Integrated processing method for super-precision polishing and texturing of injection mold surface

Abstract

This invention discloses an integrated method for ultra-precision polishing and texturing of injection mold surfaces, belonging to the field of precision mold laser processing technology. The method involves acquiring three-dimensional model data of the injection mold to be processed, extracting the free-form surface topological features of the target processing area based on the three-dimensional model data, and using a five-axis linkage laser processing control device to collect the mold's three-dimensional model data and extract the surface topological features to generate an adaptive path for continuous wave laser-assisted polishing. The true microscopic morphology and roughness of the polished surface are obtained through in-situ optical measurement, and a distortion-free texture processing trajectory is generated through conformal mapping of the surface. Combined with dynamic matching of surface state with ultrafast laser processing parameters, micro-nano biomimetic texture ablation is completed in an integrated manner, and closed-loop compensation for processing errors is achieved through plasma spectral monitoring. This invention realizes a complete process of polishing, measurement, and texturing in a single mold clamping operation, effectively eliminating positioning errors and suppressing surface processing distortion and thermal damage.

Description

Technical Field

[0001] This invention relates to the field of precision mold manufacturing and laser surface modification technology, specifically a method for ultra-precision polishing and integrated texturing of injection mold surfaces. Background Technology

[0002] With the technological iteration in fields such as automotive intelligent lighting, consumer electronics optical devices, and high-end medical devices, the requirements for the appearance precision, optical performance, and surface functional properties of polymer injection molded products are constantly increasing. The surface gloss, micro-nano texture precision, and hydrophobic anti-glare function of injection molded products depend entirely on the surface processing quality of the injection mold cavity. The polishing precision and texture forming precision of the mold cavity directly determine the yield rate and performance of the end product.

[0003] Current injection mold surface processing generally employs a segmented, discrete processing system. The process flow is as follows: macroscopic shaping of the mold steel substrate is achieved through CNC milling and EDM; then, the mold cavity is mirror-finished through manual grinding and polishing; finally, the surface texture is processed by laser marking or chemical etching equipment after secondary clamping and transfer. This traditional process system is the industry-standard processing mode, but it has many inherent technical defects and cannot meet the ultra-precision processing requirements of high-end precision injection molds.

[0004] First, manual polishing is highly dependent on the operator's experience, resulting in poor processing consistency. For complex three-dimensional free-form cavities, it is easy to cause local over-grinding or under-grinding, leading to defects such as surface collapse and surface distortion. This results in quality problems such as light scattering and optical distortion in subsequent injection molded products. In addition, manual polishing has a long processing cycle and high labor costs, making it unsuitable for the needs of large-scale precision production.

[0005] Secondly, the polishing and texturing processes are handled by different equipment, requiring the mold to be moved and clamped multiple times, inevitably leading to accumulated errors in the reference positioning. In micro-nano-level texturing scenarios, even micron-level positioning deviations can cause misalignment between the texture pattern and the curvature of the mold surface, resulting in texture distortion and directly causing mold scrapping, making the processing tolerance extremely low.

[0006] Finally, traditional chemical etching processes are highly polluting and lack processing flexibility, making it impossible to achieve three-dimensional micro-nano texture processing with varying depths. Conventional laser engraving processes directly process on mold surfaces with unknown roughness, resulting in large fluctuations in laser energy absorption rates. This can easily lead to uneven texture depth, residual recast layers in the processing area, and heat-affected zones. This not only reduces the flatness of the mold surface but also significantly shortens the mold's lifespan, affecting the stability of injection molding and the consistency of product molding.

[0007] In summary, existing injection mold processing technology suffers from technical shortcomings such as fragmented processes, large positioning errors, low processing accuracy, poor consistency, and weak adaptability. There is a lack of an ultra-precision processing solution that can achieve single-station operation, no secondary clamping, and integrated polishing and micro-nano texturing. Therefore, a method for ultra-precision polishing and texturing of injection mold surfaces is proposed. Summary of the Invention

[0008] The purpose of this invention is to provide a method, apparatus, equipment, and medium for integrated ultra-precision polishing and texturing of injection mold surfaces, solving the technical problems of fragmented polishing and texturing processes, secondary clamping and positioning errors, surface processing distortion, low texture accuracy, and numerous heat-affected defects in existing injection mold processing. This invention achieves integrated ultra-precision polishing and micro-nano texturing of complex free-form injection molds in a single-station, in-situ, and closed-loop manner, thereby improving mold processing accuracy, consistency, and efficiency.

[0009] The first aspect of this invention provides a method for ultra-precision polishing and texturing of an injection mold surface, applied to a five-axis linkage laser processing control device. The method includes: acquiring three-dimensional model data of the injection mold to be processed; extracting free-form surface topological features of the target processing area based on the three-dimensional model data; generating a globally adaptive polishing path based on the free-form surface topological features; controlling a composite processing spindle to perform continuous wave laser-assisted polishing treatment on the target processing area along the globally adaptive polishing path to prepare a preliminary polished surface; and, while the injection mold is held in place, applying an in-situ laser located on the side of the composite processing spindle... The measurement module scans and acquires three-dimensional point cloud data of the initially polished surface, and extracts the actual micro-contour and surface roughness parameters of the initially polished surface. A pre-defined three-dimensional texture pattern is conformally mapped to the three-dimensional point cloud data to generate a spatial texture processing trajectory that fits the actual micro-contour of the initially polished surface. Based on the surface roughness parameters and the spatial texture processing trajectory, the pulse energy and spot overlap rate parameters of the ultrafast laser are dynamically calculated, and the composite processing spindle is controlled to perform ultrafast laser ablation processing on the initially polished surface along the spatial texture processing trajectory, thus integrally forming a micro / nano biomimetic texture structure in the target processing area.

[0010] This invention integrates laser polishing, in-situ precision measurement, conformal surface texture processing, and closed-loop error compensation technology through a single-station in-situ processing architecture. It abandons the traditional segmented discrete processing mode, eliminates the need for secondary clamping and transfer of molds, and achieves integrated closed-loop processing of ultra-precision polishing and micro-nano texture forming by adaptively matching processing parameters and trajectories based on the real curved surface morphology.

[0011] A method for integrated ultra-precision polishing and texturing of injection mold surfaces, applied to a five-axis linkage laser processing control device, includes the following steps:

[0012] Obtain the three-dimensional model data of the injection mold to be processed, and extract the freeform surface topological features of the target processing area based on the three-dimensional model data;

[0013] Based on the freeform surface topological features, a global adaptive polishing path is generated, and the composite machining spindle is controlled to perform continuous wave laser-assisted polishing on the target machining area along the global adaptive polishing path to prepare a preliminary polished surface.

[0014] With the injection mold still clamped in place, the three-dimensional point cloud data of the initial polished surface is scanned and collected by the in-situ optical measurement module located on the side of the composite machining spindle, and the actual micro-profile and surface roughness parameters of the initial polished surface are extracted.

[0015] The preset three-dimensional texture pattern is conformally mapped to the three-dimensional point cloud data to generate a spatial texture processing trajectory that fits the actual microscopic contour of the initial polished surface.

[0016] Based on the surface roughness parameters and the spatial texture processing trajectory, the pulse energy and spot overlap rate parameters of the ultrafast laser are dynamically solved, and the composite processing spindle is controlled to perform ultrafast laser ablation processing on the initially polished surface along the spatial texture processing trajectory, so as to integrally form a micro-nano biomimetic texture structure in the target processing area.

[0017] Furthermore, the step of generating a globally adaptive polishing path based on the freeform surface topological features, and controlling the composite machining spindle to perform continuous wave laser-assisted polishing treatment on the target machining area along the globally adaptive polishing path to prepare a preliminary polished surface, specifically includes:

[0018] Calculate the principal curvature parameters and normal vector parameters corresponding to each sampling point of the freeform surface topological feature;

[0019] The dynamic spot diameter of the continuous wave laser is determined based on the principal curvature parameters of each sampling point. For the convex and concave regions of the surface where the absolute value of the principal curvature is greater than the preset curvature threshold, the dynamic spot diameter is reduced to suppress the over-melting deformation defects at the edge of the surface.

[0020] Based on the normal vector parameters of each sampling point, the yaw angle and pitch angle of the five-axis linkage machining platform are solved, and an equidistant offset polishing path with the laser beam optical axis always perpendicular to the cutting plane of the machining point is constructed as the global adaptive polishing path.

[0021] A laser beam with matched power is controlled to output a continuous wave laser, causing shallow melting of the surface material of the target processing area. The molten pool is driven to flow level by the surface tension and capillary force of the material, and after cooling and solidification, a preliminary polished surface with uniform roughness is obtained.

[0022] Furthermore, while the injection mold remains in its original clamping position, the three-dimensional point cloud data of the initial polished surface is scanned and acquired by an in-situ optical measurement module located on the side of the composite machining spindle, and the actual micro-profile and surface roughness parameters of the initial polished surface are extracted. Specifically, this includes:

[0023] The white light interferometer built into the in-situ optical measurement module is activated, and the interference fringes of the initially polished surface are collected in sections according to the preset sampling grid.

[0024] The phase-shifting algorithm is used to analyze the interference fringe data of each block, and the corresponding local three-dimensional point cloud data of each block is reconstructed.

[0025] The iterative nearest point algorithm is used to perform feature registration and global stitching on the local three-dimensional point cloud data of all blocks, and the fusion is used to obtain the complete three-dimensional point cloud data of the initial polished surface.

[0026] The three-dimensional point cloud data is subjected to low-pass filtering to remove the macroscopic surface contour component and extract the high-frequency surface morphology component. The arithmetic mean deviation of the contour is calculated based on the high-frequency surface morphology component, and the obtained value is used as the surface roughness parameter of the initial polished surface.

[0027] Furthermore, the step of performing conformal mapping between the preset three-dimensional texture pattern and the three-dimensional point cloud data to generate a spatial texture processing trajectory that fits the actual microscopic contour of the initially polished surface specifically includes:

[0028] The three-dimensional point cloud data is parameterized into a non-uniform rational B-spline surface model;

[0029] An energy functional is constructed from the two-dimensional parameter domain to the non-uniform rational B-spline surface. The conformal mapping matrix is ​​solved by minimizing the energy functional to ensure that the local angle of the three-dimensional texture pattern is constant and without distortion during the mapping process.

[0030] Based on the conformal mapping matrix, the pixel coordinates of the three-dimensional texture pattern defined in the two-dimensional plane are converted into three-dimensional spatial coordinates corresponding to the non-uniform rational B-spline surface.

[0031] Based on the matching of all three-dimensional spatial coordinates and corresponding normal vectors, five-axis linkage machining G-code instructions are generated as the machining trajectory of the spatial texture.

[0032] Furthermore, the step of dynamically solving the pulse energy and spot overlap rate parameters of the ultrafast laser based on the surface roughness parameters and the spatial texture processing trajectory specifically includes:

[0033] Determine whether the surface roughness parameter is less than a preset optical grade roughness threshold;

[0034] When the surface roughness parameter is less than the preset optical grade roughness threshold, the preset light-matter interaction two-photon absorption model is retrieved;

[0035] Based on the local curvature change rate of the spatial texture processing trajectory, the equivalent projected area of ​​the ultrafast laser beam on the surface of the mold material is calculated;

[0036] By combining the equivalent projected area, the ablation threshold of the injection mold material, and the preset spot overlap rate parameter, the pulse energy required by the ultrafast laser is calculated using a preset energy density compensation formula to ensure uniform and consistent processing texture depth.

[0037] Furthermore, during the ultrafast laser ablation process performed on the initially polished surface, the method also includes a real-time closed-loop error compensation step:

[0038] Real-time acquisition of plasma plume spectral radiation signals generated during ultrafast laser ablation processing;

[0039] Based on the characteristic spectral line intensities of the spectral radiation signal, the actual material removal rate at the current ablation point is calculated by inversion.

[0040] Calculate the deviation between the actual material removal rate and the preset theoretical material removal rate;

[0041] When the removal rate deviation exceeds the preset tolerance range, the pulse repetition frequency of the ultrafast laser or the feed speed of the composite machining spindle is adjusted in real time through a closed-loop feedback control circuit to achieve online dynamic compensation of machining errors.

[0042] A second aspect of the present invention provides an integrated device for ultra-precision polishing and texturing of injection mold surfaces, the device comprising:

[0043] The data parsing module is configured to acquire the three-dimensional model data of the injection mold to be processed, and extract the free-form surface topological features of the target processing area based on the three-dimensional model data;

[0044] The adaptive polishing module is configured to generate a global adaptive polishing path based on the freeform surface topology features, and control the composite machining spindle to perform continuous wave laser-assisted polishing treatment on the target machining area along the global adaptive polishing path to prepare a preliminary polished surface.

[0045] The in-situ measurement module is configured to scan and acquire the three-dimensional point cloud data of the initial polished surface through the in-situ optical measurement module on the side of the composite machining spindle while the injection mold is kept in the in-situ clamping state, and extract the actual micro-contour and surface roughness parameters of the initial polished surface.

[0046] The conformal mapping module is configured to perform conformal mapping between a preset 3D texture pattern and 3D point cloud data to generate a spatial texture processing trajectory that fits the actual microscopic contour of the initial polished surface.

[0047] The texture processing module is configured to dynamically solve the pulse energy and spot overlap rate parameters of the ultrafast laser based on the surface roughness parameters and the spatial texture processing trajectory, and control the composite processing spindle to perform ultrafast laser ablation processing along the spatial texture processing trajectory to form an integrated micro-nano biomimetic texture structure.

[0048] Furthermore, the device is configured with a low-level mechanical and sensing hardware architecture, which includes a five-axis linkage CNC machining platform, a gantry frame, and a composite machining spindle.

[0049] The composite machining spindle integrates a coaxial optical path switching module, which is connected to a continuous wave fiber laser and an ultrafast laser respectively, and is used to realize millisecond-level light source switching between the polishing process and the texture processing process.

[0050] The in-situ optical measurement module is suspended and mounted on the side of the composite machining spindle via a high-precision pneumatic slide. After the polishing process is completed, it is driven down to the measurement station by the pneumatic slide. During the machining process, it moves up and retracts into the protective structure, realizing the adaptive switching between the protection of the measurement module and the station. The device also includes a closed-loop monitoring and compensation module.

[0051] The closed-loop monitoring and compensation module is configured to collect plasma plume spectral radiation signals in real time during the ultrafast laser ablation process, and calculate the real-time material removal rate based on the intensity of spectral characteristic lines.

[0052] The closed-loop monitoring and compensation module is also configured to output a numerical control compensation command when the deviation between the actual material removal rate and the theoretical material removal rate exceeds the preset tolerance range, thereby adjusting the pulse repetition frequency of the ultrafast laser and the spindle feed speed in real time to complete the closed-loop compensation of the processing error.

[0053] An integrated ultra-precision polishing and texturing device for injection mold surfaces is used to implement the above-mentioned processing method. It includes a data analysis module, an adaptive polishing module, an in-situ measurement module, a conformal mapping module, a texture processing module, and a closed-loop monitoring and compensation module. The modules work together to complete the entire process of mold surface feature analysis, adaptive laser polishing, in-situ morphology detection, texture trajectory reconstruction, ultrafast laser texture processing, and online error compensation.

[0054] A third aspect of the present invention provides an electronic device, including a memory and a processor, wherein the processor executes a computer program stored in the memory, which can implement all the steps of the aforementioned method.

[0055] A fourth aspect of the present invention provides a computer-readable storage medium storing computer program instructions, which, when executed by a processor, can implement all the steps of the aforementioned method.

[0056] Beneficial effects of this invention:

[0057] Compared with the prior art, the present invention has the following substantial innovations and beneficial effects:

[0058] 1. This invention relies on a five-axis linkage composite machining platform, integrating multi-functional modules for polishing, measurement, and texture processing. The mold only needs to be clamped and fixed once. All polishing, morphology inspection, and texture etching processes are completed in a unified coordinate system, eliminating the cumulative positioning errors caused by multiple transfers and secondary tooling in traditional processes from the root, and greatly improving the processing accuracy and consistency of complex curved surface molds.

[0059] 2. This invention abandons the traditional model of planning the processing trajectory based on theoretical CAD models. Instead, it obtains the true three-dimensional micromorphology of the polished mold through in-situ optical measurement. Based on the real curved surface data, it completes the conformal mapping of the three-dimensional texture pattern, so that the texture trajectory completely fits the actual curved surface contour, effectively avoiding the stretching, compression, distortion and defects of the texture on the side wall of the complex curved surface. This invention adopts a continuous wave laser thermal flow polishing process, which relies on the surface tension of the molten pool and thermal capillary convection to achieve abrasive-free and stress-free mirror polishing, quickly reducing the surface roughness of the mold to the nanometer level. Then, an ultrafast laser cold processing process is used to complete the texture etching, which has no heat conduction, no recast layer and no heat-affected zone. Combined with the roughness adaptive energy compensation mechanism, it ensures uniform texture depth and sharp edges, significantly improving the optical performance and service life of the mold.

[0060] 4. This invention acquires laser ablation plasma spectrum signals in real time, inverts the real-time material removal rate, and dynamically adjusts laser pulse parameters and spindle feed parameters online. This effectively compensates for processing errors caused by uneven local hardness of mold materials and laser energy fluctuations, further improving the processing accuracy and batch consistency of micro-nano textures.

[0061] 5. This invention achieves fully automated processing, testing, and compensation, eliminating reliance on manual operation. It can adapt to the processing needs of injection molds with different materials and free-form surface structures, with high processing efficiency and high yield rate. It is both environmentally friendly and economical, and is suitable for the large-scale mass production needs of high-end precision injection molds. Attached Figure Description

[0062] 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.

[0063] Figure 1 This is a flowchart illustrating the ultra-precision polishing and texturing integrated treatment method for the surface of an injection mold according to the present invention.

[0064] Figure 2 This is a schematic diagram of the device module of the present invention;

[0065] Figure 3 This is a schematic diagram of the structure of the electronic device of the present invention; Detailed Implementation

[0066] 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. 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.

[0067] Figure 1 This is a schematic flowchart of the ultra-precision polishing and texturing integrated treatment method for the surface of injection molds according to an embodiment of the present invention. It should be noted that if substantially the same result is achieved, the method of this application is not necessarily identical. Figure 1 The process sequence shown is limited.

[0068] Example 1:

[0069] The execution subject of this invention is an industrial-grade CNC control system mounted on a high-end five-axis linkage laser composite machining center. This system embeds multi-axis interpolation algorithm, precision point cloud processing algorithm, laser timing synchronization control algorithm and closed-loop feedback compensation algorithm. It can achieve microsecond-level real-time communication and linkage control with laser generator, servo drive mechanism and optical measurement module through EtherCAT high-speed bus. It is suitable for ultra-precision integrated machining of various free-form surface injection molds.

[0070] Example 1

[0071] The integrated processing method disclosed in this embodiment is suitable for processing complex free-form injection molds made of common mold steels such as H13 and S136. The specific steps are as follows:

[0072] S1. Mold Model Analysis and Surface Topology Feature Extraction

[0073] The control system reads the STEP and IGES format 3D CAD model data of the injection mold to be processed and locates the target processing area of ​​the mold cavity. Based on the differential geometry algorithm, the surface mesh of the target processing area is discretized and sampled. The topological parameters such as the principal curvature and normal vector of each sampling point are calculated. Key topological features such as the ridge line, valley line, and inflection point of the surface are extracted to construct a complete freeform surface topological feature database, which provides data support for subsequent adaptive polishing path planning.

[0074] S2. Adaptive laser polishing of curved surfaces to prepare nanoscale initial polished surfaces.

[0075] The system adaptively matches the laser spot diameter based on the principal curvature parameters of each sampling point on the surface. For protrusions and depressions with abrupt curvature changes, it automatically reduces the spot diameter and lowers the laser duty cycle to avoid over-melting and collapse at the edge of the surface. Based on the surface normal vector parameters, it solves the yaw and pitch angles of the five-axis platform and constructs an equidistant offset polishing path in which the laser beam is always perpendicular to the tangent plane of the surface, ensuring the uniformity of polishing across the entire surface.

[0076] The continuous wave fiber laser is activated to output a laser beam with appropriate power to perform full-area scanning polishing on the surface of the mold cavity. This causes the surface material of the mold layer with a thickness of micrometers to melt shallowly and form a micro-melt pool. Relying on the surface tension of the metal and the Marangoni thermocapillary convection effect, the peaks and valleys of the micro-tool marks are leveled. After rapid self-quenching and solidification, the surface roughness of the mold is reduced from the initial Ra 1.2μm or more to Ra 50nm or less, resulting in a smooth and uniform initial polished surface.

[0077] S3. In-situ non-contact morphology detection to obtain the true surface micro-parameters.

[0078] The mold remains in its original clamping state throughout the process, requiring no disassembly or transport. The control system drives the Z-axis of the composite machining spindle to rise, and a pneumatic slide moves the side in-situ optical measurement module down to the measurement station. The white light interferometer is then activated to perform block interference scanning according to a preset uniform sampling grid, acquiring multiple sets of local interference fringe images.

[0079] Interference fringes were analyzed using a phase-shifting algorithm to reconstruct local 3D point cloud data for each block. An iterative nearest-point algorithm was then employed to complete the feature registration and seamless stitching of the multi-block point cloud, yielding complete and accurate 3D point cloud data for the initial polished surface of the mold cavity. Low-pass filtering was applied to the complete point cloud data for noise reduction, macroscopic surface error components of the mold were removed, high-frequency microscopic morphology components were extracted, and the arithmetic mean deviation of the profile was calculated to accurately obtain the actual roughness parameters and microscopic profile features of the initial polished surface.

[0080] S4. Conformal mapping of curved surfaces to generate distortion-free texture processing trajectories.

[0081] The detected real 3D point cloud data is reconstructed and parameterized into a non-uniform rational B-spline surface model to eliminate the disorder of discrete point clouds. An energy functional from the 2D parameter domain to the 3D surface is constructed, and the functional value is minimized through a numerical iterative algorithm to solve for the optimal conformal mapping matrix, ensuring that there is no distortion of local angles and uniform texture proportions during texture mapping.

[0082] Based on conformal mapping matrix, the two-dimensional pixel coordinates of preset three-dimensional texture patterns such as microlens array, bionic skin texture, and anti-glare brushed texture are accurately converted into three-dimensional spatial coordinates that fit the contour of the real curved surface. The normal vectors of each processing point are matched to generate five-axis linkage machining G code, resulting in a high-precision and distortion-free spatial texture processing trajectory.

[0083] S5, adaptive laser parameter matching, integrated micro / nano texture molding

[0084] After the system determines that the surface roughness of the initial polishing meets the optical-grade processing standard, it retrieves the two-photon absorption light-matter interaction model and, combined with the local curvature change rate of the spatial texture trajectory, calculates the equivalent projected area of ​​the ultrafast laser beam on the curved surface. Combining the ablation threshold of the mold steel material and preset spot overlap rate parameters, the system dynamically calculates the ultrafast laser pulse energy at each processing point using an energy density compensation formula, ensuring uniform and consistent ablation depth across the entire curved surface.

[0085] The control system switches the coaxial optical path and starts the picosecond / femtosecond ultrafast laser. Relying on the cold processing characteristics of ultrafast laser, it performs heat-free ablation processing on the initially polished surface along the spatial texture processing trajectory, forming a micro-nano biomimetic texture structure with sharp edges and a flat bottom on the mold cavity surface.

[0086] S6. Online monitoring of plasma spectroscopy to achieve closed-loop error compensation.

[0087] Throughout the ultrafast laser processing process, a high-speed spectrometer collects the plasma plume spectral radiation signal generated by laser ablation in real time, extracts the characteristic spectral line intensity of mold steels such as iron and chromium, and, based on the correlation model between spectral line intensity and material removal rate, inverts the actual material removal rate at each processing point in real time.

[0088] By comparing the real-time material removal rate with the theoretical standard removal rate, the processing deviation value is calculated. When the deviation exceeds the preset tolerance range, the system adjusts the ultrafast laser pulse repetition frequency or spindle feed speed in real time through a closed-loop feedback loop to dynamically compensate for the processing errors caused by uneven local material hardness and laser energy attenuation, ensuring batch processing consistency and texture accuracy stability.

[0089] Example 2:

[0090] This embodiment is used to implement the integrated processing method described in Embodiment 1. The device consists of an underlying hardware architecture and software functional modules. The hardware architecture includes a five-axis linkage CNC machining platform, a gantry frame, a composite machining spindle, a coaxial optical path switching module, an in-situ optical measurement module, and a spectral monitoring module. The software modules include a data parsing module, an adaptive polishing module, an in-situ measurement module, a conformal mapping module, a texture processing module, and a closed-loop monitoring and compensation module.

[0091] The composite machining spindle integrates a dual-optical-path switching structure, enabling millisecond-level rapid switching between continuous wave polishing laser and ultrafast texture processing laser, eliminating the need for manual source replacement and ensuring efficient and precise process transitions. The in-situ optical measurement module achieves automatic station switching via a pneumatic slide, providing retraction protection during processing and downward operation during measurement, balancing equipment safety and measurement accuracy.

[0092] The software modules work together to achieve fully automated control of the entire process: the data analysis module completes the analysis of mold surface features, the adaptive polishing module realizes differentiated laser polishing of the surface, the in-situ measurement module completes accurate detection of the real shape, the conformal mapping module realizes distortion-free texture trajectory reconstruction, the texture processing module completes adaptive parameter matching and texture forming, and the closed-loop monitoring and compensation module realizes real-time error correction in the processing process, thus constructing a fully closed-loop intelligent processing system of "processing-detection-modeling-processing-compensation".

[0093] For other details regarding the implementation techniques of each module in the above-described embodiments, please refer to the description in the method of Embodiment 1 above, which will not be repeated here.

[0094] It should be noted that the various embodiments in this specification are described in a progressive manner, with each embodiment focusing on the differences from other embodiments. Similar or identical parts between embodiments can be referred to interchangeably. For apparatus embodiments, since they are basically similar to method embodiments, the description is relatively simple; relevant parts can be referred to the descriptions in the method embodiments.

[0095] Example 3:

[0096] like Figure 3 This is a schematic diagram of the structure of an electronic device provided in an embodiment of the present disclosure. It illustrates a structural schematic diagram suitable for implementing the electronic device in the embodiment of the present disclosure. Figure 3 The electronic device shown is merely an example and should not be construed as limiting the functionality and scope of the embodiments disclosed herein.

[0097] like Figure 3As shown, the electronic device includes a processor, a memory, and a communication interface. The memory stores a computer program, and when the processor executes the computer program, it implements the methods of the aforementioned embodiments of this disclosure. The electronic device can exchange data with other devices or apparatuses through the communication interface, enabling real-time updates and sharing of data information.

[0098] The processor in the aforementioned electronic device serves as its core, responsible for executing the computer program stored in the memory to implement the various functions of the method. The processor can employ a high-performance multi-core CPU or a dedicated chip to meet the demands of complex calculations and real-time processing. The memory stores operating devices, application programs, data, and computer programs. In this embodiment, the memory stores the computer program of the method. The memory can be RAM, ROM, Flash memory, or other types of non-volatile memory. The communication interface connects the electronic device to other devices or networks, enabling data transmission and exchange. In this embodiment, the communication interface supports various communication protocols and interface standards, such as Wi-Fi, Bluetooth, USB, and Ethernet, to meet communication needs in different scenarios.

[0099] For a detailed description of this embodiment, please refer to the corresponding descriptions in the foregoing embodiments, which will not be repeated here.

[0100] Example 4:

[0101] According to embodiments of the present disclosure, a computer-readable storage medium stores a computer program, which, when executed by a processor, implements the functions of the methods described in the foregoing embodiments of the present disclosure.

[0102] The aforementioned computer-readable storage media include, but are not limited to: optical storage media (e.g., CD-ROM and DVD), magneto-optical storage media (e.g., MO), magnetic storage media (e.g., magnetic tape or portable hard drive), media with built-in rewritable non-volatile memory (e.g., memory card), and media with built-in ROM (e.g., ROM cartridge).

[0103] For a detailed description of this embodiment, please refer to the corresponding descriptions in the foregoing embodiments, which will not be repeated here.

[0104] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for integrated ultra-precision polishing and texturing of injection mold surfaces, characterized in that, The method, applied to a five-axis linkage laser processing control device, includes the following steps: Obtain the three-dimensional model data of the injection mold to be processed, and extract the freeform surface topological features of the target processing area based on the three-dimensional model data; Based on the freeform surface topological features, a global adaptive polishing path is generated, and the composite machining spindle is controlled to perform continuous wave laser-assisted polishing on the target machining area along the global adaptive polishing path to prepare a preliminary polished surface. With the injection mold still clamped in place, the three-dimensional point cloud data of the initial polished surface is scanned and collected by the in-situ optical measurement module located on the side of the composite machining spindle, and the actual micro-profile and surface roughness parameters of the initial polished surface are extracted. The preset three-dimensional texture pattern is conformally mapped to the three-dimensional point cloud data to generate a spatial texture processing trajectory that fits the actual microscopic contour of the initial polished surface. Based on the surface roughness parameters and the spatial texture processing trajectory, the pulse energy and spot overlap rate parameters of the ultrafast laser are dynamically solved, and the composite processing spindle is controlled to perform ultrafast laser ablation processing on the initially polished surface along the spatial texture processing trajectory, so as to integrally form a micro-nano biomimetic texture structure in the target processing area.

2. The method for integrated ultra-precision polishing and texturing of injection mold surface according to claim 1, characterized in that, The process of generating a globally adaptive polishing path based on the freeform surface topology features, and controlling the composite machining spindle to perform continuous wave laser-assisted polishing on the target machining area along the globally adaptive polishing path to prepare a preliminary polished surface, specifically includes: Calculate the principal curvature parameters and normal vector parameters corresponding to each sampling point of the freeform surface topological feature; The dynamic spot diameter of the continuous wave laser is determined based on the principal curvature parameters of each sampling point. For the convex and concave regions of the surface where the absolute value of the principal curvature is greater than the preset curvature threshold, the dynamic spot diameter is reduced to suppress the over-melting deformation defects at the edge of the surface. Based on the normal vector parameters of each sampling point, the yaw angle and pitch angle of the five-axis linkage machining platform are solved, and an equidistant offset polishing path with the laser beam optical axis always perpendicular to the cutting plane of the machining point is constructed as the global adaptive polishing path. A laser beam with matched power is controlled to output a continuous wave laser, causing shallow melting of the surface material of the target processing area. The molten pool is driven to flow level by the surface tension and capillary force of the material, and after cooling and solidification, a preliminary polished surface with uniform roughness is obtained.

3. The method for integrated ultra-precision polishing and texturing of injection mold surface according to claim 1, characterized in that, While the injection mold is held in place, an in-situ optical measurement module located on the side of the composite machining spindle scans and acquires the three-dimensional point cloud data of the initial polished surface, and extracts the actual micro-profile and surface roughness parameters of the initial polished surface, specifically including: The white light interferometer built into the in-situ optical measurement module is activated, and the interference fringes of the initially polished surface are collected in sections according to the preset sampling grid. The phase-shifting algorithm is used to analyze the interference fringe data of each block, and the corresponding local three-dimensional point cloud data of each block is reconstructed. The iterative nearest point algorithm is used to perform feature registration and global stitching on the local three-dimensional point cloud data of all blocks, and the fusion is used to obtain the complete three-dimensional point cloud data of the initial polished surface. The three-dimensional point cloud data is subjected to low-pass filtering to remove the macroscopic surface contour component and extract the high-frequency surface morphology component. The arithmetic mean deviation of the contour is calculated based on the high-frequency surface morphology component, and the obtained value is used as the surface roughness parameter of the initial polished surface.

4. The method for integrated ultra-precision polishing and texturing of injection mold surface according to claim 1, characterized in that, The step of performing conformal mapping between the preset three-dimensional texture pattern and the three-dimensional point cloud data to generate a spatial texture processing trajectory that fits the actual microscopic contour of the initially polished surface specifically includes: The three-dimensional point cloud data is parameterized into a non-uniform rational B-spline surface model; An energy functional is constructed from the two-dimensional parameter domain to the non-uniform rational B-spline surface. The conformal mapping matrix is ​​solved by minimizing the energy functional to ensure that the local angle of the three-dimensional texture pattern is constant and without distortion during the mapping process. Based on the conformal mapping matrix, the pixel coordinates of the three-dimensional texture pattern defined in the two-dimensional plane are converted into three-dimensional spatial coordinates corresponding to the non-uniform rational B-spline surface. Based on the matching of all three-dimensional spatial coordinates and corresponding normal vectors, five-axis linkage machining G-code instructions are generated as the machining trajectory of the spatial texture.

5. The method for integrated ultra-precision polishing and texturing of injection mold surface according to claim 1, characterized in that, The process of dynamically solving the pulse energy and spot overlap rate parameters of the ultrafast laser based on the surface roughness parameters and the spatial texture processing trajectory specifically includes: Determine whether the surface roughness parameter is less than a preset optical grade roughness threshold; When the surface roughness parameter is less than the preset optical grade roughness threshold, the preset light-matter interaction two-photon absorption model is retrieved; Based on the local curvature change rate of the spatial texture processing trajectory, the equivalent projected area of ​​the ultrafast laser beam on the surface of the mold material is calculated; By combining the equivalent projected area, the ablation threshold of the injection mold material, and the preset spot overlap rate parameter, the pulse energy required by the ultrafast laser is calculated using a preset energy density compensation formula to ensure uniform and consistent processing texture depth.

6. The method for integrated ultra-precision polishing and texturing of injection mold surface according to any one of claims 1 to 5, characterized in that, During the ultrafast laser ablation process performed on the initially polished surface, the method further includes a real-time closed-loop error compensation step: Real-time acquisition of plasma plume spectral radiation signals generated during ultrafast laser ablation processing; Based on the characteristic spectral line intensities of the spectral radiation signal, the actual material removal rate at the current ablation point is calculated by inversion. Calculate the deviation between the actual material removal rate and the preset theoretical material removal rate; When the removal rate deviation exceeds the preset tolerance range, the pulse repetition frequency of the ultrafast laser or the feed speed of the composite machining spindle is adjusted in real time through a closed-loop feedback control circuit to achieve online dynamic compensation of machining errors.

7. A device for integrated ultra-precision polishing and texturing of injection mold surfaces, characterized in that, The apparatus for implementing the integrated ultra-precision polishing and texturing method for the surface of an injection mold as described in any one of claims 1 to 6 comprises: The data parsing module is configured to acquire the three-dimensional model data of the injection mold to be processed, and extract the free-form surface topological features of the target processing area based on the three-dimensional model data; The adaptive polishing module is configured to generate a global adaptive polishing path based on the freeform surface topology features, and control the composite machining spindle to perform continuous wave laser-assisted polishing treatment on the target machining area along the global adaptive polishing path to prepare a preliminary polished surface. The in-situ measurement module is configured to scan and acquire the three-dimensional point cloud data of the initial polished surface through the in-situ optical measurement module on the side of the composite machining spindle while the injection mold is kept in the in-situ clamping state, and extract the actual micro-contour and surface roughness parameters of the initial polished surface. The conformal mapping module is configured to perform conformal mapping between a preset 3D texture pattern and 3D point cloud data to generate a spatial texture processing trajectory that fits the actual microscopic contour of the initial polished surface. The texture processing module is configured to dynamically solve the pulse energy and spot overlap rate parameters of the ultrafast laser based on the surface roughness parameters and the spatial texture processing trajectory, and control the composite processing spindle to perform ultrafast laser ablation processing along the spatial texture processing trajectory to form an integrated micro-nano biomimetic texture structure.

8. The ultra-precision polishing and texturing integrated treatment device for injection mold surface according to claim 7, characterized in that, The device is configured with a low-level mechanical and sensing hardware architecture, which includes a five-axis linkage CNC machining platform, a gantry frame, and a composite machining spindle. The composite machining spindle integrates a coaxial optical path switching module, which is connected to a continuous wave fiber laser and an ultrafast laser respectively, and is used to realize millisecond-level light source switching between the polishing process and the texture processing process. The in-situ optical measurement module is suspended and mounted on the side of the composite machining spindle via a high-precision pneumatic slide. After the polishing process is completed, it is driven down to the measurement station by the pneumatic slide. During the machining process, it moves up and retracts into the protective structure, realizing the adaptive switching between the protection of the measurement module and the station. The device also includes a closed-loop monitoring and compensation module. The closed-loop monitoring and compensation module is configured to collect plasma plume spectral radiation signals in real time during the ultrafast laser ablation process, and calculate the real-time material removal rate based on the intensity of spectral characteristic lines. The closed-loop monitoring and compensation module is also configured to output a numerical control compensation command when the deviation between the actual material removal rate and the theoretical material removal rate exceeds the preset tolerance range, thereby adjusting the pulse repetition frequency of the ultrafast laser and the spindle feed speed in real time to complete the closed-loop compensation of the processing error.

9. An electronic device, characterized in that, Including memory and processor; The memory stores computer programs that can run on the processor; When the processor executes the computer program, it implements the steps of the ultra-precision polishing and texturing integrated processing method for the surface of the injection mold as described in any one of claims 1 to 6.

10. A computer-readable storage medium, characterized in that, The computer-readable storage medium stores computer program instructions, which, when executed by a processor, implement the steps of the ultra-precision polishing and texturing integrated processing method for the surface of an injection mold as described in any one of claims 1 to 6.

Images