Adjustable Mirror Milling Support Head Layout for Vibration Control
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Solution Overview
Problem
Existing single support point layout schemes are inadequate for mirror milling of different types of large thin-walled parts, as they fail to adapt to diverse processing requirements and working conditions, leading to suboptimal machining accuracy and surface quality due to deformation and vibration issues.
Innovation Solution
A point layout optimization method and device for a follow-up support head in mirror milling, which adjusts the layout of central and peripheral support points based on specific working conditions, using a coupled vibration model and swarm intelligence optimization algorithms to determine the optimal distribution of support points and radius, ensuring minimal machining process vibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single fixed support point layout is used, then the structure is simple, but it cannot adapt to diversified processing requirements of different workpieces
Solution Approach 1:
The support head employs adjustable support points that can be repositioned along the support bar, transforming a static fixed layout into a dynamic configurable system. This allows the same support head to adapt to different workpiece geometries and processing requirements by changing the support point positions, thereby resolving the contradiction between adaptability and structural simplicity.
Solution Approach 2:
The support head design integrates multiple support points on a single support bar that can be configured for different workpiece types. By making the support points adjustable rather than fixed, a single support head structure can serve multiple functions across different machining scenarios, achieving versatility without requiring multiple specialized support heads.
2Manufacturing precision
If support points are added to improve vibration suppression, then machining quality improves, but the structure becomes more complex
Solution Approach 1:
The support head divides the support function into multiple discrete support points distributed along the support bar. Each support point can independently contact the workpiece at optimal locations, providing distributed vibration suppression. This segmentation approach improves machining accuracy by reducing vibrations while maintaining relatively simple individual support point structures.
Solution Approach 2:
Multiple support points are integrated into a single support bar structure that is mounted on one manipulator. By merging the multiple support points into a unified rigid support bar, the system achieves coordinated vibration suppression across different locations without requiring multiple independent actuators, thus improving precision while controlling complexity.
3Ease of manufacture
If the support head structure is simplified, then ease of manufacture improves, but adaptability to complex surfaces deteriorates
Solution Approach 1:
The support points are designed to be adjustable along the support bar rather than fixed in rigid positions. This dynamic configuration capability allows the same simple support bar structure to adapt to complex surface geometries by repositioning support points to match the workpiece contour, achieving adaptability without complicating the basic support bar manufacturing.
Data Source
AI summary
The invention relates to the field of milling, specifically a point position layout optimization method and a follow-up support head in mirror milling. It features an annular and linear sliding module to design a support head with adjustable support points. A corresponding layout optimization method is developed, starting with a coupled vibration model of the machining process. A layout optimization model is then created, with the quantity of support points and the support radius as decision variables. The goal is to minimize vibration amplitude and root mean square, constrained by structural interference and boundary conditions. The solution is achieved using a particle swarm optimization algorithm, supplemented by parameter scanning and a penalty function strategy. This invention addresses the limitations of existing single support point layouts for the mirror milling of various large thin-walled workpieces.