A method for texturing a surface of a workpiece

Abstract

The present application relates to the technical field of machining, and provides a workpiece surface net texture machining method, which comprises the following steps: determining the diameter of a net texture machining tool according to the width of a to-be-machined surface; setting the offset distance of a cutting track relative to the center line of the to-be-machined surface, so that the phase angle of the formed net texture is in a preset uniform interval; converting the turning intersection point of the cutting track into a tangent circular angle, and the radius of the tangent circular angle matches the radius of the net texture machining tool; and machining by the net texture machining tool according to the cutting track. Through the synergistic control of the above macro track offset and micro intersection point circular angle conversion, the present application solves the problem of uneven distribution of net texture caused by the lack of systematic process method in the prior art, and realizes high-quality net texture machining with a grid approximately square and overall uniform.

Description

Technical Field

[0001] This invention relates to the field of machining technology, and specifically to a method for processing a textured surface on a workpiece. Background Technology

[0002] In the field of precision mechanical equipment such as transmissions, the degree of integration of the whole machine is constantly increasing, which puts forward higher requirements for the overall sealing performance of the housing. Among them, the sealing of the housing mating surfaces is a key factor affecting the overall performance of the machine. In order to achieve a long-term stable sealing effect, a specific mesh structure is often processed on the mating surfaces. The uneven texture blocks leakage channels and improves the composite effect of the gasket or adhesive.

[0003] In existing technologies, the textured surface machining method typically uses a face milling cutter with inserts of varying heights to move along the workpiece surface contour. The combined motion of the cutter's rotation and feed motion creates intersecting patterns. As the cutter moves along the workpiece contour centerline, the intersection angles of the textured cutting edges on both sides of the cutter exhibit a noticeable gradual change at different widths. Specifically, in the width direction of the surface to be machined, the textured phase angle (i.e., the interior angle of the intersecting grid) changes continuously with the distance from the centerline. This results in the grid near the centerline appearing as a thin, elongated rhombus, while the grid at the edges becomes excessively flat, failing to form a uniform, approximately square grid structure. Consequently, the resulting texture geometry is uneven, and the intersecting grid sizes vary. Especially at contour corners and in the tool entry / exit areas, abrupt changes in the path cause sudden changes in texture density or overlap, leading to poor texture consistency and consequently affecting overall sealing performance. Summary of the Invention

[0004] To address the aforementioned technical problems, this invention provides a method for processing a textured surface on a workpiece, which can achieve uniformity and consistency of the cross-textured pattern on the workpiece surface, thereby improving the sealing performance of the mating surface and processing efficiency.

[0005] The technical solution of the present invention includes: determining the diameter of the textured cutting tool according to the width of the surface to be processed; setting the offset distance of the cutting trajectory relative to the centerline of the surface to be processed, so that the phase angle of the resulting texture is within a preset uniform range; converting the turning point of the cutting trajectory into a tangent fillet, and the radius of the tangent fillet matches the radius of the textured cutting tool; and the textured cutting tool moves according to the cutting trajectory.

[0006] In the above scheme, the formation of the mesh pattern is essentially a composite motion of the circular rotation of the mesh-forming edge of the machining tool and its movement along the cutting path. The resulting imprints intersect to form a regular pattern. Assuming the cutting path direction is positive X, the equation for the mesh trajectory formed by a single mesh-forming edge can be expressed as:

[0007] In the formula, Radial position coordinates, The diameter of the cutting tool. The angle of tool rotation. This represents the feed rate per revolution. Therefore, the cycle time of the trajectory can be determined. In any The position is located at a distance along the X direction (cutting path). The distances along the Y direction (the normal to the cutting path) are equal. Based on the above principle, combined with the coordinated control of macroscopic offset distance setting and microscopic fillet transition, the phase angle of the texture can be kept stable within the preset range during the machining process. This fundamentally solves the problems of uneven texture density and abrupt changes at transition points, ensuring the uniformity of the overall texture structure.

[0008] Optionally, the offset distance is 0.34 to 0.35 times the diameter of the textured cutting tool; the preset uniform range is 35° to 55°.

[0009] Optionally, the diameter of the textured cutting tool is greater than 8.3 times the width of the surface to be machined; the offset direction of the cutting trajectory is the outer side of the surface to be machined; or, the offset direction of the cutting trajectory is the inner side of the surface to be machined, and the radius of the textured cutting tool is smaller than the basic contour radius of the machining cavity.

[0010] Optionally, the turning point includes a cusp and / or a self-intersection point; the radius of the tangent fillet is half the diameter of the textured cutting tool.

[0011] Optionally, the method further includes: controlling the advance and retraction direction of the textured cutting tool to be perpendicular to the normal of the cutting trajectory; using an arc entry method for entry, and the radius of the entry arc is half the diameter of the textured cutting tool; controlling the advance and retraction distance to be 0.3 times the diameter of the textured cutting tool.

[0012] Optionally, the textured machining tool includes a main cutting edge and multiple textured forming edges evenly distributed along the circumference; the height difference between the textured forming edges and the main cutting edge is equal to a preset texture depth; the feed per tooth of the textured machining tool is equal to the product of the number of textured forming edges and the number of texture stripes per unit length.

[0013] Optionally, the textured forming blade is a V-shaped blade with a blade tip radius of less than 0.4 mm and a blade angle of 30°; the height difference of all the main cutting edges is within 0.01 mm, and the height difference of multiple textured forming blades is less than 0.01 mm.

[0014] Optionally, before controlling the textured cutting tool to perform textured processing on the surface to be processed according to the cutting trajectory, the method further includes: performing rough processing on the surface to be processed, so that the surface after rough processing has a reserved allowance of more than 0.15 mm and a flatness of less than 0.1 mm.

[0015] Optionally, the method further includes: obtaining the material type of the workpiece; when the material type is aluminum alloy, controlling the tip radius of the textured machining tool to be less than a preset radius threshold, and controlling the roughing allowance to be less than a preset allowance threshold; when the material type is cast iron, controlling the tip radius of the textured machining tool to be greater than or equal to the preset radius threshold.

[0016] Optionally, controlling the textured machining tool to perform textured machining on the surface to be machined according to the cutting trajectory includes: controlling the textured forming edge of the textured machining tool to perform circumferential rotation, and controlling the textured machining tool to move along the cutting trajectory to form a compound motion; wherein, the cycle distance of the textured trajectory formed by a single textured forming edge in the direction of the cutting trajectory is equal to the feed per revolution of the textured machining tool.

[0017] The technical solution provided by this invention has the following advantages compared with the prior art: The tool diameter is determined based on the width of the surface to be machined, and the offset distance of the cutting trajectory relative to the centerline is set. This macroscopically ensures that the effective and uniform mesh area fully covers the machined surface, and the mesh phase angle is adjusted to a preset uniform range, solving the problem of inconsistent cross mesh sizes. At the same time, by transforming the turning points of the cutting trajectory into tangent fillets that match the tool's rotation radius, the path abruptness at the corners is eliminated, making the tool cutting envelope transition smoothly and avoiding abrupt changes in mesh density and overlapping accumulation. The synergistic effect of these two factors ultimately achieves high-quality mesh machining with overall uniformity, effectively improving the overall sealing performance of the workpiece mating surface.

[0018] Other advantages, objectives and features of the present invention will become apparent in part from the following description, and in part from those skilled in the art through study and practice of the invention. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 This is a schematic diagram illustrating the principle of mesh formation in an embodiment of the present invention.

[0021] Figure 2 This is a schematic diagram of the mesh parameters according to an embodiment of the present invention.

[0022] Figure 3 This is a schematic diagram of the cutting trajectory and the geometric relationship of the mating surface in an embodiment of the present invention.

[0023] Figure 4 This is a schematic diagram comparing rounded corner transitions and sharp corner transitions in an embodiment of the present invention. Detailed Implementation

[0024] The following detailed description of a specific embodiment of the present invention is provided in conjunction with the accompanying drawings. However, it should be understood that the scope of protection of the present invention is not limited to the specific embodiment.

[0025] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing the technical solution of this invention and simplifying the description, and 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. Therefore, they should not be construed as limitations on this invention.

[0026] In the description of the embodiments of the present invention, unless otherwise stated, "a plurality of" means two or more.

[0027] In the description of the embodiments of the present invention, the textured end mill is a disc end mill / face mill, which belongs to rotary cutting tools.

[0028] Example 1: This embodiment describes a method for machining a mesh pattern on a workpiece surface. Its core lies in the coordinated control of the cutting process from two dimensions: macroscopic path planning and microscopic corner optimization, so as to form a uniform mesh pattern structure.

[0029] like Figure 1 As shown, the essential forming mechanism of the mesh pattern is that while the mesh forming edge of the mesh machining tool rotates at high speed around the spindle, the entire tool moves continuously relative to the workpiece along the preset cutting trajectory. The superposition of the two movements forms a continuous undulating cutting mark. The regular self-intersection of adjacent or intersecting marks eventually constitutes a periodic mesh pattern.

[0030] After obtaining the geometric parameters of the workpiece surface, the diameter of the textured surface machining tool is first determined based on the width of the surface to be machined. Broadly speaking, the tool diameter must match the width of the surface to be machined. This is to ensure that the tool can effectively cover the entire mating surface area with the generated uniform texture in a single pass or a specific trajectory plan. For example, when the surface to be machined is a narrow annular or racetrack-shaped band around a box-shaped mating surface, the selected tool diameter should be significantly larger than the width of the mating surface, ensuring that the width of the uniform texture area is sufficient to cover the sealing mating surface. This avoids a narrow central uniform texture area and an excessively large ineffective edge area due to an excessively small tool diameter. The textured surface machining tool referred to here is not an ordinary end mill, but a special tool with a textured forming edge specifically designed to carve microgrooves on its end face or circumference. Its structure will be described in detail in subsequent embodiments.

[0031] After selecting the cutting tool, the offset distance of the cutting trajectory relative to the centerline of the surface to be machined needs to be set so that the phase angle of the resulting mesh pattern is within a preset uniform range. Combined with... Figure 3 As shown, by intentionally introducing an offset distance from the tool path relative to the centerline of the workpiece mating surface outwards or inwards, the angle at which the motion imprints intersect in space can be altered. This can be understood as follows: when the tool cuts along a path completely coinciding with the centerline of the mating surface, the intersection angles of the motion imprints of the mesh-forming edges on both sides exhibit a significant gradual change at different widths, resulting in uneven texture. However, after introducing the offset, the symmetry of the paths on both sides of the centerline changes, thereby allowing the interior angles of the small mesh squares formed by each intersection—i.e., the mesh phase angles—within the most critical mating surface width to be concentrated and controlled into a more uniform distribution range. The small squares formed within this range approximate square or regular rhombus shapes, resulting in optimal texture uniformity. Technicians can determine this offset distance based on parameters such as the mating surface width and tool diameter through geometric calculations or trial cuts. The specific optimization range will be detailed later in this invention.

[0032] After the overall path planning is completed, the local features of the cutting trajectory still need to be specifically addressed. In this embodiment, the turning points of the cutting trajectory are transformed into tangent fillets, and the radii of these tangent fillets match the radius of the textured cutting tool. These turning points include, but are not limited to, sharp points resulting from abrupt changes in direction when the tool trajectory approaches the workpiece contour boundary or internal protruding structures, and self-intersections occurring in narrow, curved areas due to offset. Figure 4 As shown in the left-hand view, this embodiment applies a smooth arc transition to these originally sharp or self-intersecting turns. The radius of this arc should not be too small or too large, but must be directly related to the outer diameter of the tool, that is, matched with the tool radius, so that the actual cutting envelope of the tool at the bend can be smoothly connected rather than abruptly changed. This is because in the case of sharp corner transitions, such as... Figure 4 As shown in the comparison on the right, the tool experiences a sudden change in direction at sharp turning points. The uneven accumulation of time the cutting edge spends or deviates from the workpiece surface causes a drastic shift in texture density in that corner area, disrupting the continuity of the overall texture and becoming a weak point in sealing during practical use. However, when a tangential fillet matching the tool radius is forcibly constructed, the tool's outer contour slides synchronously with the inner and outer boundaries of the machined surface at the turning point, maintaining equidistant cutting marks and thus avoiding this problem.

[0033] Based on the above planning methods, the final optimized cutting trajectory is obtained. The cutting trajectory is used to control the textured machining tool to perform textured machining on the surface to be machined. In actual operation, the CNC system drives the spindle and tool to move relative to the workpiece according to the designed trajectory with rounded corners and specific offsets. The textured forming edge sequentially engraves several equidistant curved grooves on the workpiece surface. Combined with the superposition of rotation and tool feed, the imprints intersect and weave to form a stable cross pattern, so that the final machined surface presents a uniform texture with similar grid size and consistent pattern depth in any macroscopic observation area.

[0034] Example 2: Based on the above embodiments, this embodiment further quantifies the key parameters involved in the macroscopic trajectory bias process to explain how to ensure that the ripple phase angle falls precisely into the uniform range, and the geometric constraints implied behind the parameter values.

[0035] Specifically, the offset distance is preferably 0.34 to 0.35 times the diameter of the textured surface machining tool, with a preset uniform range of 35° to 55°. (Reference) Figure 3 The geometric relationship shown provides a more intuitive understanding of the origin of this value. The imprint formed by the combined motion of tool rotation and movement along the cutting path intersects itself, and the intersection angle is the phase angle of the pattern. The magnitude of this angle directly depends on the offset distance of the tool axis relative to the centerline of the mating surface. .

[0036] In the formula, The diameter of the cutting tool. For the maximum ripple phase angle, The minimum mesh phase angle is defined as follows. Once the tool diameter is determined, the phase angle at each intersection point is not fixed but continuously distributed across the width of the machined surface. Setting the offset distance to 0.34D to 0.35D ensures that the mesh phase angles formed at each intersection point fall within the range of 35° to 55° across the entire mating surface width. Within this range, the mesh pattern approximates small squares, resulting in optimal texture uniformity. Conversely, if the offset distance is less than 0.34D, the mesh will become excessively narrow near the centerline of the machined surface, forming elongated diamond-shaped holes; if the offset distance is greater than 0.35D, the mesh will become excessively flat and widened, also losing uniformity. Both of these deviations will lead to uneven filling depth or adhesive thickness of the sealing medium on the mating surface, thus weakening the sealing effect. Within the range of 0.34D to 0.35D, the formed mesh exhibits an ideal, regular cross intersection, providing micro-oil storage or adhesive grooves with uniform depth and volume for the sealing medium.

[0037] Based on this, the diameter of the textured surface machining tool is further set to be 8.3 times greater than the width of the surface to be machined. This dimensional constraint ensures from the outset that the width of the uniform textured area generated by a single tool pass is sufficient to completely cover the entire mating surface. Figure 3 It is known that under a single tool diameter D, the coverage width d of the uniform texture area is approximately equal to 0.12D. For any point on the mating surface to fall within the uniform texture area, d must be greater than the mating surface width W, i.e., 0.12D must be greater than W. From this, we can deduce the critical condition that D must be greater than 8.3W. When this condition is not met, the edge area of ​​the mating surface will fall into a region with a phase angle exceeding 35° to 55°. The texture pattern will transition from a square to rapid elongation or flattening, resulting in inconsistent texture patterns between the center and edge areas of the entire texture, severely affecting the overall sealing consistency of the product.

[0038] Regarding the offset direction of the cutting path, the preferred solution is to offset the cutting path outwards from the surface to be machined; alternatively, when interference structures on the outer side prevent outward offsetting, the cutting path is offset inwards from the surface to be machined, and in this case, the radius of the tool used for texture machining is required to be smaller than the basic contour radius of the machining cavity. The preferred outward offset has engineering advantages: the tool is kept away from internal bosses, reinforcing ribs, or partitions on the workpiece that may cause interference, effectively avoiding unexpected tool collisions during cutting, improving machining safety and programming convenience. However, when the outer space of the workpiece is limited, for example, if there are other machined assembly lugs or adjacent actuators around the mating surface, forcing the tool path to be offset inwards, then the upper limit of the tool diameter must be constrained—that is, ensuring that the tool radius is strictly smaller than the basic contour radius of the cavity into which the tool enters. Without this constraint, large-diameter tools would frequently intersect the contour of the cavity wall when following the inner offset path, resulting in dense sharp points and self-intersections on the path. This increases the workload of subsequent corner rounding and introduces the risk of abrupt changes in texture density at turning points. This constraint makes the inner offset path relatively smooth, reducing the number of sharp point areas requiring additional processing, ensuring machining quality while also reducing the complexity of the process.

[0039] Example 3: After planning the macroscopic layout of the cutting trajectory according to the aforementioned embodiments, this embodiment focuses on solving the problem of microscopic texture abrupt changes at tool path turns and the problem of texture protection in the tool entry and exit areas.

[0040] The turning points specifically include at least one of cusps and self-intersections. These points are geometric features that are easily generated in the narrow, curved areas of the mating surface contour boundary after trajectory offset. In this embodiment, these turning points are forcibly converted into tangent fillets, and the radius of the tangent fillet is taken as half the diameter of the textured machining tool. Figure 4 The necessity of this process can be intuitively understood. Figure 4 The right side illustrates a sharp-angle transition. When the tool travels along a trajectory with a sharp angle, the cutting motion direction undergoes a near-abrupt change at the moment of reaching the tip. The actual cutting envelope of the textured edge in the tip region experiences a brief compression or stretching, causing a drastic fluctuation in the density of the textured grooves in that localized area, resulting in a visually perceptible abrupt change from sparse to dense to sparse texture. This abrupt change disrupts the continuity of the textured structure, causing a difference in oil retention or adhesive application capacity near the sharp corner compared to the surrounding uniform area, creating a weak point in the seal. Figure 4The left side shows the rounded transition path constructed in this embodiment. The trajectory at the corner is replaced by a smooth tangent arc with a radius of D / 2 instead of an arbitrary value. This is because this dimension is directly related to the outer contour dimension of the tool, ensuring that when the tool turns along this arc, the spatial trajectory traced by the textured cutting edge on its outer circle is equidistant from the inner and outer boundaries of the corner area. The cutting marks before and after are smoothly connected and seamlessly joined, thus maintaining the same uniform density of the texture in this area as the straight section. It should be noted that although this embodiment uses a radius of D / 2 as the preferred value, in actual machining, as long as the rounded corner radius and the radius of the textured machining tool are matched, and the envelope transition of the tool at the turn does not produce abrupt accumulation, a similar effect can be achieved. A slight deviation of the radius from D / 2 within a reliable empirical range is also feasible.

[0041] In actual machining of closed-loop trajectories, to avoid large areas of overlapping or disordered textures at the tool entry and exit points, this embodiment also features a specially reinforced tool entry and exit path design. The tool entry and exit directions are controlled to be perpendicular to the normal of the cutting trajectory. An arc entry method is used, with the radius of the entry arc being half the diameter of the tool. Furthermore, the entry and exit distance W1 is controlled to be 0.3 times the diameter of the tool. Using a normal-perpendicular entry and exit direction ensures that the tool's motion vector is orthogonal to the extension direction of the existing texture when approaching and leaving the workpiece surface, avoiding repeated scraping of long-distance textures during parallel entry, thereby significantly reducing the area of ​​overlapping textures during entry and exit. The radius of the arc entry is D / 2, consistent with the aforementioned corner radius value. This ensures that the tool gradually contacts the surface with a smooth arc adapted to its own size before entering the cutting state, rather than a straight-line impact insertion. This helps protect the textured cutting tip and allows the initial textured grooves to smoothly support the main body of the trajectory. The tool approach / retract distance is set to 0.3D, which controls the length of the ineffective area with overlapping textures and poor texture quality on the mating surface within an extremely narrow band, minimizing the impact on the sealing mating surface. Even in some non-matting boundary areas that still require a certain sealing effect, high texture quality can be enjoyed due to this compact tool approach / retract distance setting. It should be understood that the tool approach / retract distance value of 0.3D is an optimized result to ensure the minimization of the ineffective area. When machining conditions are limited by workpiece geometry or clamping constraints, using values ​​higher than this can also achieve the engineering goal of reducing the ineffective area.

[0042] By transforming the turning point into a tangent fillet that matches the tool size, and combining it with a circular arc entry and exit mechanism with perpendicular normal, this embodiment supplements the micro-level texture guarantee means on the basis of the aforementioned macro-bias trajectory control, so that the surface of the finally machined workpiece has a highly consistent uniform texture from the whole to the local, from the internal continuous area to the boundary entry and exit area.

[0043] Example 4: This embodiment further elaborates on the specific structure and parameter matching relationship of the textured machining tool, providing hardware support at the execution carrier level for any of the aforementioned embodiments.

[0044] Combination Figure 2 The tool structure shown includes a main cutting edge and multiple circumferentially distributed grooving edges for patterning. The main cutting edge is responsible for cutting the substrate of the machined surface, determining the overall flatness and bottom surface smoothness of the machined surface. The grooving edges are specifically used to carve grooves into the cut substrate; their shape, number, distribution, and height directly determine the final geometry of the grooves and the machining efficiency.

[0045] The uniform distribution of the forming blades along the circumference is not merely for structural symmetry, but is closely related to the kinematic principles revealed in the aforementioned embodiments. When multiple forming blades are arranged at equal angular intervals on the circumference of the tool, each full rotation of the tool results in groove imprints equal to the number of forming blades being simultaneously formed on the workpiece surface. Assuming the number of mesh stripes to be processed per unit length is n, and the number of forming blades is a, the feed per tooth can be set as the product of a and n. Compared to the single-blade case, the feed rate is increased several times, and the processing efficiency is correspondingly greatly improved. Moreover, since the circumferential positions of each forming blade are strictly equally divided, the relationship between the imprint spacing of adjacent blades and the feed per tooth remains stable when they rotate to the same position. This ensures that the grooves maintain a uniform spacing and prevents the consistency of the texture from being destroyed by parallel processing of multiple blades.

[0046] The height difference between the forming edge and the main cutting edge is equal to the preset texture depth. This preset texture depth typically originates from the workpiece drawing's design requirements for the sealing performance of the mating surface, such as the explicit specification of the depth of an oil reservoir or adhesive application groove. When the forming edge is a certain height h higher than the main cutting edge, and this height precisely corresponds to the texture depth required by the drawing, the tool can simultaneously complete two machining steps in a single pass: base finishing and texture groove engraving. The main cutting edge cuts out the planar base, and the subsequent forming edge engraves grooves of a predetermined depth on this base, thus ensuring that the groove depth is uniform across the entire machined surface and unaffected by minor fluctuations in the base.

[0047] In terms of height control, it is particularly crucial that the height difference of all main cutting edges be kept within 0.01mm, and the height difference between multiple textured forming edges is also controlled within this tolerance zone. The former determines the quality of the base plane. If the individual heights of the main cutting edges are inconsistent, wavy tool marks will appear on the machined base, causing the depth of the textured forming edges to vary accordingly, ultimately forming textures of varying depths. The latter directly determines the consistency of the depth direction of multiple parallel textured grooves. Even a slight height deviation between the forming edges will result in a systematic difference in the depth of different grooves on the same machined surface, leading to uneven filling depth of the sealing medium and directly affecting the uniformity of the sealing performance.

[0048] The textured forming blade uses a V-shaped insert with a tip radius of less than 0.4 mm and a blade angle of 30°. The V-shaped cross-section design allows the forming blade to create a micro-groove with an approximately V-shaped cross-section when it cuts into the workpiece. Compared to rectangular or arc-shaped grooves, this V-shaped groove's narrow opening and wide belly geometry is more conducive to storing grease or sealant. During gasket pressing, the medium inside the groove is less likely to be squeezed out, resulting in better oil retention and sealant retention. The tip radius is controlled below 0.4 mm to ensure a sufficiently sharp and clear groove bottom, avoiding blurring of the groove bottom and reduction in effective groove depth due to excessively large fillets. The 30° blade angle represents an engineering balance between cutting resistance, edge strength, and groove cross-sectional shape—an angle that is too small would make the edge too weak and prone to chipping, while an angle that is too large would make the groove too open, reducing oil storage capacity. In actual production, based on the specific material characteristics of the workpiece, adaptive fine-tuning can be made on this parameter basis. For example, for aluminum alloys with strong plasticity, a smaller cutting tip radius can be used to obtain a sharper groove shape, while for cast iron materials with high hardness, the cutting tip radius can be increased to enhance the impact resistance of the cutting edge. However, all of these should not exceed the parameter framework defined in this embodiment.

[0049] Example 5: The above embodiments all focus on tool selection and cutting trajectory planning during textured surface processing. However, in actual mass production, in addition to the core control logic mentioned above, the original state of the surface to be processed also has a significant impact on the final texture quality. This embodiment further elaborates on the preparatory procedures before textured surface processing and the process adaptation for different material scenarios.

[0050] Before performing mesh machining on the surface to be machined using a cutting tool controlled according to the cutting trajectory, the surface is rough-machined to ensure that the rough-machined surface has a allowance greater than 0.15mm and a flatness less than 0.1mm. This pre-machining treatment is necessary because the rough surfaces of cast or forged workpieces often have a thick oxide layer, microscopic undulations, and even tiny sand holes, resulting in significant differences in rigidity. If mesh cutting is performed directly without rough machining, the brittle and hard surface will severely wear down the V-shaped tip of the mesh forming edge, causing the mesh depth to gradually change between the initial and later stages of machining; while the wavy error of the substrate itself directly causes the cutting depth of the forming edge to fluctuate with the workpiece contour. Only by completely removing the surface oxide layer through rough machining and leaving a uniform and dense substrate material can the subsequent precision mesh forming edge face a workpiece material with uniform mechanical properties during each cut. The allowance is kept constant at over 0.15mm because if the allowance is too thin, oxide scale or casting defects may remain in some localized recessed areas, resulting in insufficient depth of the texture or isolated spots, thus disrupting the continuous texture coverage required for sealing. Controlling the roughing flatness to less than 0.1mm provides a cutting reference with extremely high straightness for the textured cutting edge, ensuring consistency in the actual depth of cut for each tooth. It is important to understand that the height difference between multiple textured cutting edges is strictly controlled within a very small tolerance zone during tool manufacturing. If the undulation of the substrate itself approaches or exceeds this tolerance zone, some teeth will be excessively embedded in the material and suffer severe impact, leading to chipping. Other teeth may only slightly glide across the surface, forming shallow or even missing textures. The resulting textured surface will appear macroscopically uneven and discontinuous, which is unacceptable for sealing.

[0051] Furthermore, this embodiment also covers a systematic adaptation strategy for different workpiece materials. The material type of the workpiece is determined. When the material type is aluminum alloy, the tip radius of the textured cutting tool is controlled to be less than a preset radius threshold, and the roughing allowance is controlled to be less than a preset allowance threshold. When the material type is cast iron, the tip radius of the textured cutting tool is controlled to be greater than or equal to a preset radius threshold. The fundamental reason for this differentiated treatment lies in the differences in the physical properties of the materials. Aluminum alloy, as a typical ductile material, has high elongation and large cutting deformation, and is prone to plastic flow when squeezed by the tool tip. If a V-shaped insert with an excessively large tip radius is selected at this time, the blunt, rounded cutting edge will be unable to effectively "plow" out sharp and clear grooves. Instead, it will push the material to both sides of the groove, forming a blurred and irregular textured boundary. At the same time, if the roughing allowance is too large, it will also exacerbate the material softening and sticking phenomenon caused by the accumulation of cutting heat, deteriorating the surface quality. Therefore, for aluminum alloy, it is appropriate to actively favor a smaller tip radius and appropriately compress the roughing allowance to obtain a sharp and distinct textured groove morphology. Conversely, cast iron, with its high hardness, brittleness, and graphite inclusions, produces a discontinuous, fragmented cutting process, subjecting the cutting tip to far more severe impact loads than aluminum alloys. When the cutting tip radius is too small, the sharp edge is highly susceptible to microscopic chipping or even macroscopic breakage under high-frequency impacts, drastically reducing its service life. In such applications, increasing the cutting tip radius essentially sacrifices some groove sharpness for a significant increase in edge impact resistance, thus meeting the demands of long-term stable machining.

[0052] This can be understood as follows: the aforementioned roughing pretreatment and material differentiation and adaptation are not isolated conventional process choices, but rather, together with the technical features described in other embodiments, constitute a precise systematic control closed loop. Without the flat and rigid base provided by roughing, the precision advantages of tool path planning and multi-blade efficient cutting would lose their foundation; while the differentiated parameter configurations for different materials build a practical bridge for mass production between aluminum alloys and cast iron materials commonly used in transmission housings.

[0053] Example 6: In the above embodiments, the control of the textured machining tool is not only reflected in the macroscopic path and microscopic angle, but also rooted in the rigorous laws of its microscopic kinematics. This section further explains the formation mechanism of the texture from the perspective of kinematic principles.

[0054] The execution of textured machining is essentially a composite superposition of two basic motions. In this embodiment, the textured forming edge of the textured machining tool is controlled to rotate circumferentially, and the tool itself is controlled to move along the cutting trajectory to form a composite motion. It is this linkage between rotation and translation that makes the trajectory of a single forming edge on the workpiece surface not a simple straight line or arc, but a spatial curve with a specific undulating pattern. Multiple adjacent or intersecting curves eventually interweave to form a regular cross-textured pattern.

[0055] To facilitate quantitative understanding, combined with Figure 1 As shown, assuming the tool cuts along the X direction, the trajectory of a single textured cutting edge on the cutting surface can be described by the following kinematic equation: In the formula, Radial position coordinates, Let be the lateral position coordinate, D be the tool diameter, θ be the tool rotation angle, and Fz be the displacement of the tool in the X direction per revolution. Intuitively, this equation consists of two parts: the first term represents the projection component of the forming edge in the X direction when it moves in a circle around the tool axis, and the second term represents the continuous feed of the tool as a whole along the cutting direction. The superposition of these two terms forms a continuous imprint, which is an undulating curve with a clear cycle period.

[0056] The cycle period T of this curve is equal to the 360° change in rotation angle. In other words, each time the tool completes one full rotation, the forming edge undergoes a complete motion cycle. More importantly, for any two positions separated by one cycle T, i.e., θ takes a certain value... and At this point, the cosine component of the first term in the equation returns to the same value, while the second term accumulates an increase of exactly one Fz. This means that the advancing distance of the forming edge along the cutting direction is always equal to Fz, and the distance along the Y direction also coincides at equal intervals. In other words, the precise distance between the mesh stripes left on the workpiece surface in the X direction is the feed per revolution Fz. The cyclic distance of the mesh trajectory formed by a single mesh forming edge in the direction of the cutting trajectory is equal to the feed per revolution of the mesh machining tool.

[0057] This mathematical foundation is fundamental to the controllability of the uniformity of the weave pattern. Because the periodic distance of the trajectory is strictly locked to Fz, and Fz can be precisely set through tool parameters (e.g., the number of forming edges a multiplied by the number of weave stripes per unit length n), the spacing between each weave strip remains constant, unaffected by changes in workpiece geometry or the curvature of the cutting path. This also further confirms the reason mentioned earlier that the forming edges must be strictly and uniformly distributed along the circumference—when the forming edges are arranged at equal angular intervals, the imprints produced by each edge in any position are synchronized at the periodic point. If the circumferential distribution is uneven, individual imprints will be misaligned within the period, thus disrupting the row spacing consistency maintained by Fz.

[0058] Through the explanation and derivation of the above kinematic equations, this method clarifies the formation conditions of uniform mesh patterns from a fundamental perspective, and eliminates any attempt to circumvent the protection scope of this method by claiming to fine-tune the motion curve or change the tool rotation strategy.

[0059] It should be noted that any parts not disclosed or specifically described in this invention are existing technology or conventional configurations, and their specific structures and working principles will not be elaborated further. In this document, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes that element.

[0060] Although embodiments of the present invention have been disclosed above, they are not limited to the applications listed in the specification and embodiments. It can be applied to various fields suitable for the present invention. Other modifications can be readily implemented by those skilled in the art. Therefore, without departing from the general concept defined by the claims and their equivalents, the present invention is not limited to the specific details and examples shown and described herein.

Claims

1. A method for processing a textured surface on a workpiece, characterized in that, include: The diameter of the textured surface tool is determined based on the width of the surface to be processed. The textured surface tool is a rotary tool, and its diameter is greater than 8.3 times the width of the surface to be processed. The offset distance of the cutting trajectory relative to the centerline of the surface to be machined is set so that the phase angle of the resulting mesh pattern is within a preset uniform range. The offset distance is 0.34 to 0.35 times the diameter of the mesh pattern machining tool. The turning points of the cutting trajectory are transformed into tangent fillets, and the radius of the tangent fillets is half the diameter of the textured cutting tool. The textured cutting tool moves according to the cutting trajectory.

2. The method for processing a textured surface on a workpiece according to claim 1, characterized in that, The preset uniform range is 35° to 55°.

3. The method for processing a textured surface on a workpiece according to claim 2, characterized in that, The cutting trajectory is biased towards the outer side of the surface to be machined; or, the cutting trajectory is biased towards the inner side of the surface to be machined, and the radius of rotation of the textured machining tool is smaller than the basic contour radius of the machining cavity.

4. The method for processing a textured surface on a workpiece according to claim 1, characterized in that, The turning points include cusps and / or self-intersections.

5. The method for processing a textured surface on a workpiece according to claim 4, characterized in that, The method further includes: The feed and retraction directions of the textured cutting tool are controlled to be perpendicular to the normal of the cutting trajectory; The cutting is performed using an arc-shaped entry method, and the radius of the entry arc is half the diameter of the textured cutting tool; The advance and retraction distance is controlled to be 0.3 times the diameter of the textured tool.

6. The method for processing a textured surface on a workpiece according to claim 1, characterized in that, The textured machining tool includes a main cutting edge and multiple textured forming edges evenly distributed along the circumference. The height difference between the textured forming edge and the main cutting edge is equal to the preset texture depth; The feed per tooth of the textured cutting tool is equal to the product of the number of textured forming blades and the number of textured stripes per unit length.

7. The method for processing a textured surface on a workpiece according to claim 6, characterized in that, The step of controlling the textured surface machining tool to perform textured machining on the surface to be machined according to the cutting trajectory includes: The texturing forming edge of the textured machining tool is controlled to rotate circumferentially, and the main cutting edge is controlled to move along the cutting trajectory to form a compound motion; Wherein, the cyclic distance of the mesh pattern trajectory formed by a single mesh forming edge in the direction of the cutting trajectory is equal to the feed per revolution of the main cutting edge.

8. A method for processing a textured surface on a workpiece according to claim 6, characterized in that, The textured cutting edge uses a V-shaped blade with a blade tip radius of less than 0.4 mm and a blade angle of 30°. The height difference of all the main cutting edges is within 0.01 mm, and the height difference of multiple of the textured forming edges is less than 0.01 mm.

9. A method for processing a textured surface on a workpiece according to claim 1, characterized in that, Before controlling the textured surface machining tool to perform textured machining on the surface to be machined according to the cutting trajectory, the method further includes: The surface to be processed is rough-machined so that the rough-machined surface has a allowance greater than 0.15 mm and a flatness of less than 0.1 mm.

10. A method for processing a textured surface on a workpiece according to claim 1, characterized in that: When the material type is aluminum alloy, the tip radius of the textured machining tool is controlled to be less than a preset radius threshold, and the roughing allowance is controlled to be less than a preset allowance threshold. When the material type is cast iron, the tip radius of the textured cutting tool is controlled to be greater than or equal to the preset radius threshold.

Images