微小型零件車銑復(fù)合加工精度表征與控制摘要：

本文研究了微小型零件車銑復(fù)合加工中精度的表征與控制方法。針對(duì)微型加工中機(jī)床運(yùn)動(dòng)、加工刀具、加工材料等因素導(dǎo)致的加工誤差，提出了基于機(jī)器視覺和數(shù)字化控制技術(shù)的高精度加工方案。具體來說，通過對(duì)車銑復(fù)合加工過程進(jìn)行高速圖像采集和處理，提取加工中產(chǎn)生的不良表面形貌、尺寸誤差、位置偏移等信息，建立精度控制模型，實(shí)現(xiàn)對(duì)加工過程的實(shí)時(shí)監(jiān)測(cè)與反饋控制。同時(shí)，在加工參數(shù)優(yōu)化、刀具選擇、工件夾緊等方面進(jìn)行綜合考慮和優(yōu)化設(shè)計(jì)，進(jìn)一步提高加工精度，使零件尺寸精度控制在微米級(jí)別以內(nèi)。實(shí)驗(yàn)證明，所提出的微小型零件車銑復(fù)合加工精度表征與控制方法能夠有效提高加工精度，達(dá)到高精度加工的要求。

關(guān)鍵詞：微小型零件，車銑復(fù)合加工，精度表征，控制方法，機(jī)器視覺，數(shù)字化控制，加工參數(shù)優(yōu)化

Abstract:

Thispaperstudiestheprecisioncharacterizationandcontrolmethodinthecompoundmillingoftinyparts.Basedonthemachiningerrorscausedbyfactorssuchasmachinetoolmotion,machiningtools,andmaterialsduringmicro-machining,ahigh-precisionmachiningsolutionbasedonmachinevisionanddigitalcontroltechnologyisproposed.Specifically,throughhigh-speedimageacquisitionandprocessingduringtheturningandmillingcompoundprocess,theadversesurfacemorphology,sizeerror,positiondeviationandotherinformationgeneratedduringtheprocessingareextractedandtheaccuracycontrolmodelisestablishedtoachievereal-timemonitoringandfeedbackcontroloftheprocessingprocess.Atthesametime,comprehensiveconsiderationandoptimizeddesignisconductedintheaspectsofmachiningparameteroptimization,toolselection,andworkpiececlamping,furtherimprovingthemachiningaccuracyandcontrollingthedimensionalaccuracyofpartswithintherangeofmicrometers.Theexperimentprovesthattheprecisioncharacterizationandcontrolmethodofthecombinationoftinypartsturningandmillingcompoundproposedinthispapercaneffectivelyimprovethemachiningaccuracyandmeettherequirementsofhigh-precisionmachining.

Keywords:TinyParts,CompoundingTurningandMilling,PrecisionCharacterization,ControlMethod,MachineVision,DigitalControl,MachiningParameterOptimizationInordertoverifytheeffectivenessoftheproposedmethod,experimentswereconductedusingacombinationofturningandmillingprocessesontinyparts.TheexperimentswereconductedonaCNC(ComputerNumericalControl)machinewithdigitalcontrolandmachinevisionsystems.

Firstly,theprecisioncharacterizationoftheturningandmillingprocesseswascarriedoutusingmachinevision.Thisinvolvedmeasuringthesurfaceroughness,circularity,cylindricity,andflatnessofthemachinedparts.Theresultsdemonstratedthattheprecisioncharacterizationmethodwasabletoaccuratelydetectsmalldeviationsinthemachinedparts.

Next,aprecisioncontrolmethodwasdevelopedbasedontheprecisioncharacterizationresults.Thisinvolvedmodifyingthecuttingparameterssuchastoolpath,feedrate,andspindlespeed.Thecontrolmethodwasabletoreducethedeviationsandimprovetheprecisionofthemachinedparts.

Inaddition,machiningparameteroptimizationwascarriedoutusingadesignofexperiment(DOE)approach.Thisinvolvedvaryingthecuttingparameterstodeterminetheoptimalcombinationofparametersthatwouldachievethebestmachiningresults.Theoptimizedparameterswerethenusedtomachinetheparts,andtheresultsdemonstratedthatthemachiningaccuracywassignificantlyimprovedcomparedtothepreviousmachiningconditions.

Overall,theexperimentsdemonstratedthatthecombinationofturningandmillingprocesses,alongwiththeprecisioncharacterizationandcontrolmethodsproposedinthispaper,caneffectivelyimprovethemachiningaccuracyoftinypartswithintherangeofmicrometers.Thishasimportantimplicationsforthemanufactureofhigh-precisioncomponentsinvariousindustries,suchastheaerospaceandmedicaldeviceindustriesInadditiontotheexperimentalresultspresentedinthispaper,thereareseveralotherareaswherethisresearchcanbefurtherdevelopedorapplied.Onepossibledirectionistoexploretheuseofdifferentcuttingtools,suchasdiamondorcubicboronnitride(CBN)tools,inthemachiningoftinyparts.Thesematerialsareknownfortheirhighwearresistanceandhardness,whichcanhelptoprolongtoollifeandimprovethemachiningaccuracy.However,theuseofthesetoolsalsorequirescarefulselectionofcuttingparametersandtoolgeometriestoavoiddamagetotheworkpieceortoolinstability.

Anotherpromisingareaofresearchistheintegrationofsensorfeedbackandcontrolintothemachiningprocess.Byusingsensorstomonitorvariousaspectsofthemachiningprocess,suchastemperature,vibration,andtoolwear,itispossibletodevelopclosed-loopcontrolalgorithmsthatcanadjustcuttingparametersinreal-timetoensurethedesiredmachiningaccuracyandsurfacefinish.Thisapproachhasbeenwidelyusedinmacro-scalemachiningandisbeginningtobeexploredinmicro-scalemachiningaswell.

Finally,thetechniquesandmethodsdevelopedinthispapercanalsobeappliedtoothertypesofmicro-scalemanufacturingprocesses,suchasmicro-EDM,micro-lasermachining,andmicro-injectionmolding.Bycombiningprecisioncharacterizationandmeasurementtechniqueswithadvancedcontrolalgorithms,itispossibletoachievehigh-precisionmicro-manufacturingacrossawiderangeofapplicationsandindustries.

Insummary,theresearchpresentedinthispaperdemonstratesthefeasibilityandeffectivenessofusingacombinationofturningandmillingprocesses,alongwithprecisioncharacterizationandcontrolmethods,toimprovethemachiningaccuracyoftinypartswithintherangeofmicrometers.Thetechniquesandmethodsdevelopedinthisresearchhaveimportantimplicationsforthemanufactureofhigh-precisioncomponentsinvariousindustriesandcanbefurtherdevelopedandappliedtoothermicro-scalemanufacturingprocessesFurthermore,theresearchpresentedinthispapershedslightontheimportanceofaccuratecharacterizationandcontrolmethodsformicro-scalemachining,especiallywhendealingwithcomplexgeometriesandtolerances.Theuseofadvancedsensingandmonitoringtechniques,suchasin-processmeasurementsandfeedbackcontrol,canhelptomitigateerrorsandensureconsistentqualityinmicro-scalemanufacturing.Additionally,theintegrationofsimulationandmodelingtoolscanaidinoptimizingandpredictingthemachiningbehaviorofmicro-scalecomponents,savingtimeandresourcesinthemanufacturingprocess.

Moreover,thefindingsofthisresearchhighlightthepotentialforadvancingmicro-scalemachiningtechnologytomeetthedemandsofemergingfieldssuchasmicro-electromechanicalsystems(MEMS),nanotechnology,andbiotechnology.Asthedemandforsmaller,moreprecisecomponentscontinuestogrowacrossvariousindustries,thedevelopmentofreliableandefficientmicro-manufacturingtechniquesbecomesincreasinglycrucial.

Inconclusion,theresearchpresentedinthispaperdemonstratestheimportanceandpotentialofusingacombinationofturningandmillingprocesses,alongwithadvancedcharacterizationandcontrolme