A machining center-based complex casting part deburring process method and system

Abstract

The present application relates to numerical control machining and automation deburring technical field, disclose a kind of complex casting parts deburring process method based on machining center, comprising the following steps: S1, deburring quantification and analysis;S2, multi-tool path programming;S3, weave deburring main program;S4, establish tool life threshold demonstration and double error-proof mechanism;S5, process lock and standardization;S6, automatic execution and closed-loop quality inspection.The present application completely gets rid of artificial dependence, and solidifies deburring process into standard process file and locks, and operator only needs to clamp and start, solves the industry crisis of grinding worker shortage;Double error-proof mechanism eliminates management loopholes, and counting macro program not only realizes tool life expiration forced locking, but also compares the size deviation of new tool and old tool, technically eliminates the illegal operation of operator " only zeroing without changing tool", ensures that every tool is used within its effective life, and guarantees the stable and reliable deburring quality.

Description

Technical Field

[0001] This invention relates to the field of CNC machining and automated deburring technology, specifically to a deburring process and system for complex cast parts based on a machining center. Background Technology

[0002] Taking the hydraulic travel motor cover as an example of cast iron parts, burrs are mostly concentrated at the intersection lines of intersecting holes and on the inner walls of narrow holes. When deburring manually, the operator needs to hold a flashlight in one hand and a file in the other to polish by feel, which is labor-intensive and results in poor quality consistency.

[0003] Existing automation solutions have the following core defects: robots or large five-axis special machines are expensive and lack flexibility; a few tool-changeable solutions lack tool life management and error prevention mechanisms, and operators often fail to change tools on time, resulting in a decrease in removal rate; manual grinding generally adopts dry machining, and the grinding shavings of cast iron parts mix with residual cutting fluid to form black sludge, which is difficult to clean. Summary of the Invention

[0004] The technical problem to be solved by this invention is that existing automated deburring solutions suffer from high costs and lack of error prevention mechanisms.

[0005] To solve the above-mentioned technical problems, the technical solution of the present invention is to provide a deburring process method for complex cast parts based on a machining center, comprising the following steps:

[0006] S1. Burr Quantification and Analysis The location, shape, and size of burrs at various points on the target workpiece are quantitatively labeled, and a burr feature data table for the workpiece is established. S2, Multi-toolpath Programming Based on the burr feature data table established in S1, multiple multi-axis linkage path subroutines corresponding to various deburring tools are generated using CAM software. Each subroutine targets a specific burr feature area. S3, Deburring Main Program Compile the main program for deburring, and call all path subroutines according to the process sequence to form a complete processing sequence. S4. Establish empirical evidence for tool life threshold and a dual error prevention mechanism. Multiple rounds of cutting tests were conducted. After each round of tests, the workpiece was observed and reviewed, and the deburring effect was measured. Based on the review results, the service life threshold of each tool was gradually determined. The determined service life threshold was written into the counting macro program. S5, Process Lockout and Standardization Save the deburring main program and counting macro program that have passed the verification in step S4 as the unique standard process file for the target workpiece, and edit and lock the deburring main program and counting macro program. S6. Automated Execution and Closed-Loop Quality Inspection After the operator clamps the workpiece, the machining center starts automatically and completes deburring under the control of the locked standard process document. After machining, it enters the routine inspection stage. If an abnormality is detected, it is fed back to S4 for troubleshooting and correction of the corresponding parameters, forming a closed-loop feedback.

[0007] Optionally, in S4, different management strategies are adopted according to the wear characteristics of the tool: for tools whose performance drops sharply after reaching the service life threshold and are not suitable for continued use, only the service life threshold is set, and no wear compensation value is set; for tools with progressive wear, both the service life threshold and the preset wear compensation value are set, and the automatic tool compensation subroutine of the CNC system writes them into the tool bias register before each machining operation.

[0008] Optionally, in S6, when executing the deburring program, the machining center cutting fluid is simultaneously turned on for wet machining. The closed-loop feedback is only triggered in case of occasional abnormalities, and the quality inspection process captures these occasional abnormalities.

[0009] Optionally, the counting macro program is configured such that: each time a tool is called, the corresponding macro variable is incremented by 1; when the cumulative number of uses of any tool reaches its lifespan threshold, the CNC system triggers an alarm and automatically locks the program, prohibiting further machining; the program can only be unlocked and run after the tool is replaced and the tool's lifespan count is manually cleared on the CNC system interface.

[0010] Optionally, the counting macro program also includes a size deviation judgment instruction: after a new tool is replaced, the system reads or the operator inputs the initial size of the new tool and compares it with the final size of the previous tool when it reaches its lifespan; if the size deviation between the new and old tools does not exceed the preset range, it is determined that the operator has not replaced the tool correctly, and the system continues to alarm and remains locked.

[0011] Optionally, the locked state does not restrict access to routine equipment maintenance or tool replacement.

[0012] A deburring process system for complex cast parts based on a machining center includes a machining center body, which is equipped with a tool magazine, a CNC system, and a rotary table. The tool magazine contains a variety of deburring tools, including a chamfering tool, a ball end cutter, a diamond carbon brush, and an end face brush. The turntable is an A-axis turntable or a B-axis turntable, used to clamp the workpiece and drive the workpiece to swing at a preset angle. The CNC system stores a deburring main program and a counting macro program corresponding to the target workpiece, as well as multiple path subroutines generated by CAM software corresponding to each deburring tool. The deburring main program gathers and calls all path subroutines in process order, and drives the turntable to swing along the path defined by the subroutines, so that the selected tools remove burrs in sequence.

[0013] Optionally, the CNC system integrates an automatic tool compensation subroutine and a life management subroutine; the life management subroutine is configured to manage the number of times each tool is called, manage life threshold alarms and lockouts, and manage the dimensional comparison judgment of tool change authenticity.

[0014] Optionally, the tool magazine also houses a floating spring bar tool. The tool head of the floating spring bar tool is made of alloy material, and the tool shank is made of spring steel. The tool head and the tool shank are connected by welding and extended. During processing, the tool head is allowed to elastically float slightly as the burr allowance changes.

[0015] Optionally, the CNC system's operating interface only displays the start button, emergency stop button, and current machining step prompt.

[0016] In summary, the present invention has at least one of the following beneficial effects: 1. Completely eliminate reliance on manual labor, solidify the deburring process into a standard process document and lock it in, and the operator only needs to clamp and start, solving the industrial crisis of grinding labor shortage.

[0017] 2. A dual error prevention mechanism eliminates management loopholes. The counting macro program not only forcibly locks the tool when its lifespan expires, but also technically prevents operators from "only zeroing the tool without changing it" by comparing the size deviation between the new and old tools. This ensures that each tool is used within its effective lifespan and guarantees the stable and reliable quality of deburring.

[0018] 3. Differentiated tool management strategy: Different life management methods are adopted for scrapped tools such as chamfering tools and progressively worn tools such as carbon brushes. This avoids ineffective compensation and ensures the deburring effect of key parts.

[0019] 4. Wet machining solves the cleanliness problem. Cutting fluid is turned on simultaneously with grinding and polishing, eliminating the black sludge produced by dry grinding of cast iron parts and meeting the high cleanliness requirements of hydraulic components.

[0020] 5. Closed-loop quality inspection defends against occasional anomalies. The quality inspection process is dedicated to capturing occasional anomalies, forming a defensive closed loop. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the overall structure of the deburring process system for complex cast parts based on a machining center according to the present invention. Figure 2This is a partially enlarged view of the deburring process where the turntable drives the workpiece to swing. Figure 3 This is a schematic diagram of the reverse chamfering tool structure; Figure 4 This is a schematic diagram of the ball end mill structure; Figure 5 This is a schematic diagram of a diamond carbon brush structure; Figure 6 This is a schematic diagram of the end-face brush structure; Figure 7 This is a schematic diagram of a floating spring bar knife structure; Figure 8 This is a flowchart of the deburring process method for complex cast parts based on a machining center according to the present invention. In the diagram: 1. Machining center body; 2. Turntable; 3. Tool magazine; 4. CNC system; 5. Reverse chamfering tool; 6. Ball end mill; 7. Diamond carbon brush; 8. End face brush; 9. Workpiece; 10. Floating spring bar tool. Detailed Implementation

[0022] The following combination Figure 1-8 The present invention will be described in further detail below.

[0023] This invention discloses a deburring process system for complex cast parts based on a machining center, referring to... Figure 1-7 It includes a machining center body 1, which is equipped with a tool magazine 3, a CNC system 4, and a rotary table 2. The tool magazine 3 contains a variety of deburring tools, including a reverse chamfering tool 5, a ball end cutter 6, a diamond carbon brush 7, and an end face brush 8; Among them, the chamfering tool 5 is directly replaced after reaching its lifespan threshold, without any wear compensation value; the diamond carbon brush 7 and the end face brush 8 are equipped with wear compensation values. The tool magazine 3 also contains a floating spring bar tool 10. The tool head of the floating spring bar tool 10 is made of alloy material, and the tool bar is made of spring steel. The tool head and the tool bar are connected by welding and extended. During processing, the tool head is allowed to elastically float slightly as the burr allowance changes. Turntable 2 is an A-axis turntable or a B-axis turntable, used to clamp workpiece 9 and drive workpiece 9 to swing at a preset angle. In other embodiments, the turntable 2 may be omitted, and three-axis machining may be used instead, with the path subroutine correspondingly being a three-axis linkage or four-axis linkage path subroutine.

[0024] The CNC system 4 stores the deburring main program and counting macro program corresponding to the target workpiece, as well as multiple path subroutines generated by the CAM software corresponding to each deburring tool. The deburring main program gathers and calls all path subroutines in the process sequence, and drives the rotary table 2 to swing along the path defined by the subroutines, so that the selected tools remove burrs in sequence. The CNC system 4 integrates an automatic tool compensation subroutine and a life management subroutine. The life management subroutine is configured to manage the number of times each tool is called, manage the life threshold alarm and lock, and manage the dimensional comparison judgment of the tool change authenticity. The operation interface of the CNC system 4 only displays the start button, the emergency stop button, and the current machining step prompt.

[0025] This invention also discloses a deburring process for complex cast parts based on a machining center, referring to... Figure 8 This includes the following steps: S1. Burr Quantification and Analysis The location, shape, and size of burrs at various points on the target workpiece are quantitatively labeled, and a burr feature data table for the workpiece is established. S2, Multi-toolpath Programming Based on the burr feature data table established in S1, multiple multi-axis linkage path subroutines corresponding to various deburring tools are generated using CAM software. Each subroutine targets a specific burr feature area. S3, Deburring Main Program Compile the main program for deburring, and call all path subroutines according to the process sequence to form a complete processing sequence. S4. Establish empirical evidence for tool life threshold and a dual error prevention mechanism. Multiple rounds of cutting tests were conducted. After each round of tests, the workpiece was observed and reviewed, and the deburring effect was measured. Based on the review results, the service life threshold of each tool was gradually determined. The determined service life threshold was written into the counting macro program. Different management strategies are adopted according to the wear characteristics of the tool: For tools whose performance drops sharply after reaching the service life threshold and are not suitable for continued use, only the service life threshold is set and no wear compensation value is set; for tools with progressive wear, both the service life threshold and the preset wear compensation value are set, and the automatic tool compensation subroutine of the CNC system writes them into the tool bias register before each machining. S5, Process Lockout and Standardization Save the deburring main program and counting macro program that have passed the verification in step S4 as the unique standard process file for the target workpiece, and edit and lock the deburring main program and counting macro program. S6. Automated Execution and Closed-Loop Quality Inspection After the operator clamps the workpiece, the machining center starts automatically under the control of the locked standard process document. When the deburring program is executed, the cutting fluid of the machining center is turned on at the same time for wet machining to prevent the grinding chips from mixing with the residual cutting fluid to form sludge and improve the cleanliness of the workpiece. After processing, the process enters the routine inspection stage; if an abnormality is detected, it is fed back to S4 for investigation and correction of the corresponding parameters, forming a closed-loop feedback; the closed-loop feedback is only triggered in the event of an occasional abnormality, and the quality inspection stage captures occasional abnormalities.

[0026] In a further implementation, the counting macro program is configured such that: each time a tool is called, the corresponding macro variable is incremented by 1; when the cumulative number of uses of any tool reaches its lifespan threshold, the CNC system triggers an alarm and automatically locks the program, prohibiting further machining; the program can only be unlocked and run after the tool is replaced and the tool's lifespan count is manually cleared on the CNC system interface. The counting macro program also includes a size deviation judgment instruction: after a new tool is replaced, the system reads or the operator inputs the initial size of the new tool and compares it with the final size of the previous tool when it reaches the end of its lifespan; if the size deviation between the new and old tools does not exceed the preset range, it is determined that the operator has not replaced the tool correctly, the system will continue to alarm and remain in a locked state, the locked state does not restrict the daily maintenance of the equipment, tool replacement, and other routine operation permissions.

[0027] Example This embodiment uses the hydraulic walking motor cover as the target workpiece. The part is made of cast iron and has two sets of orthogonal through holes and an irregular outer contour. 23 burr feature areas are quantitatively marked.

[0028] The specific deburring process is as follows: S1. Establish a burr feature data table, some examples are as follows:

[0029] S2. Based on the data table, use CAM software to generate multiple three-axis and four-axis linkage path subroutines. Among them, the reverse chamfering cutter 5, ball end cutter 6, and floating spring bar cutter 10 adopt four-axis linkage paths, while the end face brush 8 adopts a three-axis planar path; S3. Write the main program O8003, following the process sequence of reverse chamfering cutter → ball end cutter → diamond carbon brush → end face brush → floating spring bar cutter, and use the M98 command to call the subroutines of each path. S4. Conduct three rounds of testing: 150 pieces in the first round, 300 pieces in the second round, and 500 pieces in the third round; The lifespan threshold for the chamfering tool 5 was ultimately determined to be 500 cycles (without compensation), the compensation value for the diamond carbon brush 7 was 0.1 mm, the single-cycle compensation threshold was 50 pieces, and the total threshold was 600 cycles. The compensation value for the end face 8 was 0.1 mm, the single-cycle compensation threshold was 50 pieces, and the total threshold was 1500 cycles. Each threshold was written into the counting macro program. The counting macro program logic is as follows: Each time a tool is called, the corresponding macro variable is incremented by 1; when the reverse chamfering tool 5 has been called 500 times, an alarm is triggered and the system is locked; the operator manually resets the count after replacing the tool; the system reads the initial length of the new tool (210.5mm) and compares it with the length of the previous tool (209mm). If the system's set deviation value is greater than 2mm, and the deviation of 1.5mm does not exceed the preset 2mm threshold, the system remains locked and alarms "No valid tool change detected," until the tool is correctly replaced and the new tool size is entered, at which point the system unlocks; after processing 2000 pieces, no unauthorized tool change bypassing events have occurred. S5. Set the main program O8003 and the counting macro program to read-only, and generate the standard process document SOP-HM-001; the operator's daily permissions for tool changing, tool pattern modification, equipment maintenance, etc., will not be affected; S6. After the operator clamps and starts the machine, the system automatically completes the deburring process. The diamond carbon brush 7 and end face brush 8 stages are wet-processed throughout the entire process. No abnormal burr residue was found during the continuous production of 2000 pieces. For the junction of the through hole and the blank (size number 4), this embodiment uses a floating spring bar cutter 10 as an auxiliary tool. The burrs at this location are of varying sizes. The elasticity of the floating cutter head allows the cutter to move and return to its original position, resulting in a removal rate of over 96%. However, this floating cutter is not a necessary feature. When the burr consistency is good, a conventional cutter can be used.

[0030] Actual measurements show that automatic deburring takes about 11 minutes per piece, which is comparable to the 10-12 minutes required for manual deburring, and the cleanliness of the workpiece is significantly better than that of dry grinding.

[0031] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A deburring process for complex cast parts based on a machining center, characterized in that, Includes the following steps: S1. Burr Quantification and Analysis The location, shape, and size of burrs at various points on the target workpiece are quantitatively labeled, and a burr feature data table for the workpiece is established. S2, Multi-toolpath Programming Based on the burr feature data table established in S1, multiple multi-axis linkage path subroutines corresponding to various deburring tools are generated using CAM software. Each subroutine targets a specific burr feature area. S3, Deburring Main Program Compile the main program for deburring, and call all path subroutines according to the process sequence to form a complete processing sequence. S4. Establish empirical evidence for tool life threshold and a dual error prevention mechanism. Multiple rounds of cutting tests were conducted. After each round of tests, the workpiece was observed and reviewed, and the deburring effect was measured. Based on the review results, the service life threshold of each tool was gradually determined. The determined service life threshold was written into the counting macro program. S5, Process Lockout and Standardization Save the deburring main program and counting macro program that have passed the verification in step S4 as the unique standard process file for the target workpiece, and edit and lock the deburring main program and counting macro program. S6. Automated Execution and Closed-Loop Quality Inspection After the operator clamps the workpiece, the machining center starts automatically and completes deburring under the control of the locked standard process document. After machining, it enters the routine inspection stage. If an abnormality is detected, it is fed back to S4 for troubleshooting and correction of the corresponding parameters, forming a closed-loop feedback.

2. The deburring process method for complex cast parts based on a machining center according to claim 1, characterized in that, In S4, different management strategies are adopted according to the wear characteristics of the tool: for tools whose performance drops sharply after reaching the service life threshold and are not suitable for continued use, only the service life threshold is set and no wear compensation value is set; for tools with progressive wear, both the service life threshold and the preset wear compensation value are set, and the automatic tool compensation subroutine of the CNC system writes them into the tool bias register before each machining operation.

3. The deburring process method for complex cast parts based on a machining center according to claim 1, characterized in that, In S6, when the deburring program is executed, the cutting fluid of the machining center is turned on simultaneously for wet machining. The closed-loop feedback is only triggered in case of occasional abnormalities, and the quality inspection process captures these occasional abnormalities.

4. The deburring process method for complex cast parts based on a machining center according to claim 1, characterized in that, The counting macro program is configured such that: each time a tool is called, the corresponding macro variable is incremented by 1; when the cumulative number of uses of any tool reaches its lifespan threshold, the CNC system triggers an alarm and automatically locks the program, prohibiting further machining; the program can only be unlocked and run after the tool is replaced and the tool's lifespan count is manually cleared on the CNC system interface.

5. The deburring process method for complex cast parts based on a machining center according to claim 4, characterized in that, The counting macro program also includes a size deviation judgment instruction: after a new tool is replaced, the system reads or the operator inputs the initial size of the new tool and compares it with the final size of the previous tool when it reaches its lifespan; if the size deviation between the new and old tools does not exceed the preset range, it is determined that the operator has not replaced the tool correctly, and the system will continue to alarm and remain locked.

6. The deburring process method for complex cast parts based on a machining center according to claim 5, characterized in that, The locked state does not restrict access to routine equipment maintenance or tool replacement.

7. A deburring process system for complex cast parts based on a machining center, implementing the method of any one of claims 1 to 6, characterized in that, The machining center includes a machining center body (1), which is equipped with a tool magazine (3), a CNC system (4), and a rotary table (2). The tool magazine (3) contains a variety of deburring tools, including a chamfering tool (5), a ball end cutter (6), a diamond carbon brush (7), and an end face brush (8). The turntable (2) is an A-axis turntable or a B-axis turntable, used to clamp the workpiece (9) and drive the workpiece (9) to swing at a preset angle; The CNC system (4) stores a deburring main program and a counting macro program corresponding to the target workpiece, as well as multiple path subroutines generated by CAM software corresponding to each deburring tool. The deburring main program gathers and calls all path subroutines in the process sequence and drives the turntable (2) to swing along the path defined by the subroutines, so that the selected tools remove burrs in sequence.

8. The deburring process system for complex cast parts based on a machining center according to claim 7, characterized in that, The CNC system (4) integrates an automatic tool compensation subroutine and a life management subroutine; the life management subroutine is configured to manage the number of times each tool is called, manage the life threshold alarm and lock, and manage the size comparison judgment of the authenticity of tool changing.

9. The deburring process system for complex cast parts based on a machining center according to claim 7, characterized in that, The tool magazine (3) is also equipped with a floating spring bar tool (10). The tool head of the floating spring bar tool (10) is made of alloy material, and the tool bar is made of spring steel. The tool head and the tool bar are connected by welding and lengthened. During processing, the tool head is allowed to elastically float slightly as the burr allowance changes.

10. The deburring process system for complex cast parts based on a machining center according to claim 7, characterized in that, The CNC system (4) operation interface only displays the start button, emergency stop button and current machining step prompt.

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