Rectangular process trajectory planning method for ultrasonic rough machining of honeycomb core

Abstract

The application provides a rectangular process track planning method for ultrasonic rough machining of a honeycomb core, and comprises the following steps: S1, generating a new model by regionally biasing a model to be machined; S2, creating a "variable profile milling" machining procedure for the new model; S3, setting a cutting direction and corresponding cutting mode and cutting step distance; S4, setting a tool shaft as "relative to a driving body" and applying a corresponding rake angle; S5, setting tool path parameters and generating a machining track; S6, completing track planning of another cutting direction in the same method as the first cutting direction; and S7, selecting a flat-end milling cutter to cut and remove rectangular chips. By adopting the technical scheme, numerical control programming of ultrasonic rough machining of the honeycomb core can be realized, manual programming is replaced, and the overall machining efficiency of the honeycomb core component is greatly improved.

Description

Technical Field

[0001] This invention relates to the field of ultrasonic machining, specifically to a rectangular process trajectory planning method for ultrasonic rough machining of honeycomb cores, which can provide technical support for the processing and manufacturing of honeycomb core components. Background Technology

[0002] Honeycomb core components possess excellent impact resistance, vibration reduction, and wave transmission properties, making them widely used in aerospace and rail transportation fields. However, traditional high-speed milling suffers from problems such as poor machining quality and severe dust pollution. Therefore, ultrasonic cutting has been introduced into the machining of honeycomb core components. By applying high-frequency vibrations to the cutting tool, intermittent cutting is achieved, ultimately enabling high-quality and efficient machining of honeycomb core components.

[0003] Ultrasonic machining of honeycomb cores is divided into roughing and finishing. Finishing is mainly performed by a circular milling cutter, which, being a rotating tool, can be directly programmed for CNC machining using equal-diameter milling cutters in CAM software. However, roughing primarily relies on a straight-edged, pointed cutter for dicing and division, and this cutter, being a non-rotating tool, cannot be directly programmed for CNC machining in CAM software. Furthermore, a significant portion of the honeycomb core machining time is spent on roughing to remove excess material. Therefore, achieving rational and efficient toolpath planning for roughing has become a crucial problem that urgently needs to be solved in the machining of honeycomb core components. Summary of the Invention

[0004] To address the aforementioned problems, this invention proposes a rectangular process trajectory planning method for ultrasonic rough machining of honeycomb cores, enabling high-efficiency machining of honeycomb core components. The technical means employed in this invention are as follows: The technical means employed in this invention are as follows: A rectangular process trajectory planning method for ultrasonic roughing of honeycomb cores, characterized by the following steps: S1. Generate a new model by performing a region offset on the model to be processed; S2. Create a "variable contour milling" machining operation for the new model; S3. Set the cutting direction and corresponding cutting mode and cutting step distance; S4. Set the cutter axis to "relative to the drive body" and apply the corresponding forward tilt angle; S5. Set the toolpath parameters and generate the machining trajectory; S6. Using the same method as the first cutting direction, complete the trajectory planning for the other cutting direction; S7. Use a flat-end milling cutter to cut and remove rectangular chips.

[0005] Further, step S1 includes the following steps: In the rectangular process of ultrasonic roughing of honeycomb core, the straight-edged tip cuts in two mutually perpendicular directions. First, the first cutting direction of the tool is determined. Then, in the modeling module, the offset region command is selected to offset and extend the model at both ends of the cutting direction to ensure that the tool will not interfere when changing its posture. Offset and shorten the model at both ends of the perpendicular cutting direction to ensure that the first and last cuts are both cut on the workpiece, and the shortening distance cannot exceed the effective cutting width of the circular blade.

[0006] The effective cutting width of the circular blade is w; the offset extension distance at both ends of the cutting direction is b; the offset shortening distance at both ends of the perpendicular cutting direction is c; Further, step S2 includes the following steps: Switch the software interface to the machining module, insert a new operation in the program group, select "multi-axis milling" as the operation type, and select "variable profile milling" as the operation subtype.

[0007] Further, step S3 includes the following steps: First, the cutting direction of the tool is determined based on the first cutting direction mentioned above. To improve machining efficiency, the cutting mode is uniformly selected as reciprocating. The cutting step distance is set by the number of cutting steps, which needs to be determined according to the model size, but the maximum value of the step distance cannot exceed the effective cutting width of the disc cutter.

[0008] The offset model has a length of L, a width of W, and a height of H; the number of cutting steps is n. Further, step S4 includes the following steps: The cutter axis of the straight-edged pointed tool is set "relative to the driving body." During machining, a corresponding rake angle of 15°~45° needs to be applied to the tool. Simultaneously, a small-diameter equivalent flat end mill (1~2mm) is selected to replace the straight-edged pointed tool during programming. Adding the rake angle allows for more effortless cutting. The rake angle of the tool is α; the diameter of the equivalent flat end mill is d. Furthermore, step S5 includes the following steps: when setting the toolpath parameters, the cutting parameters, non-cutting movement, feed rate and speed of the tool need to be set sequentially according to the specific actual situation, and the corresponding machining trajectory is generated after confirming that there are no errors.

[0009] Furthermore, step S6 requires determining a second cutting direction perpendicular to the first cutting direction. Once the second cutting direction is determined, the subsequent tool path planning method is the same as that for the first cutting direction. Specifically, the straight-edged point tool first completes the reciprocating machining in the first cutting direction, then processes it in the second cutting direction, dividing the workpiece into rectangular blocks, and finally uses a circular blade to remove the rectangular blocks.

[0010] Furthermore, in step S7, the diameter of the flat-end mill is equal to the diameter of the circular cutter. The diameter of the circular cutter is D; Compared with the prior art, the present invention has the following advantages: By employing the technical solution of this invention, a small-diameter equivalent flat-end mill can be used to replace the straight-edged end mill, enabling CNC programming of the straight-edged end mill in CAM software. The toolpath can be extended and the cutting effectiveness of the first and last cutters improved through a region offset method. The variable profile milling operation type allows for the application of the tool's rake angle, and the reciprocating milling mode enhances machining efficiency. The entire roughing CNC programming process is simple and easy to understand, facilitating operation by engineering technicians, and ultimately enabling high-efficiency machining of honeycomb core components. Attached Figure Description

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

[0012] Figure 1 This is a flowchart of the trajectory planning method of the present invention.

[0013] Figure 2 This is a comparison image of the model to be processed before and after the offset.

[0014] Figure 3 This is a schematic diagram of a rectangular process using a straight-bladed pointed knife and a circular blade for chip removal. Detailed Implementation

[0015] It should be noted that, unless otherwise specified, the embodiments and features described in the present invention can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0016] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the present invention or its application or use. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0017] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of exemplary embodiments according to the invention. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0018] Unless otherwise specifically stated, the relative arrangement, numerical expressions, and values ​​of the components and steps described in these embodiments do not limit the scope of the invention. It should also be understood that, for ease of description, the dimensions of the various parts shown in the drawings are not drawn to actual scale. Techniques, methods, and devices known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and devices should be considered part of the specification. In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values. It should be noted that similar reference numerals and letters in the following figures denote similar items; therefore, once an item is defined in one figure, it need not be further discussed in subsequent figures.

[0019] In the description of this invention, it should be understood that the orientation or positional relationship indicated by directional terms such as "front, back, up, down, left, right", "horizontal, vertical, horizontal" and "top, bottom" is generally based on the orientation or positional relationship shown in the accompanying drawings, and is only for the convenience of describing this invention and simplifying the description. Unless otherwise stated, these directional terms do not indicate or imply that the device or element referred to must have a specific orientation or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on the scope of protection of this invention. The directional terms "inner" and "outer" refer to the inner and outer contours relative to the outline of each component itself.

[0020] For ease of description, spatial relative terms such as "above," "over," "on the upper surface of," "above," etc., are used herein to describe the spatial positional relationship of a device or feature as shown in the figures to other devices or features. It should be understood that spatial relative terms are intended to encompass different orientations in use or operation besides the orientation of the device as described in the figures. For example, if the device in the figures is inverted, a device described as "above" or "above" other devices or structures would subsequently be positioned as "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below." The device may also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0021] Furthermore, it should be noted that the use of terms such as "first" and "second" to define components is merely for the purpose of distinguishing the corresponding components. Unless otherwise stated, the above terms have no special meaning and therefore should not be construed as limiting the scope of protection of this invention.

[0022] like Figures 1-3 As shown in the figure, this embodiment presents a rectangular process trajectory planning method for ultrasonic roughing of honeycomb cores, which includes the following steps: S1. Generate a new model by performing a region offset on the model to be processed; S2. Create a "variable contour milling" machining operation for the new model; S3. Set the cutting direction and corresponding cutting mode and cutting step distance; S4. Set the cutter axis to "relative to the drive body" and apply the corresponding forward tilt angle; S5. Set the toolpath parameters and generate the machining trajectory; S6. Using the same method as the first cutting direction, complete the trajectory planning for the other cutting direction; S7. Use a flat-end milling cutter to remove the rectangular chips. Specifically, the rectangular blocks cut by the straight-edged milling cutter will not fall off directly; a round milling cutter is needed for bottom-cutting.

[0023] After the roughing process of the rectangular block is removed, the finishing process begins. Specifically, a 2mm thick slice is removed using a circular blade to obtain the final machined surface.

[0024] In this embodiment, the focus is on a straight-edged pointed cutter. The parameters of the circular cutter are used to calibrate the parameters during the machining of the straight-edged pointed cutter. In the roughing process of S7, the circular cutter can cut along the trajectory of the straight-edged pointed cutter, resulting in high overall cutting efficiency.

[0025] Step S1 includes the following steps: In the rectangular process of ultrasonic roughing of honeycomb cores, the straight-edged tool will cut in two mutually perpendicular directions, so it is necessary to first determine the first cutting direction of the tool. Then, in the modeling module, select the offset region command to offset and extend the model at both ends of the cutting direction (extend distance b) to ensure that the tool will not interfere during posture changes. Offset and shorten at both ends of the perpendicular cutting direction (shorten distance c) to ensure that the first and last cuts both cut on the workpiece, and the shortening distance cannot exceed the effective cutting width of the circular blade.

[0026] The effective cutting width of the circular blade is: w ; The offset extension distance at both ends of the cutting direction is: b ; The offset shortening distance at both ends of the vertical cutting direction is: c ; In this embodiment, the effective cutting width of the circular blade is... w =20mm, offset extension distance at both ends in the cutting direction b =50mm, offset at both ends in the perpendicular cutting direction to shorten the distance. c =20mm; Figure 2 A more intuitive comparison and explanation of the models before and after biasing is provided; Step S2 includes the following steps: Switch the software interface to the machining module, insert a new operation in the program group, select "multi-axis milling" as the operation type, and select "variable profile milling" as the operation subtype.

[0027] Step S3 includes the following steps: First, the cutting direction of the tool is determined based on the first cutting direction mentioned above. To improve machining efficiency, the cutting mode is uniformly selected as reciprocating. The cutting step distance is set by the number of cutting steps, which needs to be determined according to the model size, but the maximum value of the step distance cannot exceed the effective cutting width of the disc cutter.

[0028] The length of the model is L Width is W The height is H ; The cutting step number is n ; In this embodiment, the length of the model L =300mm, width W =200mm, height H =30mm, cutting step distance n =13; Step S4 includes the following steps: To improve the machinability of the honeycomb core, the cutter axis should be set "relative to the drive body." During machining, a corresponding rake angle of 15° to 45° should be applied to the cutter. Simultaneously, to reduce machining errors, a small-diameter equivalent flat-end mill (1-2 mm) should be used instead of a straight-edged end mill during programming.

[0029] The forward tilt angle of the cutter is α ; The diameter of the equivalent flat end mill is d ; In this embodiment, the tool tilt angle α =30°, equivalent flat end mill diameter d =2mm; Step S5 includes the following steps: When setting toolpath parameters, the cutting parameters, non-cutting movement, feed rate and speed of the tool should be set sequentially according to the specific actual situation, and the corresponding machining trajectory should be generated after confirming that there are no errors.

[0030] Step S6 requires determining a second cutting direction perpendicular to the first cutting direction. Once the second cutting direction is determined, the subsequent tool path planning method is the same as that for the first cutting direction.

[0031] In step S7, the diameter of the flat-end mill is equal to the diameter of the disc mill.

[0032] The diameter of the circular blade is D ; In this embodiment, the diameter of the circular blade... D =50.8mm; Figure 3 The rectangular cutting process of a straight-edged pointed knife and the chip removal process of a circular blade are illustrated.

[0033] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention 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 or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A rectangular process trajectory planning method for ultrasonic roughing of honeycomb cores, characterized in that, Includes the following steps: S1. Generate a new model by performing a region offset on the model to be processed; S2. Create a "variable profile milling" machining operation for the new model; S3. Set the cutting direction and corresponding cutting mode and cutting step distance; S4. Set the cutter axis to "relative to the drive body" and apply the corresponding forward tilt angle; S5. Set the toolpath parameters and generate the machining trajectory; S6. Using the same method as the first cutting direction, complete the trajectory planning for the other cutting direction; S7. Use a flat-end milling cutter to cut and remove rectangular chips.

2. The method according to claim 1, characterized in that, Step S1 includes the following steps: In the rectangular process of ultrasonic roughing of honeycomb core, the straight-edged tip cuts in two mutually perpendicular directions. First, the first cutting direction of the tool is determined. Then, in the modeling module, the offset region command is selected to offset and extend the model at both ends of the cutting direction to ensure that the tool will not interfere when changing its posture. Offset and shorten the model at both ends of the perpendicular cutting direction to ensure that the first and last cuts are both cut on the workpiece, and the shortening distance cannot exceed the effective cutting width of the circular blade.

3. The method according to claim 1, characterized in that, Step S2 includes the following steps: Switch the software interface to the machining module, insert a new operation in the program group, select "multi-axis milling" as the operation type, and select "variable profile milling" as the operation subtype.

4. The method according to claim 2, characterized in that, Step S3 includes the following steps: The cutting direction of the tool is determined based on the first cutting direction. The cutting mode is uniformly selected as reciprocating. The cutting step distance is set by the number of cutting step distances, which needs to be determined according to the model size. The maximum value of the step distance cannot exceed the effective cutting width of the disc cutter.

5. The method according to claim 1, characterized in that, Step S4 includes the following steps: Set the cutter axis to "relative to the drive body". During machining, apply a corresponding forward tilt angle to the tool, which is 15°~45°. At the same time, when programming, use a small-diameter equivalent flat end mill instead of a straight-edged tip cutter, with a diameter of 1~2mm.

6. The method according to claim 1, characterized in that, Step S5 includes the following steps: When setting toolpath parameters, the cutting parameters, non-cutting movement, feed rate and speed of the tool should be set sequentially according to the specific actual situation, and the corresponding machining trajectory should be generated after confirming that there are no errors.

7. The method according to claim 2, characterized in that, Step S6 requires determining a second cutting direction perpendicular to the first cutting direction. Once the second cutting direction is determined, the subsequent tool path planning method is the same as that for the first cutting direction.

8. The method according to claim 1, characterized in that, In step S7, the diameter of the flat-end mill is equal to the diameter of the disc mill.

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