A method of machining a core support forging

Abstract

The present application relates to the technical field of core support forging processing, and discloses a kind of core support forging processing method, comprising: step 100, the critical signal value of the state of reaction processing from stable to deterioration is obtained, and the early warning threshold is set according to critical signal value;Step 200, the process state signal value of workpiece in current machining process is obtained;Step 300, compare process state signal and early warning threshold;If process state signal value is less than early warning threshold, maintain current cutting parameter and continue to process;If process state signal value reaches or exceeds early warning threshold, then pause processing and calculate predicted deformation, continue to process after compensating tool position according to predicted deformation, or adjust cutting parameter, or adjust tooling support force or clamping force, or stop and record abnormal data;Step 400, after step 300 is executed, return to step 200, and execute repeatedly layer by layer until processing is completed.The present application solves the technical problem that a certain number of flaws exist in core support forging processing.

Description

Technical Field

[0001] This invention relates to the field of core support forging technology, and in particular to a method for processing core support forgings. Background Technology

[0002] The core support plate forging is one of the core components of a nuclear reactor internals. It is an ultra-large circular plate forging made of austenitic stainless steel. In the reactor, the core support plate forging plays a crucial role in bearing the weight of the entire core and providing precise support and positioning for the fuel assemblies.

[0003] Currently, in traditional machining, operators mainly rely on experience to judge the machining status, which makes it impossible to detect abnormalities such as chatter and tool deflection in time, resulting in a certain number of defects in the machined workpieces. Summary of the Invention

[0004] This application discloses a processing method for core support forgings to solve the technical problem of a certain number of defects in the processing of core support forgings in related technologies.

[0005] To solve the above problems, the present invention adopts the following technical solution: This application discloses a method for processing a core support forging, comprising the following steps: Step 100: Obtain the critical signal value that changes the reaction processing state from stable to deteriorating, and set an early warning threshold based on the critical signal value; Step 200: Obtain the process status signal value of the workpiece in the current processing stage; Step 300: Compare the process status signal with the warning threshold; if the process status signal value is less than the warning threshold, maintain the current cutting parameters and continue machining; if the process status signal value reaches or exceeds the warning threshold, pause machining and calculate the predicted deformation amount, compensate the tool position according to the predicted deformation amount and continue machining, or adjust the cutting parameters, or adjust the tool support force or clamping force, or stop the machine and record abnormal data. After steps 400 and 300 are completed, return to step 200 and repeat the process layer by layer until the processing is complete.

[0006] In some schemes, step 100 includes: Step 110: Divide the non-functional area of ​​the workpiece into multiple continuous sub-segments, and change the cutting parameters between each sub-segment in an equal step increment or decrease manner, and perform multiple sets of calibration cutting. Step 120: Collect the process status signals corresponding to each group of calibration cuts, and detect the machining quality indicators corresponding to each group of calibration cuts; Step 130: Establish a corresponding relationship curve with cutting parameters as the horizontal axis and process status signals and machining quality indicators as the vertical axes respectively; Step 140: Determine the process state signal value corresponding to the point when the processing quality index begins to increase sharply as the first critical signal value, and determine the process state signal value corresponding to the point when the processing quality index reaches the upper limit of the allowable value as the second critical signal value; Step 150: Set the warning threshold based on the first or second critical signal value.

[0007] In some schemes, in step 120, the process status signal includes at least one of the effective value of vibration, peak cutting force, and rate of temperature rise; The processing quality indicators include at least one of surface roughness and dimensional deviation.

[0008] In some schemes, in step 150, the first critical signal value is multiplied by a preset safety factor and set as the first-level warning threshold; the second critical signal value is directly set as the second-level warning threshold.

[0009] In some schemes, step 200 includes: Step 210: Install a vibration sensor on the machine tool spindle or tool side, install a force sensor between the workpiece and the tooling, install a displacement sensor above the workpiece surface, and install a temperature sensor near the cutting area. Step 220: During the processing, the vibration sensor, force sensor, displacement sensor and temperature sensor synchronously collect data at a preset sampling frequency, and perform signal processing on the collected data to obtain the effective value of vibration, peak cutting force, displacement deviation and temperature rise rate of the current processing process as process status signal values.

[0010] In some schemes, step 300 includes: Step 310: Compare the process status signal value with the first-level warning threshold and the second-level warning threshold; if the process status signal value is less than the first-level warning threshold, maintain the current cutting parameters and continue machining; if the process status signal value reaches or exceeds the first-level warning threshold but is less than the second-level warning threshold, execute the first-level control; if the process status signal value reaches or exceeds the second-level warning threshold, execute the second-level control. The first-level control includes at least one of the following operations: reducing the feed rate, adjusting the spindle speed, and increasing the support force at the corresponding support point; The second level of control includes: pausing machining and retracting the tool to a safe position; acquiring the current cutting force signal and calculating the predicted deformation based on the pre-stored deformation compensation coefficient and the current cutting force signal; detecting the current deformation of the workpiece and comparing the predicted deformation with the detected current deformation; if the verification passes, compensating the tool position based on the predicted deformation and continuing machining; if the verification fails, adjusting the tool support force or clamping force and waiting for the deformation to stabilize before resetting the tool and continuing machining.

[0011] In some solutions, specific methods for detecting the current deformation of the workpiece include: A displacement sensor is placed above the workpiece. The displacement sensor detects the displacement deviation between the current position and the initial position on the workpiece surface, which is used as the current deformation of the workpiece.

[0012] In some solutions, the feed rate is reduced by 20%-30%; Adjust the spindle speed offset to ±10%.

[0013] In some schemes, the steps also include: Step 320: When the process status signal value exceeds the preset emergency stop threshold, perform an emergency stop and issue an alarm, and record the process status signal data before and after the alarm time.

[0014] In some schemes, the preset sampling frequency is greater than 1KHz.

[0015] The technical solution adopted in this invention can achieve the following beneficial effects: The processing method for core support forgings disclosed in this application solves the problem of traditional processes relying on experience to set parameters and lacking quantitative basis by obtaining critical signal values ​​through simple trial cutting before processing. During processing, the method monitors process status signals in real time and compares them with thresholds, enabling immediate perception of processing anomalies (such as chatter precursors or excessive deformation). Once an early warning is triggered, the method can autonomously select multiple response modes, such as compensating for tool position, adjusting cutting parameters, adjusting tooling, or safely stopping the machine, forming a closed-loop control of "perception-discrimination-response". Furthermore, the method is executed layer by layer, allowing each layer of processing to adaptively adjust based on the state of the previous layer. Without relying on complex models and high-cost equipment, this method significantly improves the accuracy, stability, and process safety of processing large thin-walled components, thereby reducing the number of processing defects. Attached Figure Description

[0016] 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.

[0017] Figure 1 This is a flowchart of a method for processing core support forgings disclosed in some embodiments of this application. Detailed Implementation

[0018] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be described in detail below. Obviously, the described embodiments are merely some embodiments of this invention, and not all embodiments. Based on the embodiments of this invention, all other implementation methods obtained by those skilled in the art without creative effort are within the scope of protection of this invention.

[0019] The terms "first," "second," etc., used in the specification and claims of this application are used to distinguish similar objects and not to describe a specific order or sequence. It should be understood that such use of data can be interchanged where appropriate so that embodiments of this application can be implemented in orders other than those illustrated or described herein, and the objects distinguished by "first," "second," etc., are generally of the same class and the number of objects is not limited; for example, a first object can be one or more. Furthermore, in the specification and claims, "and / or" indicates at least one of the connected objects, and the character " / " generally indicates that the preceding and following objects are in an "or" relationship.

[0020] The following is in conjunction with the appendix Figure 1 The processing method of a core support forging provided in this application will be described in detail through specific embodiments and application scenarios.

[0021] Some embodiments of this application disclose a method for processing a core support forging, including the following steps: Step 100: Obtain the critical signal value that changes the reaction processing state from stable to deteriorating, and set an early warning threshold based on the critical signal value; Step 200: Obtain the process status signal value of the workpiece in the current processing stage; Step 300: Compare the process status signal with the warning threshold; if the process status signal value is less than the warning threshold, maintain the current cutting parameters and continue machining; if the process status signal value reaches or exceeds the warning threshold, pause machining and calculate the predicted deformation amount, compensate the tool position according to the predicted deformation amount and continue machining, or adjust the cutting parameters, or adjust the tool support force or clamping force, or stop the machine and record abnormal data. After steps 400 and 300 are completed, return to step 200 and repeat the process layer by layer until the processing is complete.

[0022] In step 100, by pre-acquiring the critical signal value reflecting the change of processing state from stable to deteriorated and setting the early warning threshold accordingly, an objective and quantitative evaluation benchmark for whether the processing state has deteriorated is provided, replacing the subjective judgment method that relies on the operator's personal experience in traditional processing, and providing a basis for automatic monitoring and judgment in subsequent steps.

[0023] In step 200, the current process status signal value of the workpiece is acquired in real time during the processing, so that the monitoring of the processing status no longer depends on the operator's visual observation and experience judgment, but reflects the real situation of the processing process continuously and objectively through data, providing a data basis for timely detection of abnormalities such as chatter and tool deflection.

[0024] In step 300, by automatically comparing the real-time acquired process status signal value with the early warning threshold, and triggering corresponding control actions when the signal value reaches or exceeds the threshold, the processing abnormality can be identified and automatically intervened in a timely manner when it occurs or deteriorates, thus avoiding the problem of workpiece defects caused by the operator's inability to detect abnormalities in a timely manner in traditional processing.

[0025] In step 400, by repeating steps 200 to 300 layer by layer until the processing is completed, each layer of processing can be continuously monitored and timely adjusted and responded to, ensuring that abnormalities that occur during processing will not accumulate across layers, thereby maintaining effective monitoring and automatic intervention capabilities of the processing status throughout the entire processing cycle.

[0026] Specifically, step 100 includes: Step 110: Divide the non-functional area of ​​the workpiece into multiple continuous sub-segments, and change the cutting parameters between each sub-segment in an equal step increment or decrease manner, and perform multiple sets of calibration cutting. Step 120: Collect the process status signals corresponding to each group of calibration cuts, and detect the machining quality indicators corresponding to each group of calibration cuts; Step 130: Establish a corresponding relationship curve with cutting parameters as the horizontal axis and process status signals and machining quality indicators as the vertical axes respectively; Step 140: Determine the process state signal value corresponding to the point when the processing quality index begins to increase sharply as the first critical signal value, and determine the process state signal value corresponding to the point when the processing quality index reaches the upper limit of the allowable value as the second critical signal value; Step 150: Set the warning threshold based on the first or second critical signal value.

[0027] In step 110, the non-functional area of ​​the workpiece refers to the area that will eventually be removed and will not affect the quality of the finished product, such as the machining allowance. A calibration cutting zone is planned and divided into multiple continuous sub-segments. Between each sub-segment, a certain cutting parameter (e.g., spindle speed or feed rate) is changed in equal increments or decreases, while other cutting parameters remain unchanged. Multiple sets of calibration cuts are executed sequentially. By changing the cutting parameters, different cutting states from stable machining to deteriorated machining are actively created, thereby obtaining process signal data and corresponding machining quality data covering different machining states, providing data samples for subsequent determination of critical signal values.

[0028] In step 120, while performing each set of calibration cuts in step 110, process status signals (such as vibration signals, cutting force signals, temperature signals, etc.) corresponding to each set of cuts are collected through a pre-deployed sensor group. After each set of calibration cuts is completed, the machining quality indicators (such as surface roughness, dimensional deviations, etc.) of the corresponding area of ​​each set of cuts are measured using appropriate testing tools (such as roughness testers, micrometers, etc.). An input-output data pair is established for each set of calibration cuts, where the input is the known cutting parameters, and the output is the process status signals collected by the sensors and the detected machining quality indicators. These data pairs are the basic material for subsequently establishing the corresponding relationship curves.

[0029] In step 130, the data obtained in step 120 is organized, and two sets of corresponding curves are plotted: the first set uses the cutting parameters changed in step 110 (such as feed rate) as the horizontal axis and the process state signal value (such as effective vibration value) as the vertical axis; the second set uses the same cutting parameters as the horizontal axis and the machining quality index value (such as surface roughness) as the vertical axis. The data points of each set of calibrated cutting are plotted on the coordinate system and connected to form a curve. The curves visually reflect "how the process state signal changes with the cutting parameters" and "how the machining quality index changes with the cutting parameters," thus providing a visual basis for determining "the process state signal value corresponding to the start of machining quality deterioration."

[0030] In step 140, observe the correspondence curve established in step 130. In the processing quality index curve, find the inflection point (i.e., the turning point) where the index suddenly changes from a relatively flat range to a rapid increase; the process state signal value corresponding to this point is the first critical signal value. Find the process state signal value corresponding to when the processing quality index just reaches the upper limit of the process allowable value; this is the second critical signal value. Extract two critical points with practical engineering significance from the calibration data: the first marks the starting point of significant deterioration in the processing state, and the second marks the warning point where the processing quality is about to exceed the tolerance, thus providing specific numerical basis for subsequently setting early warning thresholds.

[0031] In step 150, one or both of the first and second critical signal values ​​determined in step 140 are appropriately processed and set as a warning threshold for status identification in subsequent processing. For example, the first critical signal value can be multiplied by a safety factor less than 1 and set as the warning threshold (for early warning), or the second critical signal value can be directly set as the warning threshold (for final warning before quality deviation). Converting the critical signal values ​​obtained in the calibration stage into warning thresholds that can be practically used in the processing provides a clear quantitative comparison benchmark for the real-time process status signal values ​​obtained in subsequent step 200, thereby achieving automatic identification of the processing status.

[0032] In step 120, the process status signal includes at least one of vibration RMS value, peak cutting force, and temperature rise rate; the machining quality index includes at least one of surface roughness and dimensional deviation. Vibration RMS value, peak cutting force, and temperature rise rate are chosen as process status signals because they reflect changes in machining status from different dimensions: vibration RMS value directly characterizes whether chatter or cutting instability exists during machining; peak cutting force directly reflects the magnitude and fluctuation of the cutting load; and temperature rise rate reflects the temperature change trend in the cutting area. These three signals complement each other and can comprehensively capture early signs of machining status deteriorating from stable to deteriorating. Surface roughness and dimensional deviation are chosen as machining quality indexes because these two indicators are the most direct and core parameters for measuring the machining quality of the core support plate. Surface roughness directly reflects the integrity of the machined surface, and dimensional deviation directly reflects whether the machining accuracy meets design requirements. Both can objectively quantify the quality of machining. By establishing a correspondence between the process status signal and the machining quality index, the process status signal value corresponding to the beginning of machining quality deterioration can be identified, thus providing a reliable basis for setting warning thresholds.

[0033] In step 150, the first critical signal value is multiplied by a preset safety factor and set as the first-level early warning threshold; the second critical signal value is directly set as the second-level early warning threshold. The preset safety factor is a value between 0 and 1, and its function is to artificially set the first-level early warning threshold to be slightly lower than the first critical signal value (i.e., more sensitive), so that the system can trigger an early warning before the process state signal reaches the first critical signal value, thereby buying time for subsequent control actions. The specific value of the preset safety factor can be determined according to the strictness of the processing requirements and the specific signal type being monitored.

[0034] The reason for setting two levels of warning thresholds is that the first and second critical signal values ​​physically correspond to different risk levels, requiring different warning strategies. The first critical signal value is the process state signal value corresponding to when the processing quality index begins to increase sharply, indicating that the processing state has just entered the initial stage of deterioration. At this time, the processing quality has not yet truly exceeded the tolerance and there is still a safety buffer. Therefore, the first critical signal value is multiplied by a preset safety factor less than 1 and set as the first-level warning threshold. Its function is to issue an early warning when the processing state just shows a deterioration trend, reserving sufficient response time for subsequent control. The second critical signal value is the process state signal value corresponding to when the processing quality index reaches the allowable upper limit, indicating that the processing quality has approached or reached the qualified boundary. At this time, there is no safety margin to consume. Therefore, the second critical signal value is directly set as the second-level warning threshold. Its function is to serve as the final line of defense for quality control, ensuring that the processing quality is not detected only after it has actually exceeded the tolerance.

[0035] Step 200 includes: Step 210: Install a vibration sensor on the machine tool spindle or tool side, install a force sensor between the workpiece and the tooling, install a displacement sensor above the workpiece surface, and install a temperature sensor near the cutting area. Step 220: During the processing, the vibration sensor, force sensor, displacement sensor and temperature sensor synchronously collect data at a preset sampling frequency, and perform signal processing on the collected data to obtain the effective value of vibration, peak cutting force, displacement deviation and temperature rise rate of the current processing process as process status signal values.

[0036] In step 210, a vibration sensor is installed on the machine tool spindle or tool side to sense mechanical vibration signals caused by cutting force fluctuations, tool wear, or chatter during machining; a force sensor is installed between the workpiece and the tooling to sense the magnitude and changes of the cutting load exerted by the tool on the workpiece during machining; a displacement sensor is installed above the workpiece surface to sense the displacement changes of the workpiece surface under the action of cutting force; and a temperature sensor is installed near the cutting area to sense the heat generated during cutting and the temperature change trend. These four types of sensors are deployed in different key locations, each undertaking a different sensing task, and together constitute the acquisition channel for machining process status signals, providing the hardware foundation for data acquisition and signal processing in the subsequent step 220.

[0037] In step 220, during the machining process, the four types of sensors installed in step 210 synchronously acquire their respective original physical signals according to a preset sampling frequency, and transmit the acquired data to the control system. The control system processes the original vibration signals acquired by the vibration sensors, extracts their effective values ​​as the effective vibration value, which reflects the average energy level of the vibration during the current machining process and is used to characterize whether chatter or cutting instability occurs during machining; it extracts the peak value of the original force signals acquired by the force sensors to obtain the cutting force peak value, which reflects the maximum cutting load borne during the current cutting process and is used to characterize whether the cutting load has increased abnormally; it calculates the deviation of the original displacement signals acquired by the displacement sensors, that is, it calculates the difference between the current displacement and the initial displacement to obtain the displacement deviation, which reflects the actual displacement change of the workpiece under the action of the cutting force and is used to characterize the degree of tool deflection or overall workpiece deformation; it performs differential calculation on the original temperature signals acquired by the temperature sensors, that is, it calculates the change in temperature per unit time to obtain the temperature rise rate, which reflects the rate of temperature increase in the cutting area and is used to characterize whether the cutting temperature has an abnormal upward trend. Finally, the effective value of vibration, peak cutting force, displacement deviation and temperature rise rate obtained after the above processing are used as process status signal values ​​of the current machining process for comparison and judgment in step 300.

[0038] In step 220, the preset sampling frequency is greater than 1 kHz. By setting the sampling frequency to greater than 1 kHz, the rapidly changing vibration, force, displacement, and temperature signals during the processing can be captured with a sufficiently high time resolution. This ensures that sudden anomalies such as chatter and sudden increases in cutting force can be collected and identified in a timely manner at the initial stage of occurrence, avoiding the omission of key signal features due to a low sampling rate. This ensures the timeliness and reliability of subsequent comparison, discrimination, and graded control.

[0039] Step 300 includes: Step 310: Compare the process status signal value with the first-level warning threshold and the second-level warning threshold; if the process status signal value is less than the first-level warning threshold, maintain the current cutting parameters and continue machining; if the process status signal value reaches or exceeds the first-level warning threshold but is less than the second-level warning threshold, execute the first-level control; if the process status signal value reaches or exceeds the second-level warning threshold, execute the second-level control. The first-level control includes at least one of the following operations: reducing the feed rate, adjusting the spindle speed, and increasing the support force at the corresponding support point; The second level of control includes: pausing machining and retracting the tool to a safe position; acquiring the current cutting force signal and calculating the predicted deformation based on the pre-stored deformation compensation coefficient and the current cutting force signal; detecting the current deformation of the workpiece and comparing the predicted deformation with the detected current deformation; if the verification passes, compensating the tool position based on the predicted deformation and continuing machining; if the verification fails, adjusting the tool support force or clamping force and waiting for the deformation to stabilize before resetting the tool and continuing machining. Step 320: When the process status signal value exceeds the preset emergency stop threshold, perform an emergency stop and issue an alarm, and record the process status signal data before and after the alarm time.

[0040] In step 310, the process status signal value obtained in step 220 is compared with the first-level warning threshold and the second-level warning threshold set in step 150. Based on the comparison result, three different processing methods are executed: If the process status signal value is less than the first-level warning threshold, it indicates that the current machining state is in a stable range and has not yet shown a deterioration trend; therefore, the current cutting parameters are maintained and machining continues. If the process status signal value reaches or exceeds the first-level warning threshold but is less than the second-level warning threshold, it indicates that the machining state has entered the initial stage of a deterioration trend, but the machining quality has not yet reached the out-of-tolerance critical point. In this case, first-level control is executed, including at least one of the following: reducing the feed rate, adjusting the spindle speed, and increasing the support force of the corresponding support point. This system employs a three-tiered approach to proactively intervene and suppress further deterioration of the machining process. If the process status signal value reaches or exceeds the second-level warning threshold, it indicates that the machining quality has approached or reached the acceptable boundary. At this point, the second-level control is executed: machining is paused, the tool is returned to a safe position, the current cutting force signal is acquired, and the predicted deformation is calculated using a pre-stored deformation compensation coefficient. Simultaneously, the actual deformation of the workpiece is detected by a displacement sensor, and the predicted deformation is compared with the actual deformation. If the deviation is within the allowable range, the verification is successful, and the tool position is compensated based on the predicted deformation before machining continues. If the verification fails, the tooling support force or clamping force is adjusted, and machining resumes after the deformation stabilizes. Through this three-tiered progressive comparison and graded control, appropriate intervention measures are implemented when the machining state is at different levels of deterioration. This avoids unnecessary intervention in a stable state and ensures that minor adjustments can be made to restore stability when the deterioration is mild, while comprehensive intervention is used to guarantee machining quality when the deterioration is severe.

[0041] In step 310, the pre-stored deformation compensation coefficient is a proportionality coefficient obtained by fitting the cutting force signal and the corresponding deformation data during the calibration cutting stage. It is used to characterize the deformation change corresponding to the unit cutting force change, and to calculate and predict the deformation based on the current cutting force signal during the machining process for use in tool position compensation.

[0042] In step 320, when the process status signal value exceeds the preset emergency stop threshold, it indicates that the current deterioration of the machining state has exceeded the range covered by the second-level warning threshold, reaching a dangerous level that may cause serious damage to the tool, workpiece, or equipment. At this time, the control system automatically executes an emergency stop and issues an audible and visual alarm to terminate the machining process as quickly as possible. Simultaneously, it records all process status signal data for a period of time before and after the alarm, which can be reviewed later for fault cause analysis. This step is a protective measure taken as a final safety assurance when both the first-level and second-level controls fail to effectively prevent the machining state from continuing to deteriorate.

[0043] In step 310, the specific method for detecting the current deformation of the workpiece includes: placing a displacement sensor above the workpiece, and detecting the displacement deviation between the current position and the initial position of the workpiece surface using the displacement sensor, which is then used as the current deformation of the workpiece. Placing a displacement sensor above the workpiece and using the displacement deviation between the current position and the initial position of the workpiece surface as the current deformation allows for the direct acquisition of real-time deformation data of the workpiece at the current moment without contacting the workpiece surface or affecting the processing progress. This provides an objective basis for subsequent comparison and verification of the predicted deformation with the measured deformation, avoiding compensation errors caused by relying solely on predicted values ​​and failing to detect changes in clamping status or model deviations.

[0044] In step 310, the feed rate is reduced by 20%-30%. This reduction range can effectively reduce the cutting force to suppress the deterioration of the machining condition, while avoiding insufficient control due to too small a reduction or a significant decrease in machining efficiency due to too large a reduction, thus achieving a balance between suppressing deterioration and maintaining efficiency.

[0045] In step 310, the spindle speed offset is adjusted to ±10%. The feed rate is reduced by 20%-30%. This offset range can avoid the resonance frequency of the machining system by changing the spindle speed to change the tool cutting frequency, while avoiding the increased tool wear or deterioration of the machined surface quality caused by excessive changes in speed that lead to a significant deviation of the cutting linear velocity from the reasonable range.

[0046] It should be noted that, in this document, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Unless otherwise specified, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes that element.

[0047] Furthermore, it should be noted that the scope of the methods and apparatus in the embodiments of this application is not limited to performing functions in the order shown or discussed, but may also include performing functions substantially simultaneously or in the reverse order, depending on the functions involved. For example, the described methods may be performed in a different order than described, and various steps may be added, omitted, or combined. In addition, features described with reference to certain examples may be combined in other examples.

[0048] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any changes or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in the present invention should be included within the scope of protection of the present invention.

Claims

1. A method for processing a core support forging, characterized in that, Includes the following steps: Step 100: Obtain the critical signal value that changes the reaction processing state from stable to deteriorating, and set an early warning threshold based on the critical signal value; Step 200: Obtain the process status signal value of the workpiece in the current processing stage; Step 300: Compare the process status signal with the early warning threshold; If the process status signal value is less than the warning threshold, maintain the current cutting parameters and continue machining; if the process status signal value reaches or exceeds the warning threshold, pause machining and calculate the predicted deformation amount. After compensating the tool position based on the predicted deformation amount, continue machining, or adjust the cutting parameters, or adjust the tool support force or clamping force, or stop the machine and record abnormal data. After steps 400 and 300 are completed, return to step 200 and repeat the process layer by layer until the processing is complete.

2. A method for processing a core support forging according to claim 1, characterized in that, Step 100 includes: Step 110: Divide the non-functional area of ​​the workpiece into multiple continuous sub-segments, and change the cutting parameters between each sub-segment in an equal step increment or decrease manner, and perform multiple sets of calibration cutting. Step 120: Collect the process status signals corresponding to each group of calibration cuts, and detect the machining quality indicators corresponding to each group of calibration cuts; Step 130: Establish a corresponding relationship curve with cutting parameters as the horizontal axis and process status signals and machining quality indicators as the vertical axes respectively; Step 140: Determine the process state signal value corresponding to the point when the processing quality index begins to increase sharply as the first critical signal value, and determine the process state signal value corresponding to the point when the processing quality index reaches the upper limit of the allowable value as the second critical signal value; Step 150: Set the warning threshold based on the first or second critical signal value.

3. A method for processing a core support forging according to claim 2, characterized in that, In step 120, the process status signal includes at least one of the following: effective vibration value, peak cutting force, and temperature rise rate; The processing quality indicators include at least one of surface roughness and dimensional deviation.

4. A method for processing a core support forging according to claim 2, characterized in that, In step 150, the first critical signal value is multiplied by a preset safety factor and set as the first-level warning threshold; the second critical signal value is directly set as the second-level warning threshold.

5. A method for processing a core support forging according to claim 2, characterized in that, Step 200 includes: Step 210: Install a vibration sensor on the machine tool spindle or tool side, install a force sensor between the workpiece and the tooling, install a displacement sensor above the workpiece surface, and install a temperature sensor near the cutting area. Step 220: During the processing, the vibration sensor, force sensor, displacement sensor and temperature sensor synchronously collect data at a preset sampling frequency, and perform signal processing on the collected data to obtain the effective value of vibration, peak cutting force, displacement deviation and temperature rise rate of the current processing process as process status signal values.

6. A method for processing a core support forging according to claim 5, characterized in that, Step 300 includes: Step 310: Compare the process status signal value with the first-level warning threshold and the second-level warning threshold; if the process status signal value is less than the first-level warning threshold, maintain the current cutting parameters and continue machining; if the process status signal value reaches or exceeds the first-level warning threshold but is less than the second-level warning threshold, execute the first-level control; if the process status signal value reaches or exceeds the second-level warning threshold, execute the second-level control. The first-level control includes at least one of the following operations: reducing the feed rate, adjusting the spindle speed, and increasing the support force at the corresponding support point; The second level of control includes: pausing machining and retracting the tool to a safe position; acquiring the current cutting force signal and calculating the predicted deformation based on the pre-stored deformation compensation coefficient and the current cutting force signal; detecting the current deformation of the workpiece and comparing the predicted deformation with the detected current deformation; if the verification passes, compensating the tool position based on the predicted deformation and continuing machining; if the verification fails, adjusting the tool support force or clamping force and waiting for the deformation to stabilize before resetting the tool and continuing machining.

7. A method for processing a core support forging according to claim 6, characterized in that, Specific methods for detecting the current deformation of a workpiece include: A displacement sensor is placed above the workpiece. The displacement sensor detects the displacement deviation between the current position and the initial position on the workpiece surface, which is used as the current deformation of the workpiece.

8. A method for processing a core support forging according to claim 6, characterized in that, The feed rate can be reduced by 20%-30%; Adjust the spindle speed offset to ±10%.

9. A method for processing a core support forging according to claim 6, characterized in that, The steps also include: Step 320: When the process status signal value exceeds the preset emergency stop threshold, perform an emergency stop and issue an alarm, and record the process status signal data before and after the alarm time.

10. A method for processing a core support forging according to claim 5, wherein the preset sampling frequency is greater than 1 kHz.

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