Research On The Calculation Of Tool Edge Wear And The Related Technology Of On-Machine Detection

With the continuous development of machining technology,higher requirements are placed on the machining accuracy of parts in high-tech fields,such as aerospace,automotive,and precision instruments.In the process of machining,tool wear is one of the main influencing factors affecting the machining accuracy of parts.Therefore,it is of high practicality and socioeconomic value to carry out research on machine tool monitoring and wear to ensure the machining quality of parts.Firstly,by analyzing the tool wear mechanism and the tool edge contour change,the hardware and software design scheme of the tool edge wear onmachine detection system is formulated.Then the hardware is selected according to the requirements of the system,and the software structure is rationally divided.The data acquisition module,data processing and wear amount calculation module and industrial computer-machine communication module in the software are designed and implemented.Secondly,the dynamic acquisition principle of 3D camera based on line structured light is studied.The acquisition method of edge shape data of end mill edge is designed,and the relative acquisition path of tool edge and 3D camera is planned.According to the control task of the tool movement carried by the spindle in the acquisition path,the calculation formulas of the relevant parameters of the machine motion control are derived.The photoelectric switch is used to detect the positioning of the cutting edge acquisition reference,and the on-machine acquisition of the edge shape data of the end mill is realized.Thirdly,by analyzing the characteristics of the tool edge cross-section profile data collected by the 3D camera based on line structured light,the smoothing and denoising processing is firstly performed,and the differential curvature and K-nearest neighbor algorithm are used to effectively classify the data according to the discrete point curvature of the data.According to the classified data characteristics,the collected tool edge wear profile data and the non-wear profile data are unified into the wear amount calculation coordinate system,and the change of the two profile lines is analyzed and calculated to obtain the blunt circle radius,the VB value and Wear volume of the tool edge.Finally,the VC++6.0 and MATLAB mixed programming method are used to effectively integrate the software modules in the system.By analyzing the technical principle of the open CNC system based on SERCOS communication,and based on the Windows+RTX environment,the test platform integrated in the machine tool detection system of the open CNC system is built.The system stability verification and error analysis are carried out for the side edge wear detection of the end mill.