and the consistency of the contour directly determine the subsequent assembly accuracy and operational stability of the workpiece. The rough milling process, as a core pre-process for keyway forming, plays a crucial role in quickly removing redundant material, reserving finishing allowance, and ensuring the basic contour of the keyway.

[0003] Aluminum alloys are relatively soft and are highly susceptible to elastic and plastic deformation during milling due to cutting forces and structural stresses. This is especially true for keyways, which are irregularly shaped grooves where the wall thickness, groove depth, and groove width vary significantly across different areas of the workpiece, resulting in completely different stress states and deformation degrees in each area. If the rough milling process cannot accommodate these varying deformation characteristics, problems such as localized overcutting, undercutting, and uneven allowance distribution can easily occur. This not only significantly increases the difficulty of subsequent finishing processes but also leads to quality defects such as keyway contour deviations, depth errors, and substandard groove wall flatness, potentially causing the entire workpiece to be scrapped. Summary of the Invention

[0004] This application provides a method and equipment for rough milling aluminum alloy workpieces, which can solve the problem that the rough milling process cannot adapt to the differentiated deformation characteristics of the groove structure, and is prone to problems such as local overcutting, undercutting, and uneven distribution of allowance. This not only greatly increases the processing difficulty of subsequent finishing, but also leads to quality defects such as key groove contour deviation, depth deviation, and substandard groove wall flatness after forming, which can directly cause the workpiece to be scrapped in severe cases.

[0005] In a first aspect, embodiments of this application provide a method for rough milling aluminum alloy workpieces, including: Obtain the groove structure feature data corresponding to the key groove of the aluminum alloy to be processed; wherein, the groove structure feature data includes the single-side wall thickness, groove depth and groove width corresponding to each local area of ​​the key groove; The theoretical milling deformation corresponding to each local area is determined based on the single-side wall thickness, groove depth, and groove width of each local area of ​​the key groove. Based on the theoretical milling deformation corresponding to each local region, the preset basic machining allowance is adaptively compensated to obtain the dynamic finishing allowance corresponding to each local region. Based on the dynamic finishing allowance corresponding to each local area, a rough milling toolpath for the keyway is generated, and the rough milling of the keyway is completed according to the rough milling toolpath.

[0006] The technical solutions described in this application embodiment have at least the following technical effects: The rough milling method for aluminum alloy workpieces provided in this application involves obtaining the structural feature data of the keyway corresponding to the aluminum alloy keyway to be machined. The structural feature data includes the single-sided wall thickness, groove depth, and groove width of each local area of ​​the keyway. The theoretical milling deformation of each local area is determined based on the single-sided wall thickness, groove depth, and groove width. Based on the theoretical milling deformation of each local area, an adaptive compensation process is performed on the preset basic machining allowance to obtain the dynamic finishing allowance for each local area. Based on the dynamic finishing allowance for each local area, a rough milling toolpath for the keyway is generated, and the rough milling of the keyway is completed according to the toolpath. This application obtains the structural feature data of the aluminum alloy keyway, accurately determines the theoretical milling deformation of each local area based on the single-sided wall thickness, groove depth, and groove width, adaptively compensates the basic machining allowance based on the theoretical milling deformation, obtains the differentiated dynamic finishing allowance for each area, and generates a rough milling toolpath adapted to the groove structure based on the dynamic finishing allowance to complete the rough milling of the keyway. The above method can solve the problem that the rough milling process cannot adapt to the differentiated deformation characteristics of the groove structure. The irregular partitioned coupling deformation of the key groove is superimposed and canceled out. The total macroscopic milling deformation value is large, but the effective net deformation difference that can be used for allowance compensation is extremely small. Conventional simple allowance compensation and single-dimensional wall thickness calculation methods cannot distinguish between interference deformation and effective deformation. Directly applying fixed allowance and simple partition allowance cannot match the differential law of coupled deformation, and problems such as local overcutting, undercutting, and uneven allowance distribution are likely to occur. This will not only greatly increase the processing difficulty of subsequent finishing, but also lead to quality defects such as key groove contour deviation, depth deviation, and substandard groove wall flatness after forming. In severe cases, it will directly cause the workpiece to be scrapped.

[0007] Secondly, embodiments of this application provide an aluminum alloy workpiece rough milling apparatus, applied to a rough milling machine, for implementing the aluminum alloy workpiece rough milling method described in any one of the first aspects above. The aluminum alloy workpiece rough milling apparatus includes: The acquisition unit is used to acquire the groove structure feature data corresponding to the key groove of the aluminum alloy to be processed; wherein, the groove structure feature data includes the single-side wall thickness, groove depth and groove width corresponding to each local area of ​​the key groove; The deformation unit is used to determine the theoretical milling deformation of each local area based on the single-side wall thickness, groove depth and groove width of each local area of ​​the keyway. The allowance unit is used to adaptively compensate the preset basic machining allowance according to the theoretical milling deformation corresponding to each local area, so as to obtain the dynamic finishing allowance corresponding to each local area. The machining unit is used to generate a rough milling toolpath for the keyway based on the dynamic finishing allowance corresponding to each local area, and to complete the rough milling of the keyway according to the rough milling toolpath.

[0008] Thirdly, embodiments of this application provide a rough milling apparatus, including a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor executes the computer program to implement the method as described in any of the first aspects above.

[0009] Fourthly, embodiments of this application provide a computer program product that, when run on a rough milling machine, causes the rough milling machine to perform the method described in any one of the first aspects above.

[0010] It is understood that the beneficial effects of the second to fourth aspects mentioned above can be found in the relevant descriptions in the first aspect mentioned above, and will not be repeated here. Attached Figure Description

[0011] To more clearly illustrate the technical solutions in the embodiments of this application, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0012] Figure 1 This is a schematic flowchart of a rough milling method for aluminum alloy workpieces provided in an embodiment of this application; Figure 2 This is a schematic diagram of the operation of a rough milling method for aluminum alloy workpieces provided in an embodiment of this application; Figure 3 This is a schematic diagram of the structure of the rough milling device for aluminum alloy workpieces provided in the embodiments of this application; Figure 4 This is a schematic diagram of the rough milling equipment provided in the embodiments of this application. Detailed Implementation

[0013] In the following description, specific details such as particular system architectures and techniques are set forth for illustrative purposes and not for limitation, in order to provide a thorough understanding of the embodiments of this application. However, those skilled in the art will understand that this application may also be implemented in other embodiments without these specific details. In other instances, detailed descriptions of well-known systems, apparatuses, circuits, and methods have been omitted so as not to obscure the description of this application with unnecessary detail.

[0014] In related technologies, aluminum alloys are relatively soft and are easily subjected to cutting forces and structural stresses during milling, resulting in elastic and plastic deformation. This is especially true for keyways, which are irregularly shaped grooves. Significant differences in wall thickness, groove depth, and groove width exist in different areas of the workpiece, leading to completely different stress states and deformation degrees in each area. If the rough milling process cannot adapt to the differentiated deformation characteristics of the groove structure, problems such as local overcutting, undercutting, and uneven allowance distribution can easily occur. This not only greatly increases the difficulty of subsequent finishing processes but also leads to quality defects such as keyway contour deviation, depth deviation, and substandard groove wall flatness after forming, and in severe cases, directly causing the workpiece to be scrapped.

[0015] To address the aforementioned problems, embodiments of this application provide a method for rough milling aluminum alloy workpieces. This method includes: acquiring the structural feature data of the keyway corresponding to the aluminum alloy keyway to be machined; wherein the structural feature data includes the single-side wall thickness, groove depth, and groove width corresponding to each local region of the keyway; determining the theoretical milling deformation corresponding to each local region based on the single-side wall thickness, groove depth, and groove width; adaptively compensating the preset basic machining allowance based on the theoretical milling deformation corresponding to each local region to obtain the dynamic finishing allowance corresponding to each local region; generating a rough milling toolpath for the keyway based on the dynamic finishing allowance corresponding to each local region, and completing the rough milling of the keyway according to the rough milling toolpath. This application obtains the structural feature data of the aluminum alloy keyway, accurately determines the theoretical milling deformation of each local area based on the single-sided wall thickness, groove depth, and groove width, and adaptively compensates the basic machining allowance based on the theoretical milling deformation to obtain the differentiated dynamic finishing allowance for each area. Then, based on the dynamic finishing allowance, a rough milling toolpath adapted to the groove structure is generated to complete the rough milling of the keyway. This method solves the problem that the rough milling process cannot adapt to the differentiated deformation characteristics of the groove structure, easily leading to problems such as local overcutting, undercutting, and uneven allowance distribution. This not only significantly increases the difficulty of subsequent finishing machining but also causes quality defects such as keyway contour deviation, depth deviation, and substandard groove wall flatness after forming, which in severe cases directly cause the workpiece to be scrapped.

[0016] The rough milling method for aluminum alloy workpieces provided in this application embodiment can be applied to a rough milling equipment. In this case, the rough milling equipment is the main body for executing the rough milling method for aluminum alloy workpieces provided in this application embodiment. This application embodiment does not impose any restrictions on the specific type of rough milling equipment.

[0017] For example, rough milling equipment can be a vertical CNC milling machine, a machining center, a key milling CNC machine tool, etc. Rough milling equipment includes a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor executes the computer program to implement any of the methods described above.

[0018] To better understand the rough milling method for aluminum alloy workpieces provided in the embodiments of this application, the specific implementation process of the rough milling method for aluminum alloy workpieces provided in the embodiments of this application will be described by way of example below.

[0019] Figure 1 A flowchart illustrating the rough milling method for aluminum alloy workpieces provided in an embodiment of this application is shown. Figure 2 This illustration shows an operational schematic of the rough milling method for aluminum alloy workpieces provided in an embodiment of this application. The rough milling method for aluminum alloy workpieces includes: S100: Obtain the structural feature data of the keyway corresponding to the aluminum alloy keyway to be processed. This structural feature data includes the single-side wall thickness, depth, and width of each local area of ​​the keyway.

[0020] It can be understood that the aluminum alloy key slot to be processed refers to the tooth-shaped transmission slot opened on the one-piece 6061-T6 aluminum alloy key blank for folding key blanks of civilian passenger vehicles, which is a common standard key base material in the industry. Single-sided wall thickness: The vertical solid wall thickness from the inner sidewall of the slot to the outer contour edge of the key blank after the key slot is slotted. Slot depth: The vertical cutting depth from the opening end face of the key slot to the lowest point of the slot bottom. Slot width: The straight-line distance between the inner edges of the two sides of the slot wall under the same horizontal section. The acquisition method is: relying on a fixed 3D laser contour scanner in the workshop, the pre-made slotted cavity of the key slot is scanned in its entirety using a fixed scanning step size. For example, the key slot is divided into 5 local areas according to the number of slots, labeled as Area 1, Area 2, Area 3, Area 4, and Area 5, with unified measured feature data: Area 1: Single-sided wall thickness 1.12mm, slot depth 2.00mm, slot width 2.15mm. Area 2: Single-sided wall thickness 0.98mm, slot depth 2.30mm, slot width 2.40mm. Area 3: Single-sided wall thickness 0.85mm, groove depth 2.60mm, groove width 2.65mm. Area 4: Single-sided wall thickness 0.96mm, groove depth 2.25mm, groove width 2.38mm. Area 5: Single-sided wall thickness 1.10mm, groove depth 2.05mm, groove width 2.18mm. The above data are standard measured data from a large batch of 6061 aluminum alloy key slots and can be directly reused from scanning data.

[0021] S200, the theoretical milling deformation of each local area is determined based on the single-side wall thickness, groove depth and groove width of each local area of ​​the keyway.

[0022] It can be understood that the theoretical milling deformation represents the total positive displacement of the groove wall and bottom of a 6061-T6 aluminum alloy keyway under a fixed rough milling process, caused by the combined effects of cutting pressure, tool friction, and structural stress. The deformation direction is towards the inside of the keyway cavity. The determination logic is: based on the coupling relationship between structural wall thickness and cutting dimensions, the smaller the wall thickness, the greater the groove depth, and the greater the groove width, the greater the milling pressure, and the greater the theoretical milling deformation value. Preliminary determination of the deformation pattern: Region 3 has the smallest wall thickness and the largest groove size, resulting in the largest theoretical deformation; Regions 1 and 5 have relatively large wall thicknesses, resulting in the smallest theoretical deformation.

[0023] As an optional embodiment of this application, S200, the theoretical milling deformation corresponding to each local area is determined based on the single-side wall thickness, groove depth, and groove width corresponding to each local area of ​​the keyway, including: S210, Obtain the pre-constructed milling deformation fitting model of the aluminum alloy keyway. The milling deformation fitting model uses the single-sided wall thickness, groove depth, and groove width as input feature parameters, and the milling elastic deformation and plastic deformation as output parameters.

[0024] It can be understood that milling elastic deformation is the displacement value of the aluminum alloy groove that undergoes reversible springback deformation under milling load, and the deformation is completely restored after the cutting load is removed. Milling plastic deformation is the displacement value of the groove that undergoes irreversible permanent deformation after the milling load exceeds the yield strength of the aluminum alloy, and the deformation cannot be repaired by springback after the cutting load is removed. The milling deformation fitting model of the aluminum alloy keyway includes the elastic deformation fitting sub-model formula: And the formula for the plastic deformation fitting sub-model: ,in, For elastic deformation, The values ​​represent plastic deformation, where x is the thickness of the wall on one side, y is the groove depth, and z is the groove width. , , The specific regression coefficient for the elastic deformation of 6061-T6 aluminum alloy; , , These are the regression coefficients specific to the plastic deformation of 6061-T6 aluminum alloy. In one specific embodiment, the regression coefficients of the elastic deformation fitting sub-model can be: The regression coefficients of the plastic deformation fitting sub-model can be: The regression coefficients mentioned above are based on 200 sets of 6061-T6 aluminum alloy cutting simulation data and were obtained by fitting using a multivariate nonlinear regression algorithm. Example: The milling deformation fitting model is fixedly adapted to the 6061 key blank substrate. Only the three-dimensional dimensions of the single-side wall thickness, groove depth, and groove width are input, and the elastic and plastic deformation values ​​of each zone can be output separately.

[0025] S220, input the single-side wall thickness, groove depth, and groove width parameters corresponding to each local area of ​​the key groove into the milling deformation fitting model.

[0026] It is understandable that the input method involves one-click batch import of partition feature data through the MES port of the CNC system, matching input parameters in the order of region 1 to region 5, and uniformly retaining two decimal places for the parameter format to avoid model calculation errors caused by inconsistent parameter digits. Example: Batch import input parameters: region 3, which are individually and directed to a single calculation port of the model to achieve independent calculation of each partition and avoid global parameter coupling interference.

[0027] S230, through fitting and calculation using a milling deformation fitting model, obtains the elastic and plastic deformation variables corresponding to each local region.

[0028] It is understandable that the deformation values ​​for each zone are calculated independently: the deformation values ​​are calculated exclusively for the dimensional parameters of a single zone, unaffected by the stress coupling interference of the structural dimensions of adjacent zones. The fitting calculation logic: the model has a built-in stress finite element subroutine that, combined with the Poisson's ratio and elastic modulus parameters of the aluminum alloy, calculates the cutting extrusion springback and permanent extrusion deformation step by step. Following the unified working condition example above, the model's initial fitting output is as follows: Zone 1: Elastic deformation 12.6μm, Plastic deformation 3.2μm. Zone 2: Elastic deformation 16.8μm, Plastic deformation 4.5μm. Zone 3: Elastic deformation 22.4μm, Plastic deformation 6.8μm. Zone 4: Elastic deformation 16.2μm, Plastic deformation 4.2μm. Zone 5: Elastic deformation 13.0μm, Plastic deformation 3.3μm.

[0029] In one possible implementation, S230, the elastic and plastic deformation variables corresponding to each local region are obtained by fitting and calculating using a milling deformation fitting model, including: S231, obtain the aluminum alloy material properties parameters and rough milling cutting process parameters.

[0030] It is understood that the aluminum alloy material properties include the fixed physical properties for room temperature machining of 6061-T6, including elastic modulus, Poisson's ratio, yield strength, Brinell hardness, and thermal conductivity. The rough milling cutting process parameters include the standardized rough milling process parameters for carbide end mills used in the workshop, including tool diameter, spindle speed, feed rate, depth of cut, dry air cooling, and tool edge radius. The parameters are obtained by locally retrieving preset process library parameters from the CNC machine tool's PLC, eliminating the need for manual input. These parameters are compatible with all keyway batches of workpieces in this batch.

[0031] S232, the aluminum alloy material properties and rough milling cutting process parameters are simultaneously imported into the milling deformation fitting model as correction constraints for the milling deformation fitting model.

[0032] It is understandable that correction constraints are boundary limiting parameters used to offset the difference between the ideal simulation conditions of the standard fitting model and the actual machining conditions in the workshop, correcting for deformation calculation errors caused by tool wear, material grain differences, and air cooling. The import method allows for simultaneous binding of input parameters through dual channels. Dimensional parameters are the main variables for calculation, while material and process parameters are the boundary constraint variables, locking the model's calculation boundaries. Example: Without constraints, the calculated plastic deformation value for region 3 is 7.5 μm. After importing this batch of 6061 material and adding the 4800 r / min milling constraint parameter, the correction calibration is set to a standard 6.8 μm, closely matching the actual measured deformation on-site.

[0033] S233, based on the parameters of the single-sided wall thickness, groove depth, and groove width of each local region, combined with the modified constraint conditions, outputs the independent elastic deformation and plastic deformation values ​​of each local region.

[0034] This step is understandable as part of the model closed-loop calibration output process. Output rules: independent calculation and output for each region, with values ​​retained to one decimal place to adapt to the CNC system's margin retrieval accuracy. The final calibration output shows the following region deformation data: Region 1: Elastic 12.6μm, Plastic 3.2μm; Region 2: Elastic 16.8μm, Plastic 4.5μm; Region 3: Elastic 22.4μm, Plastic 6.8μm; Region 4: Elastic 16.2μm, Plastic 4.2μm; Region 5: Elastic 13.0μm, Plastic 3.3μm. All values ​​are the effective deformation values ​​after calibration for this batch of workpieces.

[0035] By adopting the above steps S231 to S233, it is helpful to bind the actual material and milling process boundary conditions in the workshop, eliminate the deformation calculation deviation between the ideal working conditions of the simulation model and the actual working conditions of machining, avoid ignoring tool parameters and material hardness fluctuations that cause deformation calculation to be too large or too small, improve the measured matching degree of single-area elastic and plastic deformation values, and ensure the accuracy of subsequent allowance compensation.

[0036] S240, the elastic and plastic deformation variables of each local region are weighted and summed to obtain the theoretical milling deformation variables of the corresponding local region.

[0037] The weighted summation algorithm is understood to be a differentiated summation algorithm adapted to the deformation characteristics of aluminum alloy milling. It considers the process characteristics of elastic deformation being springback and only plastic deformation requiring allowance compensation, and uses fixed weighting coefficients: 0.2 for elastic deformation and 1.0 for plastic deformation. The calculation formula is: Theoretical milling deformation = Elastic deformation × 0.2 + Plastic deformation × 1.0. Calculation examples: Theoretical milling deformation in Region 3 = 22.4 × 0.2 + 6.8 × 1.0 = 11.28 μm. Theoretical milling deformation in Region 1 = 12.6 × 0.2 + 3.2 × 1.0 = 5.72 μm. Calculation results for other regions: Region 2 = 7.86 μm, Region 4 = 7.44 μm, Region 5 = 5.80 μm.

[0038] By adopting the above steps S210 to S240, it is helpful to rely on the machine learning fitting model to separate reversible and irreversible deformations, differentiate and weighted calculate the total theoretical deformation, abandon the traditional coarse calculation method of uniform global deformation value, adapt to the deformation difference characteristics of different wall thickness areas of the keyway, accurately quantify the total amount of milling deformation that needs to be compensated in each area, provide quantitative data support for zoned adaptive allowance compensation, and reduce the milling edge collapse and dimensional deviation defect rate of thin-walled slots.

[0039] S300, based on the theoretical milling deformation corresponding to each local area, performs adaptive compensation processing on the preset basic machining allowance to obtain the dynamic finishing allowance corresponding to each local area.

[0040] It is understandable that the preset basic machining allowance represents the industry-standard rough milling allowance for finishing of 6061 aluminum alloy key slots, which is the preset value of the machine tool's factory process. Adaptive compensation processing: Based on the magnitude of deformation in each zone, the compensation amount is differentially superimposed, with less compensation for thick-walled areas with small deformation and more compensation for thin-walled areas with large deformation. Dynamic finishing allowance represents the differentiated finishing cutting allowance reserved in each zone after rough milling and adapted to offset deformation. Compensation logic: The greater the deformation, the more compensation is superimposed to offset the inward deformation during milling, ensuring that the groove dimensions meet the standards after finishing.

[0041] As an optional embodiment of this application, in step S300, based on the theoretical milling deformation corresponding to each local region, an adaptive compensation process is performed on the preset basic machining allowance to obtain the dynamic finishing allowance corresponding to each local region, including: S310, superimpose the theoretical milling deformation corresponding to each local area onto the preset basic machining allowance to obtain the initial compensation allowance corresponding to each local area.

[0042] It can be understood that the initial compensation allowance represents the initial superposition allowance without coefficient correction or interval limitation. It only completes the basic calculation of the basic allowance plus the deformation compensation amount, without considering the stress coupling compensation loss of the trench wall. The basic logic for superposition of the initial compensation allowance is: Initial compensation allowance = Basic machining allowance + Regional deformation compensation amount. Example: Under the premise of direct superposition, the initial compensation allowance of region 3 = 80μm + 11.28μm = 91.28μm.

[0043] In one possible implementation, S310, the theoretical milling deformation corresponding to each local region is superimposed onto a preset basic machining allowance to obtain the initial compensation allowance corresponding to each local region, including: S311, based on the theoretical milling deformation of different local areas of the keyway, match the corresponding deformation compensation correction coefficient.

[0044] It can be understood that the deformation compensation correction coefficient represents the loss correction parameter adapted to the bidirectional stress of the groove wall and the lateral cutting thrust of the tool. It is calibrated by historical machining big data in the workshop, and the coefficient value ranges from 0.85 to 1.10. Matching rules: If the absolute value of the theoretical deformation is ≤6μm, the correction coefficient is 0.90. If the absolute value of the theoretical deformation is ≤9μm, the correction coefficient is 1.00. If the absolute value of the theoretical deformation is >9μm, the correction coefficient is 1.08. Continuing from the previous section on the matching coefficients of theoretical deformation values ​​by region: Region 1 (5.72μm) coefficient 0.90, Region 2 (7.86μm) coefficient 1.00, Region 3 (11.28μm) coefficient 1.08, Region 4 (7.44μm) coefficient 1.00, Region 5 (5.80μm) coefficient 0.90.

[0045] S312, multiply the theoretical milling deformation of each local area with the corresponding deformation compensation correction coefficient to obtain the precise compensation amount of each area.

[0046] It can be understood that the precise compensation amount is the actual effective deformation compensation value that needs to be superimposed after deducting the lateral thrust of the tool and the stress offset loss of adjacent groove walls. The calculation formula is: Precise compensation amount = Theoretical milling deformation × Deformation compensation correction coefficient. Example calculations with unified parameters: Region 1: 5.72 × 0.90 = 5.15 μm. Region 2: 7.86 × 1.00 = 7.86 μm. Region 3: 11.28 × 1.08 = 12.18 μm. Region 4: 7.44 × 1.00 = 7.44 μm. Region 5: 5.80 × 0.90 = 5.22 μm.

[0047] S313, the precise compensation amount is superimposed with the preset basic processing allowance to obtain the initial compensation allowance with structurally differentiated compensation attributes for each local area.

[0048] As can be understood, the initial compensation allowance represents a non-uniform initial allowance for different zones based on wall thickness and deformation, unlike the traditional uniform allowance machining mode for the entire keyway. The calculation formula is: Initial Compensation Allowance = Basic Machining Allowance + Precision Compensation Amount. Example zone results: Zone 1: 85.15μm. Zone 2: 87.86μm. Zone 3: 92.18μm. Zone 4: 87.44μm. Zone 5: 85.22μm.

[0049] By adopting the above steps S311 to S313, it is helpful to avoid the problems of excessive or insufficient compensation caused by directly superimposing theoretical deformation. By using graded correction coefficients to offset the compensation loss caused by sidewall stress coupling and tool side pressure, the compensation amount can be made to match the actual deformation compensation requirements of aluminum alloy thin-walled grooves. This achieves the increase of compensation amount in thin-walled large deformation areas and the appropriate reduction of compensation amount in thick-walled small deformation areas, thus completing the structural differentiation of the allowance.

[0050] S320 performs interval limiting constraint processing on the initial compensation margin corresponding to each local area, eliminates abnormal margin values ​​that exceed the preset margin range, and obtains dynamic finishing margin.

[0051] It is understood that the preset allowance range represents the safe finishing allowance range for milling 6061 aluminum with this carbide end mill, an industry process threshold, including a minimum allowance threshold and a maximum allowance threshold. Allowance limiting constraints: prevent excessive allowance after compensation from causing tool breakage and groove wall chipping during finishing, and prevent insufficient allowance from causing deformation to be uncompensated and dimensional rework exceeding tolerances. Judgment logic: After the allowance in each zone is benchmarked against the upper and lower thresholds, the final machining allowance is locked. In a specific embodiment, the minimum allowance threshold of 65μm and the maximum allowance threshold of 95μm are determined as follows: A 2.0mm diameter carbide end mill is used to perform a cutting test on a 6061-T6 aluminum alloy specimen. The cutting parameters are a spindle speed of 4800r / min, a feed rate of 120mm / min, and a depth of cut of 0.15mm. Experimental results show that when the finishing allowance is less than 65 μm, chatter occurs during milling, and the surface roughness Ra of the groove exceeds 1.6 μm; when the finishing allowance is greater than 95 μm, the cutting load exceeds the tool's limit, resulting in chipping of the groove wall. Therefore, the safe range for the finishing allowance is determined to be 65 μm to 95 μm.

[0052] In one possible implementation, S320, the initial compensation margin corresponding to each local region is subjected to interval limiting constraint processing to eliminate abnormal margin values ​​that exceed the preset margin interval, thereby obtaining the dynamic finishing margin, including: S321, if the initial compensation allowance is less than the minimum allowance threshold, then the minimum allowance threshold is determined as the dynamic finishing allowance of the corresponding local area.

[0053] It is understandable that the minimum allowance threshold is the minimum force allowance for tool finishing. Below the minimum allowance threshold, milling chatter and tool marks on the groove surface will occur. Example: If the initial compensation allowance for a certain corner area is 62μm, which is lower than the lower limit of 65μm, then a dynamic finishing allowance of 65μm will be forcibly assigned to ensure the stability of finishing cutting.

[0054] S322, if the initial compensation allowance is greater than the maximum allowance threshold, then the maximum allowance threshold is determined as the dynamic finishing allowance of the corresponding local area.

[0055] It is understandable that the maximum allowance threshold is the limit of the cutting allowance for a single finishing operation by the milling cutter. Exceeding the maximum allowance threshold will result in cutting load overload and plastic chipping of the groove wall. Example: If the initial compensation allowance for an extremely thin-walled region is 98μm, which is higher than the upper limit of 95μm, then a dynamic finishing allowance of 95μm will be forcibly assigned to avoid tool overload machining defects.

[0056] S323, if the initial compensation allowance is within the preset allowance range, the initial compensation allowance is directly determined as the dynamic finishing allowance of the corresponding local area.

[0057] This step is understandable; it follows the normal allowance reuse logic, ensuring optimal force balance and deformation mitigation within the allowance range. Continuing from the initial allowances of all zones mentioned earlier, all falling within the 65-95μm range, these are directly reused as the final dynamic finishing allowances: Zone 1: 85.15μm; Zone 2: 87.86μm; Zone 3: 92.18μm; Zone 4: 87.44μm; Zone 5: 85.22μm.

[0058] By adopting the above steps S321 to S323, it is helpful to build a dual protection mechanism for the upper and lower limits of the allowance, eliminate the processing risks caused by excessive or insufficient deformation compensation in extreme structural areas, uniformly lock the safe processing range of the finishing allowance, take into account both the deformation compensation effect and the stability of the milling process, unify the allowance control standard for all workpieces in this batch, and facilitate the unified control of the subsequent machine tool toolpath.

[0059] By adopting the above steps S310 to S320, it is helpful to complete the full-process adaptive conversion from theoretical deformation to safe and usable machining allowance. Combined with stress coefficient correction and range limiting dual optimization, it not only ensures accurate compensation of deformation allowance, but also adapts to the cutting load limit of the tool, and optimizes the industry pain points of insufficient deformation compensation in thin-walled areas, waste of allowance in thick-walled areas, and poor consistency of finishing dimensions.

[0060] S400 generates a rough milling toolpath for the keyway based on the dynamic finishing allowance corresponding to each local area, and completes the rough milling of the keyway according to the rough milling toolpath.

[0061] It is understandable that the rough milling toolpath represents the layered cutting trajectory of G-codes recognizable by the CNC machine tool. In this case, a climb milling layered cutting toolpath is used, with the feed rate matched to the feed parameters. The differentiated toolpath represents a non-equidistant toolpath where the groove wall offset and groove bottom cutting depth change synchronously with the dynamic allowance of the partition. The machining logic is to rough mill the reserved dynamic allowance of the partition, and then finish mill the reserved allowance by equal cutting to offset the deformation of the previous milling.

[0062] As an optional embodiment of this application, in step S400, based on the dynamic finishing allowance corresponding to each local area, a rough milling toolpath for the keyway is generated, and the rough milling of the keyway is completed according to the rough milling toolpath, including: S410, establish the mapping relationship between the spatial coordinates of each local area of ​​the key slot and the corresponding dynamic finishing allowance. The local areas of the key slot include the first key slot area and the second key slot area.

[0063] The spatial coordinates are as follows: A three-dimensional workpiece coordinate system is established with the lower left corner of the key blank as the workpiece origin, encompassing the X-axis (length), Y-axis (width), and Z-axis (depth), with an accuracy of 0.01mm. The first region of the key slot is the sidewall region of the key slot, i.e., the annular wall region around the opening of the key slot; the second region of the key slot is the bottom region of the key slot, i.e., the bottom sealing surface region of the key slot. The first and second regions of the key slot are perpendicular. Mapping method: The CNC system coordinate system binds each set of XYZ coordinate points to a corresponding dynamic allowance value, one coordinate per allowance. Example: X10mm binds an allowance of 92.18μm, X5mm binds an allowance of 85.15μm.

[0064] S420, for the first area of ​​the keyway, sets the normal profile offset according to the corresponding dynamic finishing allowance.

[0065] As can be understood, normal profile offset involves shifting outwards along the direction perpendicular to the normal of the groove wall profile, corresponding to the dynamic allowance value. This enlarges the rough milling groove wall profile dimensions and allows for finishing machining allowances. The offset rule is: the larger the allowance, the greater the outward normal offset distance. Example: The normal offset of the groove wall on the front side of region 3 is 92.18 μm, and the normal offset of the groove wall on the front side of region 1 is 85.15 μm, to accommodate the sidewall deformation retraction.

[0066] S430, for the second area of ​​the keyway, the axial depth is reserved according to the corresponding dynamic finishing allowance.

[0067] It can be understood that axial depth reservation means raising the height of the rough milling groove bottom along the Z-axis milling depth direction to reserve the finishing cutting depth in the Z-axis. The reservation rule is: the greater the deformation of the groove bottom, the greater the Z-axis raised reserved depth. Example: In region 3, the Z-axis bottom of the groove is raised by 92.18 μm, reducing the rough milling depth and reserving the finishing cutting allowance.

[0068] S440 generates a rough milling toolpath with globally differentiated allowance based on the normal profile offset setting and axial depth reservation setting, and completes the keyway rough milling according to the rough milling toolpath.

[0069] This is understandable. A fully differentiated toolpath is an integrated continuous cutting toolpath that distinguishes between positive and negative offset logic and adapts to gradual changes in allowance across five zones, with no toolpath inflection points or abrupt breakpoints in allowance. Generation method: The allowance coordinate mapping table is imported into the UG-NX milling module, which automatically compiles adaptive cutting G-code and directly sends it to the machining center for execution.

[0070] By adopting the above steps S410 to S440, it is helpful to distinguish the allowance control logic of the working surface and non-working surface of the keyway, control the contour dimension from the front and control the depth dimension from the back, and specifically adapt to the two types of deformation characteristics of sidewall deformation and groove bottom deformation, so that the toolpath allowance completely matches the deformation distribution law, and reduce the finished product size deviation caused by milling deformation from the source of the cutting trajectory.

[0071] In one possible implementation, S440 generates a rough milling toolpath with globally differentiated allowance based on the normal profile offset setting and the axial depth reservation setting, and completes the keyway rough milling based on the rough milling toolpath, including: S441, perform continuous gradient normal offset processing on the normal profile offset setting to obtain the groove wall profile curve.

[0072] This can be understood as a continuous, gradual offset: the offsets of adjacent zones are smoothly interpolated to prevent abrupt changes in offset at zone boundaries and avoid stepped tank walls. Processing method: The system fits the offset trajectory using interpolation in 0.1mm steps. Example: A smooth transition occurs from an offset of 85.15μm in region 1 to an offset of 92.18μm in region 3, with no abrupt changes in the tank wall profile and a smooth, continuous surface.

[0073] S442, perform smooth transition interpolation on the axial depth reservation setting to obtain the groove bottom depth surface.

[0074] This can be understood as smooth transition interpolation: fitting a circular arc transition between adjacent areas in the Z-axis height of the groove bottom to prevent cutting edges from appearing at the groove bottom boundary. Interpolation algorithm: a third-order spline interpolation algorithm, adapted to the milling process of curved surfaces in aluminum materials. Example: Gradual transition of the Z-axis height of the groove bottom in five zones; no uneven steps after rough milling; uniform cutting load during finishing.

[0075] S443 generates a rough milling toolpath with globally differentiated allowance based on the groove wall contour curve and groove bottom depth surface after allowance offset, and completes the keyway rough milling according to the rough milling toolpath.

[0076] It is understandable that the output standard for rough milling toolpaths is: rounded corners, unidirectional climb milling, no reciprocating tool retraction, and adapted to the spindle speed. The output toolpaths can be directly used for batch machining, with a single keyway rough milling time of 28 seconds, which meets the workshop's production capacity cycle.

[0077] By adopting the above steps S441 to S443, it is helpful to eliminate abrupt changes in toolpath, cutting steps, and edge defects at the boundary of partition allowance, ensure smoothness of the entire rough milled cavity surface, and improve the surface finish of the keyway engagement surface.

[0078] After rough milling of S500, the actual machining allowance of each local area of ​​the keyway is obtained.

[0079] Understandably, the online precision inspection equipment—an in-machine online laser micrometer—allows for in-situ inspection at the machine tool station without removing the workpiece, achieving an accuracy of 0.1μm. Actual machining allowance: After rough milling, the remaining finishing allowance is measured in-situ in each zone. Data collection example: Average measured values ​​for this batch of workpieces: Area 1 actual allowance 84.92μm; Area 3 actual allowance 91.90μm. The measured values ​​deviate very little from the previous theoretical values.

[0080] S600: When the actual machining allowance is greater than or equal to the preset machining threshold, a workpiece machining abnormality alarm is issued. The preset machining threshold is greater than the maximum allowance threshold.

[0081] It is understandable that the preset machining threshold is a preset abnormal alarm threshold, which can be calibrated through cutting tests. The abnormal allowance mechanism indicates that when the actual machining allowance is greater than or equal to the preset machining threshold, it means that the rough milling cutting amount in a local area is insufficient and the deformation compensation is excessive. In the subsequent finishing process, the single-blade cutting load exceeds the standard, which can easily cause chipping of the groove wall, tool chipping, and scrapping of the finished groove due to excessive size. Alarm execution logic: The measured data of the laser micrometer is transmitted to the machine tool CNC control system in real time. The system compares the measured allowance of each zone with the machining threshold in real time. If the allowance of any zone meets the standard, an alarm is triggered, and the machine tool immediately stops feeding and locks the current machining station. Alarm classification: If only a single local area exceeds the standard, a yellow light alarm is issued for that point. If two or more areas in the entire area exceed the standard, a red light alarm for the whole machine is issued to stop the machine. Example: The machining threshold can be set to 105μm. If the actual machining allowance of the measured area 3 is 105.30μm ≥ 105μm of the preset machining threshold, the machine tool will immediately issue a yellow light machining abnormality alarm, lock the machining point in the area, and prohibit the flow to the finishing process.

[0082] By adopting the above steps S100 to S600, it is possible to perform online detection of the actual machining allowance after rough milling. Compared with the traditional method of unified detection after machining, it is possible to detect abnormal areas of allowance in a timely manner, prevent abnormal workpieces from flowing into the finishing process, thereby reducing the risk of tool breakage and workpiece scrap rate in finishing.

[0083] It should be understood that the sequence number of each step in the above embodiments does not imply the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of this application.

[0084] Corresponding to the rough milling method for aluminum alloy workpieces described in the above embodiments, this application also provides an aluminum alloy workpiece rough milling apparatus, the various units of which can realize the various steps of the aluminum alloy workpiece rough milling method. Figure 3 A structural block diagram of an aluminum alloy workpiece rough milling device provided in an embodiment of this application is shown. For ease of explanation, only the parts related to the embodiment of this application are shown.

[0085] Reference Figure 3 The device includes: The acquisition unit is used to acquire the groove structure feature data corresponding to the key groove of the aluminum alloy to be processed. The groove structure feature data includes the single-side wall thickness, groove depth, and groove width of each local area of ​​the key groove.

[0086] The deformation unit is used to determine the theoretical milling deformation of each local area based on the single-side wall thickness, groove depth, and groove width of each local area of ​​the keyway.

[0087] The allowance unit is used to adaptively compensate the preset basic machining allowance based on the theoretical milling deformation of each local area, so as to obtain the dynamic finishing allowance corresponding to each local area.

[0088] The machining unit is used to generate a rough milling toolpath for the keyway based on the dynamic finishing allowance corresponding to each local area, and to complete the rough milling of the keyway according to the rough milling toolpath.

[0089] It should be noted that the information interaction and execution process between the above-mentioned units are based on the same concept as the method embodiments of this application. For details on their specific functions and technical effects, please refer to the method embodiments section, which will not be repeated here.

[0090] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the above-described division of functional units is used as an example. In practical applications, the above functions can be assigned to different functional units as needed, that is, the internal structure of the device can be divided into different functional units to complete all or part of the functions described above. The functional units in the embodiments can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated unit can be implemented in hardware or as a software functional unit. Furthermore, the specific names of the functional units are only for easy differentiation and are not intended to limit the scope of protection of this application. The specific working process of the units in the above device can be referred to the corresponding process in the foregoing method embodiments, and will not be repeated here.

[0091] This application also provides a rough milling device. Figure 4 This is a schematic diagram of the structure of a rough milling device provided in one embodiment of this application. Figure 4 As shown, the rough milling equipment 6 of this embodiment includes: at least one processor 60 ( Figure 4 Only one is shown in the image), at least one memory 61 ( Figure 4 (Only one is shown in the image) and a computer program 62 stored in the at least one memory 61 and executable on the at least one processor 60, wherein when the processor 60 executes the computer program 62, it causes the rough milling equipment 6 to perform the steps in any of the above-described rough milling method embodiments for aluminum alloy workpieces, or causes the rough milling equipment 6 to perform the functions of the units in the above-described device embodiments.

[0092] For example, the computer program 62 may be divided into one or more units, which are stored in the memory 61 and executed by the processor 60 to complete this application. The one or more units may be a series of computer program instruction segments capable of performing a specific function, which describe the execution process of the computer program 62 in the rough milling machine 6.

[0093] The rough milling equipment 6 can be a vertical CNC milling machine, machining center, key milling CNC machine tool, etc. The rough milling equipment includes a memory, a processor, and a computer program stored in the memory and executable on the processor. When the processor executes the computer program, it implements the method as described in any of the foregoing aspects. The rough milling equipment 6 may include, but is not limited to, a processor 60 and a memory 61. Those skilled in the art will understand that... Figure 4This is merely an example of the rough milling equipment 6 and does not constitute a limitation on the rough milling equipment 6. It may include more or fewer components than shown, or combine certain components, or different components, such as input / output devices, network access devices, buses, etc.

[0094] The processor 60 can be a Central Processing Unit (CPU), or it can be other general-purpose processors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc. The general-purpose processor can be a microprocessor or any conventional processor.

[0095] In some embodiments, the memory 61 may be an internal storage unit of the rough milling machine 6, such as a hard disk or memory of the rough milling machine 6. In other embodiments, the memory 61 may be an external storage device of the rough milling machine 6, such as a plug-in hard disk, smart media card (SMC), secure digital (SD) card, flash card, etc., equipped on the rough milling machine 6. Furthermore, the memory 61 may include both internal and external storage units of the rough milling machine 6. The memory 61 is used to store operating systems, applications, bootloaders, data, and other programs, such as the program code of computer programs. The memory 61 can also be used to temporarily store data that has been output or will be output.

[0096] This application also provides a computer-readable storage medium storing a computer program that, when executed by a processor, implements the steps in any of the above method embodiments.

[0097] This application provides a computer program product that, when run on a rough milling machine, causes the rough milling machine to perform the steps in any of the above-described method embodiments.

[0098] If the integrated unit is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, all or part of the processes in the methods of the above embodiments of this application can be implemented by a computer program instructing related hardware. The computer program can be stored in a computer-readable storage medium, and when executed by a processor, it can implement the steps of the various method embodiments described above. The computer program includes computer program code, which can be in the form of source code, object code, executable files, or certain intermediate forms. The computer-readable medium can include at least: any entity or system capable of carrying computer program code to a rough milling machine, a recording medium, a computer memory, a read-only memory (ROM), a random access memory (RAM), an electrical carrier signal, a telecommunication signal, and a software distribution medium, such as a USB flash drive, a portable hard drive, a magnetic disk, or an optical disk.

[0099] In the above embodiments, the descriptions of each embodiment have different focuses. For parts that are not described in detail or recorded in a certain embodiment, please refer to the relevant descriptions of other embodiments.

[0100] Those skilled in the art will recognize that the units and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this application.

[0101] In the embodiments provided in this application, it should be understood that the disclosed aluminum alloy workpiece rough milling method, aluminum alloy workpiece rough milling device, and rough milling equipment can be implemented in other ways. For example, the embodiments of the aluminum alloy workpiece rough milling device and rough milling equipment described above are merely illustrative. For instance, the division of units is merely a logical functional division, and in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another device, or some features may be ignored or not executed. Furthermore, the displayed or discussed mutual coupling or direct coupling or communication connection may be through some interfaces, and the indirect coupling or communication connection between units may be electrical, mechanical, or other forms.

[0102] The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0103] The above-described embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this application, and should all be included within the protection scope of this application.

Claims

1. A method for rough milling aluminum alloy workpieces, characterized in that, include: Obtain the groove structure feature data corresponding to the key groove of the aluminum alloy to be processed; wherein, the groove structure feature data includes the single-side wall thickness, groove depth and groove width corresponding to each local area of ​​the key groove; The theoretical milling deformation corresponding to each local area is determined based on the single-side wall thickness, groove depth, and groove width corresponding to each local area of ​​the key groove; Based on the theoretical milling deformation corresponding to each local region, the preset basic machining allowance is adaptively compensated to obtain the dynamic finishing allowance corresponding to each local region. Based on the dynamic finishing allowance corresponding to each local area, a rough milling toolpath for the keyway is generated, and the rough milling of the keyway is completed according to the rough milling toolpath.

2. The rough milling method for aluminum alloy workpieces according to claim 1, characterized in that, The step of adaptively compensating the preset basic machining allowance based on the theoretical milling deformation corresponding to each local region to obtain the dynamic finishing allowance corresponding to each local region includes: The theoretical milling deformation corresponding to each local region is superimposed onto the preset basic machining allowance to obtain the initial compensation allowance corresponding to each local region. The initial compensation margin corresponding to each local area is subjected to interval limiting constraint processing to eliminate abnormal margin values ​​that exceed the preset margin range, thereby obtaining the dynamic finishing margin.

3. The rough milling method for aluminum alloy workpieces according to claim 2, characterized in that, The step of superimposing the theoretical milling deformation corresponding to each local region onto a preset basic machining allowance to obtain the initial compensation allowance corresponding to each local region includes: Based on the theoretical milling deformation of different local areas of the keyway, the corresponding deformation compensation correction coefficient is matched; The precise compensation amount for each region is obtained by multiplying the theoretical milling deformation of each local region with the corresponding deformation compensation correction coefficient. The precise compensation amount is superimposed with the preset basic processing allowance to obtain the initial compensation allowance with structurally differentiated compensation attributes for each local area.

4. The rough milling method for aluminum alloy workpieces according to claim 2, characterized in that, The preset margin range includes a minimum margin threshold and a maximum margin threshold. The initial compensation margin corresponding to each local region is subjected to range-limiting constraint processing to eliminate abnormal margin values ​​exceeding the preset margin range, resulting in a dynamic finishing margin, including: If the initial compensation margin is less than the minimum margin threshold, then the minimum margin threshold is determined as the dynamic finishing margin for the corresponding local area; If the initial compensation margin is greater than the maximum margin threshold, then the maximum margin threshold is determined as the dynamic finishing margin for the corresponding local area; If the initial compensation margin is within the preset margin range, then the initial compensation margin is directly determined as the dynamic finishing margin of the corresponding local area.

5. The rough milling method for aluminum alloy workpieces according to claim 1, characterized in that, The process of generating a rough milling toolpath for the keyway based on the dynamic finishing allowance corresponding to each local region, and completing the rough milling of the keyway according to the rough milling toolpath, includes: Establish a mapping relationship between the spatial coordinates of each local area of ​​the key slot and the corresponding dynamic finishing allowance; wherein, each local area of ​​the key slot includes a first key slot area and a second key slot area; For the first region of the key slot, the normal contour offset is set according to the corresponding dynamic finishing allowance; wherein, the first region of the key slot is the side wall region of the key slot; For the second region of the keyway, an axial depth is reserved according to the corresponding dynamic finishing allowance; wherein, the second region of the keyway is the bottom region of the keyway; Based on the normal profile offset setting and the axial depth reservation setting, a rough milling toolpath with global differential allowance is generated, and the keyway rough milling is completed according to the rough milling toolpath.

6. The rough milling method for aluminum alloy workpieces according to claim 5, characterized in that, The process of generating a rough milling toolpath with globally differentiated allowance based on the normal contour offset setting and the axial depth reservation setting, and completing the keyway rough milling according to the rough milling toolpath, includes: The normal profile offset setting is subjected to continuous gradient normal offset processing to obtain the groove wall profile curve; The axial depth reservation setting is subjected to smooth transition interpolation processing to obtain the groove bottom depth surface; Based on the groove wall contour curve after the allowance offset and the groove bottom depth surface, a rough milling toolpath with global differential allowance is generated, and the keyway rough milling is completed according to the rough milling toolpath.

7. The rough milling method for aluminum alloy workpieces according to claim 1, characterized in that, The step of determining the theoretical milling deformation corresponding to each local area based on the single-side wall thickness, groove depth, and groove width of each local area of ​​the keyway includes: Obtain a pre-constructed milling deformation fitting model of an aluminum alloy keyway; wherein the milling deformation fitting model uses the single-sided wall thickness, the groove depth, and the groove width as input feature parameters, and the milling elastic deformation and plastic deformation as output parameters; The single-side wall thickness, groove depth, and groove width parameters corresponding to each local area of ​​the key groove are input into the milling deformation fitting model; The elastic and plastic deformation variables corresponding to each local region are obtained by fitting and calculating using the milling deformation fitting model. The theoretical milling deformation of the corresponding local region is obtained by weighted summation of the elastic and plastic deformations of each local region.

8. The rough milling method for aluminum alloy workpieces according to claim 7, characterized in that, The process of fitting and calculating the elastic and plastic deformation variables corresponding to each local region using the milling deformation fitting model includes: Obtain aluminum alloy material properties and rough milling cutting process parameters; The aluminum alloy material properties and the rough milling cutting process parameters are simultaneously imported into the milling deformation fitting model as correction constraints for the milling deformation fitting model. Based on the parameters of the single-sided wall thickness, the groove depth, and the groove width of each local region, and in conjunction with the modified constraint conditions, the values ​​of elastic deformation and plastic deformation corresponding to each local region are output independently.

9. The rough milling method for aluminum alloy workpieces according to claim 4, characterized in that, The method further includes: After rough milling is completed, the actual machining allowance of each local area of ​​the keyway is obtained; When the actual machining allowance is greater than or equal to the preset machining threshold, a workpiece machining abnormality alarm is issued; wherein, the preset machining threshold is greater than the maximum allowance threshold.

10. A rough milling apparatus, comprising a memory, a processor, and a computer program stored in the memory and executable on the processor, characterized in that, When the processor executes the computer program, it implements the method as described in any one of claims 1 to 9.

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