High-speed railway wheel straight spoke parallelism closed-loop processing control method and system

Abstract

The application discloses a kind of high-speed rail wheel straight spoke plate parallelism closed loop processing control method and system, belong to high-speed rail wheel precision machining manufacturing field.This method includes: process precision parallel reference establishment, finite element simulation partition quantitative clamping control, low stress subsection progressive cutting and in-machine online closed loop measurement and dynamic compensation control;Wherein, process precision parallel reference establishment is obtained by establishing the deformation compensation amount of inner rim surface and straight spoke plate parallelism correlation mathematical model;Finite element simulation partition quantitative clamping control determines the optimal partition chucking pressure of tread and rim;Low stress subsection progressive cutting divides spoke finishing allowance into multiple layers of progressive cutting;In-machine online closed loop measurement and dynamic compensation control compares with theoretical parallelism model by measuring head real-time data acquisition after each layer cutting, and automatically corrects tool path.The application effectively improves the high-speed rail wheel straight spoke plate parallelism processing precision and batch consistency, and can be popularized to industry wheelset manufacturing enterprise.

Description

Technical Field

[0001] This invention belongs to the field of precision machining and manufacturing of high-speed rail wheel components, specifically relating to a closed-loop machining control method and system for the parallelism of straight spokes of high-speed rail wheels. Background Technology

[0002] High-speed train wheels are critical load-bearing components for train operation, and their machining precision directly affects the safety, smoothness, and passenger comfort of the train. The parallelism accuracy of the straight spokes of the high-speed train wheel, which serve as the mounting reference surface for the brake disc, is one of the core indicators for measuring the quality of wheel machining.

[0003] According to the "Rules for Overhauling Wheelsets of Railway EMUs (TB / T 3559-2023)," the basic tolerance for spoke parallelism is no greater than 0.06 mm. Currently, high-end customers are demanding even higher control standards, requiring spoke parallelism to be consistently controlled within ±0.03 mm. However, high-speed train wheels are large, thin-walled annular parts with significant material removal and uneven structural rigidity distribution. During precision machining, clamping deformation and residual cutting stress can easily lead to spoke parallelism exceeding the tolerance.

[0004] Currently, the precision machining of high-speed rail wheels both domestically and internationally generally adopts the process mode of "open-loop machining + offline three-coordinate inspection after machining".

[0005] In similar overseas processes, the finishing process relies on offline aging to release machining stress, and clamping uses fixed jaws to clamp the tread and wheel flange. However, there is no quantitative simulation optimization basis for the clamping force; after machining, the wheels are uniformly inspected offline without real-time process compensation; switching between different wheel specifications requires changing the jaws, resulting in poor flexibility and a high risk of scrap due to excessive parallelism in small-batch production. Although some existing technologies have attempted to apply the finite element method for clamping simulation analysis, a systematic quantitative clamping force optimization scheme and its organic integration with online closed-loop control have not yet been formed.

[0006] In terms of traditional domestic machining processes, there is no systematic stress and deformation control scheme. Clamping pressure is set based on operator experience, and cutting parameters are not optimized for low stress. Residual stress is high, and workpiece clamping deformation is uncontrollable. After all workpieces are machined, 100% offline coordinate measuring machine (CMM) inspection is performed, resulting in significant inspection delays. Once deviations are detected, rework or scrapping is the only option, and clamping adjustments are time-consuming, severely restricting production capacity. In recent years, some research has proposed in-machine inspection techniques, but an integrated solution covering the entire process of datum establishment, clamping optimization, cutting control, and online compensation has not yet been developed.

[0007] In summary, the existing technology mainly suffers from the following core technical defects: 1. Uncontrollable clamping deformation. There is no simulation basis for the clamping force of the finishing tread and rim. Excessive pressure causes elastic deformation of the rim and spokes. Rebound after pressure relief directly leads to excessive spoke parallelism. There is no control over the transfer of reference points between processes; deformation of the inner rim surface in process one is directly transferred to the finishing process in process two, resulting in cumulative accuracy errors due to the superposition of reference deviations. 2. High residual stress during cutting. Under conventional cutting parameters, cutting force and heat are concentrated. The allowance is removed in one go, resulting in uneven residual stress in the spokes. Slow deformation after machining leads to poor parallelism consistency. 3. Delayed detection and lack of closed-loop compensation. All detection processes are conducted offline, with no real-time data feedback during machining. When deviations are detected, the workpiece has already been machined, making it impossible to correct tool paths and process parameters in real time, resulting in high scrap and rework rates. 4. Poor process stability. There is no standardized integrated control system. Process adjustments rely on operator experience, resulting in low process capability index and an inability to consistently meet the ±0.03mm high-precision spoke parallelism control requirements. Summary of the Invention

[0008] The purpose of this invention is to overcome the technical problems existing in the processing of straight spokes of high-speed train wheels, such as uncontrollable clamping deformation, large residual cutting stress, detection lag without closed-loop compensation, and poor process stability. It provides a three-in-one closed-loop processing control method and system for the parallelism of straight spokes of high-speed train wheels, which integrates "parallel reference control + finite element quantitative clamping force clamping + online closed-loop measurement".

[0009] This invention eliminates superimposed errors in process reference transfer by establishing a precise parallel reference transfer model between processes and strictly controlling the levelness of tooling shims. It uses finite element simulation to quantitatively optimize the clamping pressure in both the tread and wheel flange areas, precisely controlling elastic deformation from the clamping source. A low-stress segmented progressive cutting strategy is adopted to effectively reduce spoke springback deformation caused by residual cutting stress. Simultaneously, an integrated in-machine online probe constructs a closed-loop control system of "machining-real-time detection-data feedback-parameter / tool ​​compensation," completely changing the traditional offline lag detection mode. Ultimately, the parallelism of the straight spokes of high-speed train wheels is stably controlled within the 0-0.03mm range throughout the entire batch production process, significantly improving process capability, greatly reducing scrap loss and inspection labor costs, and meeting the stringent manufacturing precision requirements of 350km / h high-speed train wheels.

[0010] To achieve the above objectives, the present invention adopts the following technical solution: a closed-loop machining control method for the parallelism of straight spokes of high-speed train wheels, which is divided into four core steps: establishment of precise parallel benchmarks for the process, quantitative clamping control by finite element simulation, optimization of low-stress cutting process, and online closed-loop measurement feedback compensation.

[0011] (a) Establishment of precise parallel benchmarks for processes.

[0012] The inner side of the wheel is precision machined, and data on the deformation of the inner rim surface under different tread clamping forces are collected. A mathematical model relating the parallelism between the inner rim surface and the straight spokes is established to obtain the deformation compensation amount.

[0013] Before finishing the straight spokes, the levelness of the tooling shims is strictly controlled as a unified benchmark for finishing, and the deformation compensation amount is matched to eliminate the deviation of the process benchmark transmission.

[0014] The workpiece clamping posture is constrained by the horizontal reference of the shim to ensure the uniformity of the machining reference of the spokes and avoid parallelism errors caused by reference offset.

[0015] Preferably, a level is used to calibrate the tooling shims before finishing the straight spokes, and the levelness error is controlled within ≤0.03mm.

[0016] (ii) Finite element simulation zoned quantitative clamping control.

[0017] A three-dimensional finite element simulation model of a high-speed train wheel was established to simulate the elastic deformation fields of the rim and spokes in the tread and flange regions under different clamping pressures.

[0018] Determine the optimal zone clamping pressure within the safe deformation threshold: tread clamping pressure 70-72 bar, wheel flange clamping pressure 30-32 bar.

[0019] The machine tool's hydraulic system is programmed to lock the clamping pressure in two zones, ensuring constant pressure throughout the machining process and preventing deformation fluctuations.

[0020] Preferably, the machine tool hydraulic program automatically outputs a tread clamping pressure of 71 bar and a wheel flange clamping pressure of 31 bar. After the pressure stabilizes, a delay of 5-10 seconds is made for the workpiece's elastic deformation to stabilize before cutting is started.

[0021] (III) Optimization of low-stress segmented progressive cutting process.

[0022] The optimized cutting parameters are: cutting speed V = 210 m / min, feed rate F = 0.4-0.5 mm / r, and depth of cut ap = 0.1-0.2 mm.

[0023] A segmented allowance allocation strategy is adopted, which divides the finishing allowance of the spokes into multiple layers of progressive cutting to disperse the single cutting force and cutting heat.

[0024] A progressive feed method is adopted to reduce local stress concentration, reduce residual stress during machining, and suppress springback deformation of the spokes after machining.

[0025] Preferably, the total allowance of the spokes is progressively cut in three layers, with a single cutting depth of 0.15 mm.

[0026] (iv) In-machine online closed-loop measurement and dynamic compensation control.

[0027] The Renishaw RMP60 high-precision optical probe is integrated into the CNC RQMC machining unit, and the CNC machining program loop is embedded.

[0028] After each layer of cutting is completed, the machine tool automatically calls the probe to collect raw data on the horizontality and parallelism of the spokes in real time.

[0029] By comparing the measured data with the theoretical parallelism model, the deviation compensation amount is automatically calculated, and the tool path is corrected in real time.

[0030] If the deviation exceeds the preset warning threshold, the system will automatically prompt manual fine-tuning of the clamping pressure and / or cutting parameters, forming a closed-loop control of "machining-real-time detection-data feedback-parameter / tool ​​compensation".

[0031] Preferably, after each layer of cutting is completed, cutting is paused, online measurement is initiated, and data on the levelness and parallelism of the spokes are collected.

[0032] Preferably, the preset warning threshold is a parallelism deviation of 0.025 mm.

[0033] Preferably, after batch processing is completed, 30% of the samples are randomly inspected, and the parallelism data are verified by a coordinate measuring machine.

[0034] This invention also provides a closed-loop machining control system for the parallelism of straight spokes on high-speed train wheels, used to implement the above-mentioned method, comprising:

[0035] The benchmark establishment module is used to collect deformation data of the inner rim surface under different tread clamping forces when finishing the inner side of the wheel, establish a mathematical model related to the parallelism between the inner rim surface and the straight spoke plate, obtain the deformation compensation amount, and control the levelness of the tooling pad before finishing the straight spoke plate as a unified benchmark for finishing, and match the deformation compensation amount.

[0036] The finite element simulation clamping control module is used to establish a three-dimensional finite element simulation model of a high-speed rail wheel, simulate the elastic deformation field of the rim and the elastic deformation field of the spokes under different clamping pressures in the tread area and the flange area, determine the optimal partition clamping pressure within the safe deformation threshold, and lock the clamping pressure of the tread area and the flange area through the machine tool hydraulic system.

[0037] The low-stress segmented cutting module is used to divide the finishing allowance of the spokes into multiple layers of progressive cutting using a segmented allowance allocation strategy, and to perform layered cutting according to the set cutting parameters.

[0038] The online closed-loop measurement and dynamic compensation control module is used to integrate an in-machine probe into the CNC machining unit and embed the CNC machining program loop. After each layer of cutting is completed, the probe is automatically called to collect the horizontality and parallelism data of the spokes in real time. After comparing the measured data with the theoretical parallelism model, the deviation compensation amount is automatically calculated and the tool path is corrected in real time. When the deviation exceeds the preset warning threshold, it automatically prompts manual adjustment of clamping pressure and / or cutting parameters.

[0039] Compared with existing technologies, this invention has the following advantages: Through a three-in-one integrated control system of "parallel reference control + finite element quantitative clamping force clamping + online closed-loop measurement," this invention effectively improves the parallelism processing accuracy and batch consistency of high-speed rail wheel spokes, significantly exceeding industry standards and high-end customer control requirements. It eliminates reference superposition errors through process reference transfer control, controls elastic deformation from the source using finite element simulation-based zonal quantitative clamping, effectively reduces springback deformation caused by residual stress through low-stress segmented progressive cutting, and integrates an in-machine online probe to construct a closed-loop control system, completely changing the traditional offline hysteresis detection mode and realizing dynamic quality intervention in the processing process. While reducing scrap losses and inspection costs and increasing production capacity, this invention forms a universal closed-loop process solution that can be promoted throughout the industry, which is of positive significance for improving the manufacturing accuracy of domestically produced high-speed rail wheels, ensuring the safe operation of EMU trains, and promoting the digital and intelligent manufacturing upgrade of rail transit equipment. Attached Figure Description

[0040] Figure 1 This is a flowchart of the closed-loop machining control process according to an embodiment of the present invention, showing the complete control process of reference establishment → clamping → cutting → online measurement → compensation;

[0041] Figure 2 This is a diagram of the straight spoke plate of a high-speed train wheel in an embodiment of the present invention, with the parallelism tolerance 0.06 reference B and the spoke plate detection area marked.

[0042] Figure 3 The image shows a finite element model of wheel clamping deformation in an embodiment of the present invention; where (a), (b), and (c) show the pressure deformation distribution of the spokes, tread, and rim respectively.

[0043] Figure 4 The Process Capability Sixpack process capability analysis report in this embodiment of the invention shows parallelism control statistics charts. Detailed Implementation

[0044] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0045] It should be noted that the following detailed descriptions are exemplary and intended to provide further explanation of this application. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains.

[0046] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0047] like Figure 1 As shown, this embodiment provides a closed-loop machining control method for the parallelism of straight spokes on high-speed train wheels, including the following steps:

[0048] Establishment of precision parallel reference for the process: Precision machining of the inner side of the wheel, collecting deformation data of the inner rim surface under different tread clamping forces, establishing a mathematical model related to the parallelism between the inner rim surface and the straight spoke plate, and obtaining the deformation compensation amount; before precision machining of the straight spoke plate, controlling the level of the tooling shim as a unified reference for precision machining, matching the deformation compensation amount, and using the level of the shim as a reference to constrain the workpiece clamping posture.

[0049] Finite element simulation zoned quantitative clamping control: A three-dimensional finite element simulation model of a high-speed train wheel is established to simulate the elastic deformation fields of the rim and spokes of the tread area and the flange area under different clamping pressures, respectively. The optimal zoned clamping pressure within the safe deformation threshold is determined, and the clamping pressure of the tread area and flange area is locked by the machine tool hydraulic system.

[0050] Low-stress segmented progressive cutting: A segmented allowance allocation strategy is adopted to divide the finishing allowance of the spokes into multiple layers of progressive cutting, and cutting parameters are set for layered cutting;

[0051] In-machine online closed-loop measurement and dynamic compensation control: An in-machine probe is integrated into the CNC machining unit and embedded into the CNC machining program loop; after each layer of cutting is completed, the machine tool automatically calls the probe to collect the horizontality and parallelism data of the spokes in real time; the measured data is compared with the theoretical parallelism model, the deviation compensation amount is automatically calculated, and the tool path is corrected in real time; if the deviation exceeds the preset warning threshold, the system automatically prompts manual adjustment of clamping pressure and / or cutting parameters, forming a closed-loop control of machining-real-time detection-data feedback-parameter / tool ​​compensation.

[0052] The implementation process of this method will be further explained below through specific embodiments.

[0053] I. Complete Implementation Process for Batch Processing of Wheels

[0054] 1. Workpieces and equipment.

[0055] The workpiece to be processed is a standard EMU integral rolled steel wheel, with a straight-spoke wheel type and a spoke thickness of (32±0.5) mm. The parallelism tolerance requirements for the straight spokes and the spoke inspection area are as follows: Figure 2 As shown. The processing equipment is the Maanshan Iron & Steel RQMC CNC wheel processing unit, equipped with a hydraulic dual-zone chuck (tread clamping area and wheel flange clamping area), a Renishaw RMP60 in-machine optical probe, and finite element simulation analysis software.

[0056] 2. Establishment of a mathematical model relating benchmark preprocessing and parallelism.

[0057] The inner side of the wheel is precision machined, and data on the deformation of the inner rim surface under different tread clamping forces are collected. The deformation compensation amount is then generated and stored in the machine tool program.

[0058] A mathematical model relating the inner rim surface to the parallelism of the spokes was established: using the tread clamping force as the input variable and the inner rim surface deformation as the output variable, multiple sets of inner rim surface deformation data under different tread clamping force conditions were collected. A polynomial regression or finite element surrogate model was used to fit the functional relationship between the inner rim surface deformation and the tread clamping force. Then, based on the geometric transfer relationship between the inner rim surface deformation and the spoke parallelism (i.e., the geometric conversion relationship between the angular deviation and displacement deviation of the spoke spatial posture caused by the inner rim surface deformation), the deformation compensation amount used to compensate for the spoke parallelism deviation was calculated. This deformation compensation amount was stored in the machine tool CNC program as a tool path offset and automatically called by the machine tool control system during the finishing of the spokes.

[0059] Before clamping the straight spokes for finishing, use a level to calibrate the tooling shims, controlling the levelness error to ≤0.03mm, and lock the reference posture. During the finishing of the straight spokes, match the aforementioned deformation compensation amount.

[0060] 3. Finite element simulation clamping optimization and safety deformation threshold.

[0061] A three-dimensional finite element simulation model of a high-speed train wheel was established, with material parameters set based on the actual steel properties of the wheel. Elastic deformation fields of the rim and spokes under different clamping pressures were simulated in the tread and flange regions, respectively (see [reference]). Figure 3 ).

[0062] Based on the simulation results, the optimal clamping pressure for each zone is determined within the safe deformation threshold. The safe deformation threshold refers to the maximum allowable elastic deformation of the wheel rim and spokes under clamping force, determined by finite element simulation, which takes the spoke parallelism tolerance requirement and the material elastic deformation limit as constraints. This maximum allowable elastic deformation ensures that the spokes do not undergo permanent plastic deformation under clamping force, and that the springback after pressure relief does not cause the spoke parallelism to exceed the set tolerance range.

[0063] Simulation analysis revealed that when the tread clamping pressure is too high, the elastic deformation of the rim exceeds the safe deformation threshold, and the rebound deformation after pressure relief leads to excessive spoke parallelism. Conversely, when the flange clamping pressure is too low, the workpiece positioning stiffness is insufficient, resulting in increased cutting vibration. The optimal clamping pressure for each zone was determined to be: 71 bar for the tread and 31 bar for the flange.

[0064] 4. Clamping pressure setting.

[0065] The machine tool's hydraulic program automatically outputs a tread clamping pressure of 71 bar and a wheel flange clamping pressure of 31 bar. After the pressure stabilizes, there is a 5-10 second delay to allow the workpiece's elastic deformation to stabilize before cutting begins. The pressure is maintained constant throughout the machining process under closed-loop control of the hydraulic system.

[0066] 5. Layered low-stress cutting.

[0067] The optimal cutting parameters were determined through orthogonal simulation experiments. The orthogonal simulation experiments used cutting speed, feed rate, and depth of cut as experimental factors, selecting multiple levels and conducting finite element simulation cutting experiments according to the orthogonal experimental design table. With the objectives of minimizing residual stress in the spokes and optimizing parallelism, the optimal combination of cutting parameters was determined to be: cutting speed 210 m / min, feed rate 0.45 mm / r, and single-pass depth of cut 0.15 mm.

[0068] The cutting path employs a progressive toolpath: starting from the center of the spoke, it expands radially from the inside out layer by layer. Each layer's toolpath uses a spiral progressive approach to avoid repeated cuts at the same radial position, thereby reducing local stress concentration. The total spoke allowance is cut progressively in three layers. After each layer is completed, cutting is paused, and online measurement is initiated.

[0069] 6. Online closed-loop measurement, theoretical parallelism model and compensation.

[0070] After each layer of cutting is completed, the machine tool automatically calls the Renishaw RMP60 optical probe to collect the horizontality and parallelism data of the spokes in real time.

[0071] The theoretical parallelism model is a mathematical model established based on the theoretical spatial position and angle of the spokes in the wheel design drawings. It includes the theoretical parallelism baseline of the spokes and the theoretical coordinate values ​​of each detection point. The specific method for comparing the measured data with this model is as follows: the measured spatial coordinates of each detection point collected by the probe are compared one by one with the corresponding theoretical coordinates in the theoretical parallelism model, the spatial position deviation of each detection point is calculated, and then the actual parallelism deviation value of the spokes is obtained by combining the results.

[0072] After comparing the measured data with the theoretical parallelism model, the deviation compensation amount is automatically calculated, and the tool path for the next cutting layer is corrected in real time.

[0073] If the deviation exceeds the preset warning threshold, the system will automatically prompt manual adjustment of the clamping pressure or cutting parameters.

[0074] 7. Inspection and sampling control.

[0075] After batch processing is completed, 30% of the samples are randomly inspected, and the parallelism data is verified using a coordinate measuring machine (see [reference]). Figure 4 Process capability analysis report).

[0076] II. Adaptability Implementation for Different Wheel Types and Specifications

[0077] For high-speed train wheels of different specifications (such as different diameters and different spoke thicknesses), the implementation steps of this invention are as follows:

[0078] First, based on the geometric parameters and material properties of the specific wheel type, a three-dimensional finite element simulation model is re-established to simulate the deformation field distribution under different tread and flange clamping pressures, and the optimal partition clamping pressure of the wheel type is re-determined.

[0079] Secondly, based on the total allowance of the wheel spokes, the number of layers and the depth of cut per pass were reset, but the parameter range of cutting speed 210m / min and feed rate 0.4-0.5mm / r remained unchanged.

[0080] Finally, the measurement program and closed-loop compensation algorithm of the in-machine online probe do not need to be changed and can be directly adapted to different wheel types.

[0081] This embodiment demonstrates that the present invention has good process flexibility and can be adapted to the processing of multiple wheel specifications without changing the chucks.

[0082] III. Comparison with existing open-loop processing technology

[0083] Batch processing using the method of this invention, compared with existing open-loop machining processes, reveals that: Existing open-loop machining processes, lacking quantitative clamping optimization and online detection compensation, result in poor parallelism consistency of the machined spokes, a high rate of deviations, and require offline inspection of all workpieces before screening for qualified products, leading to rework or scrapping. In contrast, this invention uses finite element simulation to quantitatively optimize clamping pressure, employs low-stress layered progressive cutting, and introduces online detection and closed-loop compensation after each layer of cutting. Deviations can be corrected in real time during processing, and the batch processing results consistently meet high-precision parallelism control requirements. The comparative results demonstrate that this invention significantly outperforms existing open-loop machining processes in terms of spoke parallelism control accuracy and batch consistency.

[0084] IV. Specific Implementation of System Control Logic

[0085] In this embodiment, the specific control logic for online closed-loop measurement and dynamic compensation control is as follows:

[0086] (1) Embed a measurement macro program in the CNC machining program, which is automatically called after each layer of cutting is completed.

[0087] (2) The Renishaw RMP60 optical probe performs non-contact measurements on multiple detection points on the spoke surface according to a preset path, and collects the height data of each point.

[0088] (3) The control system calculates the actual levelness and parallelism of the spokes based on the height data of each detection point.

[0089] (4) Compare the measured value with the theoretical value and calculate the deviation. Based on the magnitude of the deviation, the control system automatically determines: if the deviation is within the allowable range, no compensation is needed and the next layer of cutting continues; if the deviation exceeds the allowable range but is within the compensable range, the system automatically calculates the toolpath compensation and corrects it; if the deviation exceeds the compensable range, the system issues an early warning and prompts manual intervention.

[0090] (5) After the tool path compensation is completed, continue to the next layer of cutting, repeat the above measurement-comparison-compensation cycle until all the remaining material is machined.

[0091] This control logic achieves a fully closed-loop control of "machining-real-time detection-data feedback-parameter / tool ​​compensation", fundamentally solving the problem of lagging traditional offline detection.

[0092] V. Process Capability and Machining Accuracy Verification

[0093] The method of this invention is used to process a batch of standard EMU wheels. After processing, 30% of the wheels are randomly inspected, and the parallelism data of the spokes is verified by a coordinate measuring machine.

[0094] Statistical results show that the parallelism of the straight spokes is stably controlled within 0-0.03mm, which is better than the industry standard of ±0.05mm and the high-end customer requirement of ±0.03mm; the pass rate of the coordinate measuring machine (CMM) inspection reaches 100%, and the scrap rate of spokes with excessive parallelism has been reduced from 1.0% in the traditional process to 0; clamping springback deformation and cutting residual stress deformation are reduced by more than 70%, and there are no post-processing aging deformation problems; the process capability index Cp reaches 3.5 (see...). Figure 4 The accuracy is significantly higher than that of conventional processing (conventional Cp < 1.0). This result fully verifies that the present invention has excellent precision retention and process stability in mass production, and can stably meet the manufacturing precision requirements of 350km / h high-speed train wheels.

[0095] VI. Verification of Economic Benefits

[0096] Based on an annual production of approximately 1000 wheels of this specification, the present invention offers the following economic advantages compared to existing technologies:

[0097] The loss per scrap item is approximately 8,500 yuan. Because the scrap rate decreased from 1.0% to 0%, the annual reduction in scrap loss is 85,000 yuan. The inspection method was changed from 100% full inspection to 30% sampling inspection, reducing coordinate measuring machine (CMM) inspection time by 70%. The cost per inspection is 50 yuan, resulting in annual cost savings of 35,000 yuan. The total annual cost reduction benefit is 120,000 yuan. Furthermore, eliminating the full inspection waiting process increased the daily production capacity of a single unit by 12%, and significantly reduced tooling adjustment time.

[0098] This embodiment also provides a closed-loop machining control system for the parallelism of straight spokes on high-speed train wheels, used to implement the above method, including:

[0099] The benchmark establishment module is used to collect deformation data of the inner rim surface under different tread clamping forces when finishing the inner side of the wheel, establish a mathematical model related to the parallelism between the inner rim surface and the straight spoke plate, obtain the deformation compensation amount, and control the levelness of the tooling pad before finishing the straight spoke plate as a unified benchmark for finishing, and match the deformation compensation amount.

[0100] The finite element simulation clamping control module is used to establish a three-dimensional finite element simulation model of a high-speed rail wheel, simulate the elastic deformation field of the rim and the elastic deformation field of the spokes under different clamping pressures in the tread area and the flange area, determine the optimal partition clamping pressure within the safe deformation threshold, and lock the clamping pressure of the tread area and the flange area through the machine tool hydraulic system.

[0101] The low-stress segmented cutting module is used to divide the finishing allowance of the spokes into multiple layers of progressive cutting using a segmented allowance allocation strategy, and to perform layered cutting according to the set cutting parameters.

[0102] The online closed-loop measurement and dynamic compensation control module is used to integrate an in-machine probe into the CNC machining unit and embed the CNC machining program loop. After each layer of cutting is completed, the probe is automatically called to collect the horizontality and parallelism data of the spokes in real time. After comparing the measured data with the theoretical parallelism model, the deviation compensation amount is automatically calculated and the tool path is corrected in real time. When the deviation exceeds the preset warning threshold, it automatically prompts manual adjustment of clamping pressure and / or cutting parameters.

[0103] The aforementioned functional modules can be integrated into the control system of the same CNC machining unit, or they can be distributed in multiple independent devices that are interconnected (such as the host computer containing finite element simulation analysis software and the industrial control computer of the CNC machining unit communicating through a data interface).

[0104] This embodiment also provides a computer device, including: at least one processor, at least one memory, and computer program instructions stored in the memory, which implement the above-described method when executed by the processor.

[0105] This embodiment also provides a computer-readable storage medium storing computer program instructions that, when executed by a processor, implement the above-described method.

[0106] Those skilled in the art will understand that embodiments of this application can be provided as methods, systems, or computer program products. Therefore, this application can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, this application can take the form of a computer program product embodied on one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0107] This application is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of this application. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart... Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.

[0108] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.

[0109] These computer program instructions may also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.

[0110] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any other way. Any person skilled in the art may make changes or modifications to the above-disclosed technical content to create equivalent embodiments. However, any simple modifications, equivalent changes, and modifications made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the protection scope of the present invention.

Claims

1. A closed-loop machining control method for the parallelism of straight spokes on high-speed train wheels, characterized in that, Includes the following steps: Establishment of precision parallel reference for the process: Precision machining of the inner side of the wheel, collecting deformation data of the inner rim surface under different tread clamping forces, establishing a mathematical model related to the parallelism between the inner rim surface and the straight spoke plate, and obtaining the deformation compensation amount; before precision machining of the straight spoke plate, controlling the level of the tooling shim as a unified reference for precision machining, matching the deformation compensation amount, and using the level of the shim as a reference to constrain the workpiece clamping posture. Finite element simulation zoned quantitative clamping control: A three-dimensional finite element simulation model of a high-speed train wheel is established to simulate the elastic deformation fields of the rim and spokes of the tread area and the flange area under different clamping pressures, respectively. The optimal zoned clamping pressure within the safe deformation threshold is determined, and the clamping pressure of the tread area and flange area is locked by the machine tool hydraulic system. Low-stress segmented progressive cutting: A segmented allowance allocation strategy is adopted to divide the finishing allowance of the spokes into multiple layers of progressive cutting, and cutting parameters are set for layered cutting; In-machine online closed-loop measurement and dynamic compensation control: An in-machine probe is integrated into the CNC machining unit and embedded into the CNC machining program loop; after each layer of cutting is completed, the machine tool automatically calls the probe to collect the horizontality and parallelism data of the spokes in real time; the measured data is compared with the theoretical parallelism model, the deviation compensation amount is automatically calculated, and the tool path is corrected in real time; if the deviation exceeds the preset warning threshold, the system automatically prompts manual adjustment of clamping pressure and / or cutting parameters, forming a closed-loop control of machining-real-time detection-data feedback-parameter / tool ​​compensation.

2. The closed-loop machining control method for the parallelism of straight spokes of high-speed train wheels according to claim 1, characterized in that, During the establishment of a precise parallel benchmark for the process, a level is used to calibrate the tooling shims before finishing the straight spokes, and the levelness error is controlled within ≤0.03mm.

3. The closed-loop machining control method for the parallelism of straight spokes of high-speed train wheels according to claim 1, characterized in that, In the finite element simulation of zonal quantitative clamping control, the optimal zonal clamping pressure is: tread clamping pressure 70-72 bar, wheel flange clamping pressure 30-32 bar.

4. The closed-loop machining control method for the parallelism of straight spokes of high-speed train wheels according to claim 3, characterized in that, The machine tool hydraulic program automatically outputs a tread clamping pressure of 71 bar and a wheel flange clamping pressure of 31 bar. After the pressure stabilizes, there is a 5-10 second delay to allow the workpiece's elastic deformation to stabilize before starting cutting.

5. The closed-loop machining control method for the parallelism of straight spokes of high-speed train wheels according to claim 1, characterized in that, In low-stress segmented progressive cutting, the cutting parameters are: cutting speed 210 m / min, feed rate 0.4-0.5 mm / r, and depth of cut 0.1-0.2 mm per pass.

6. The closed-loop machining control method for the parallelism of straight spokes of high-speed train wheels according to claim 5, characterized in that, The total allowance of the spokes is cut progressively in three layers, with a single cutting depth of 0.15 mm.

7. The closed-loop machining control method for the parallelism of straight spokes of high-speed train wheels according to claim 1, characterized in that, In the in-machine online closed-loop measurement and dynamic compensation control, cutting is paused after each layer of cutting is completed, and online measurement is started to collect the levelness and parallelism data of the spokes.

8. The closed-loop machining control method for the parallelism of straight spokes of high-speed train wheels according to claim 1, characterized in that, In the in-machine online closed-loop measurement and dynamic compensation control, the preset warning threshold is a parallelism deviation of 0.025 mm.

9. The closed-loop machining control method for the parallelism of straight spokes of high-speed train wheels according to claim 1, characterized in that, After batch processing is completed, 30% of the samples are randomly inspected, and the parallelism data is verified by a coordinate measuring machine.

10. A closed-loop machining control system for the parallelism of straight spokes on high-speed train wheels, used to implement the method described in claims 1-9, characterized in that, include: The benchmark establishment module is used to collect deformation data of the inner rim surface under different tread clamping forces when finishing the inner side of the wheel, establish a mathematical model related to the parallelism between the inner rim surface and the straight spoke plate, obtain the deformation compensation amount, and control the levelness of the tooling pad before finishing the straight spoke plate as a unified benchmark for finishing, and match the deformation compensation amount. The finite element simulation clamping control module is used to establish a three-dimensional finite element simulation model of a high-speed rail wheel, simulate the elastic deformation field of the rim and the elastic deformation field of the spokes under different clamping pressures in the tread area and the flange area, determine the optimal partition clamping pressure within the safe deformation threshold, and lock the clamping pressure of the tread area and the flange area through the machine tool hydraulic system. The low-stress segmented cutting module is used to divide the finishing allowance of the spokes into multiple layers of progressive cutting using a segmented allowance allocation strategy, and to perform layered cutting according to the set cutting parameters. The online closed-loop measurement and dynamic compensation control module is used to integrate an in-machine probe into the CNC machining unit and embed the CNC machining program loop. After each layer of cutting is completed, the probe is automatically called to collect the horizontality and parallelism data of the spokes in real time. After comparing the measured data with the theoretical parallelism model, the deviation compensation amount is automatically calculated and the tool path is corrected in real time. When the deviation exceeds the preset warning threshold, it automatically prompts manual adjustment of clamping pressure and / or cutting parameters.

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