Mirror Milling Path Transplantation for Thin-Walled Surface Accuracy
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Solution Overview
Problem
Existing mirror milling processes for thin-walled parts, such as aircraft skin, suffer from deformation during processing, leading to inaccuracies in the curved surface not matching the design, which affects processing accuracy.
Innovation Solution
A method involving clamping and transferring procedures, point cloud acquisition, processing path transplantation, and real-time thickness measurement using ultrasonic probes to align cutter location points with the actual curved surface, ensuring accurate tool path transplantation and deformation compensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional milling is used for thin-walled parts, then the processing method is simple, but the curved surface accuracy deteriorates due to deformation during processing
Solution Approach 1:
The patent applies preliminary action by performing clamping and support operations before the actual milling process. The support measuring device is positioned and adjusted to provide pre-support at multiple points on the back of the thin-walled part, preventing deformation before it occurs during machining. This preliminary setup ensures the workpiece maintains its intended geometry throughout processing.
Solution Approach 2:
The patent introduces an intermediary support measuring device that acts as a mediator between the workpiece and the milling process. This device includes multiple support points with adjustable height and position, allowing it to compensate for variations in the thin-walled part geometry and provide stable support during machining, thereby maintaining curved surface accuracy without requiring complex direct control systems.
2Manufacturing precision
If support measuring device is applied on the back of the skin, then the curved surface accuracy is improved, but the device complexity increases
Solution Approach 1:
The support measuring device is segmented into multiple independent support points or modules distributed across the back surface of the thin-walled part. Each support point can be independently adjusted in position and height, allowing the system to accommodate complex curved geometries while maintaining modular simplicity. This segmentation enables precise local support without requiring a monolithic complex device.
Solution Approach 2:
The patent utilizes parameter changes by allowing the support measuring device to dynamically adjust its support height, position, and force distribution during the machining process. These parameter adjustments enable the device to adapt to variations in the thin-walled part geometry and maintain optimal support conditions, achieving high precision through flexible parameter control rather than complex mechanical structures.
3Reliability
If clamping and support operations are performed, then the processing stability is improved, but the time consumption increases
Solution Approach 1:
The support measuring device incorporates self-adjustment capabilities that allow it to automatically adapt to the workpiece geometry without requiring extensive manual intervention. The device can self-position and self-adjust its support points based on the thin-walled part's actual shape, significantly reducing the time needed for manual clamping and setup while maintaining processing stability throughout the machining operation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Improves machining accuracy by aligning cutter locations with the actual surface geometry, reducing deformation-induced errors, and ensuring consistent processing with the design curved surface.
Implementation Method 1
measuring the thickness of the thin-walled part in real time by an ultrasonic probe to obtain the real-time thickness of the thin-walled part
Implementation Method 2
the plurality of eddy current sensor sensors are used for generating an eddy current to measure the eddy current spacing between the ultrasonic probe and the thin-walled part
Implementation Method 3
the nozzle is used to output a water flow filling an area between the coupling part and the thin-walled part during the measurement procedure of the ultrasonic probe
Implementation Method 4
the pressure of the water flow is adjusted by comparing the real-time water pressure value with a standard water pressure value, and the thin-walled part is supported by the pressure of the water
Data Source
AI summary
The present invention relates to the technical field of mirror milling, in particular to a mirror milling processing and measurement process and control process method, and system thereof, wherein, the thin-walled part processing path program transplantation procedure comprises: aligning, according to an actual positioning hole in a point cloud data obtained by scanning the thin-walled part and the theoretical positioning hole on a theoretical triangle mesh curved surface generated by a design curved surface, an actual triangle mesh curved surface corresponding to the point cloud data with the theoretical triangle mesh curved surface; calculating, for a plurality of cutter location points in a cutter location file, geodesic information between each of the cutter location points and the theoretical positioning hole respectively; transplanting, according to the geodesic information, the cutter location points to the actual triangular mesh curved surface to form a transplantation processing path.