Dynamic tool orientation adjustment system for numerical control lathe roughing

Abstract

The present disclosure provides a system for dynamic tool orientation adjustment in numerical control lathe roughing machining. The system includes a tool orientation control (TOC) configured to receive an initial tool orientation (TO1) and a tool orientation range (RNG), define clearance values (CLR) for safe tool rotation, and generate an initial tool path (PTH) based on a workpiece (WPC) geometry. A collision detection module (CDM) detects potential collisions (CLS) along the tool path (PTH). A tool orientation adjuster (TOA) dynamically tilts a tool (TOL) within the tool orientation range (RNG) in response to detected potential collisions (CLS). An interpolation module (IPM) interpolates tool path motions with new tool orientations (TOR). A feed rate recalculator (FRR) recalculates feed rates (FDR) for each interpolated motion based on the new tool orientations (TOR). The system optimizes machining efficiency by dynamically adjusting tool orientation (TOR) and feed rates (FDR) during the roughing process.

Description

DYNAMIC TOOL ORIENTATION ADJUSTMENT SYSTEM FOR NUMERICAL CONTROL LATHE ROUGHING TECHNICAL FIELD

[0001] The present disclosure relates to numerical control [NC] lathe machining, and more particularly to a system and method for dynamic tool orientation adjustment in NC lathe roughing operations to optimize machining efficiency.BACKGROUND

[0002] Turning machining is a widely used manufacturing process for producing cylindrical parts (in the sense of rotational symmetry) with high precision. In recent years, there has been increasing demand for more complex geometries and improved surface finishes in turned components. This has led to the development of multi-axis CNC lathes capable of rotating the cutting tool and workpiece about multiple axes during machining operations.

[0003] US Patent Application Publication No. 2009 / 0182451 describes a system for controlling a multi-axis turning machine with rotary B and C axes for the cutting tool. While this addresses tool orientation control, it does not fully solve the problem of optimizing tool paths and cutting parameters that the present disclosure aims to address. The method relies on converting rotated tool positions back to a basic non-rotated state, which can introduce inaccuracies.

[0004] US Patent Application Publication No. 2015 / 0205284 discloses a method for interpolating tool positions and orientations in 5-axis machining. Although this provides smooth tool motion, it falls short in dynamically adjusting cutting parameters based on changing engagement conditions, which the present disclosure improves upon. The disclosed technique focuses primarily on tool kinematics rather than optimizing the cutting process itself.

[0005] US Patent Application Publication No. 2015 / 0346707 presents a technique for inserting chip-breaking motions into lathe turning operations using a numerical controller that has a cutting in / out motion inserting function. While this approach offers improved chip control, it does not address comprehensive optimization of tool orientation, feed rates, and cutting depths that the current disclosure seeks to overcome. The method inserts predefined motions rather than adapting parameters based on real-time analysis.

[0006] US Patent Application Publication No. 2022 / 0128968 introduces a system for generating CNC lathe control commands with variable cutting depths. Despite its advancements in roughing strategies, this does not fully resolve simultaneous optimization of multiple cutting parameters which is a key focus of the present disclosure. The disclosed method primarily considers cutting depth and the starting and end point of the tool path while not integrating tool orientation and other variables.

[0007] These approaches, while advancing various aspects of CNC turning control, still leave room for improvement in holistically optimizing multi-axis turning operations. Thereremains a need for more sophisticated control methods that can dynamically adjust multiple cutting parameters simultaneously to achieve optimal material removal rates, surface finish, and tool life across a range of part geometries and materials.SUMMARY

[0008] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

[0009] According to an aspect of the present disclosure, a system for dynamic tool orientation adjustment in numerical control lathe roughing machining is provided. The system includes a tool orientation control configured to receive an initial tool orientation and a tool orientation range, define clearance values for safe tool rotation, and generate an initial tool path based on a workpiece geometry. The system further includes a collision detection module configured to detect potential collisions along the tool path, a tool orientation adjuster configured to dynamically tilt a tool within the tool orientation range in response to detected potential collisions, and a feed rate calculator configured to recalculate feed rates for each motion based on the new tool orientations.

[0010] As used herein, the term "feed rate calculator" refers to a component or module within the dynamic tool orientation adjustment system that determines appropriate feed rates for machining operations based on various input parameters, including tool orientation and cutting conditions.

[0011] The feed rate calculator recalculates feed rates for each motion based on the new tool orientations by considering factors such as the tool's engagement angle with the workpiece, the material being machined, and the desired chip thickness. In some aspects, the feed rate calculator may use a mathematical model that takes into account the changing tool orientation to optimize material removal rates while maintaining acceptable tool wear and surface finish.

[0012] For example, the feed rate calculator may implement a formula that adjusts the feed rate based on the cosine of the tool's engagement angle. As the tool orientation changes, the engagement angle may vary, affecting the effective cutting speed and chip formation.

[0013] The feed rate calculator may use a relationship such as:^adjusted ^base ' COs(0)wherein Fadjustedis the adjusted feed rate, Fbaseis the base feed rate for optimal cutting conditions, and 9 is the tool engagement angle.

[0014] In some cases, the feed rate calculator may also consider the changing chip thickness as the tool orientation is adjusted. It may use a more complex model that incorporatesfactors such as the tool's rake angle, the material's specific cutting energy, and the desired surface finish. This may allow for more precise control of the cutting process, potentially resulting in improved part quality and extended tool life.

[0015] The feed rate calculator may work in conjunction with the tool orientation adjuster and collision detection module to continuously update feed rates as the tool path is modified. This dynamic recalculation may enable the system to maintain optimal cutting conditions throughout the machining operation, even as the tool orientation changes to avoid collisions or adapt to complex part geometries.

[0016] As used herein, the term "dynamically tilting" may refer to changing the tool's orientation during machining while the tool is in feed, without stopping the machining process for this orientation change, and while continuing to subtract material from the workpiece. This capability may allow for real-time adjustments to the tool's position and angle as it moves along the tool path.

[0017] In some aspects, dynamically tilting the tool may involve continuous or incremental changes to the tool's orientation as it progresses through the machining operation. The system may adjust the tool's tilt angle in response to various factors, such as detected potential collisions, changing workpiece geometry, or optimized cutting conditions.

[0018] The dynamic tilting capability may enable the system to adapt to complex part geometries more efficiently. For instance, when machining a workpiece with varying surface contours, the tool may continuously adjust its orientation to maintain optimal cutting angles and clearances. This may result in improved surface finish and potentially reduced machining time.

[0019] In some cases, the dynamic tilting may be coordinated with simultaneous adjustments to other machining parameters, such as feed rates and cutting depths. This coordinated approach may allow for comprehensive optimization of the machining process, potentially leading to enhanced material removal rates and extended tool life.

[0020] According to other aspects of the present disclosure, the system may include one or more of the following features. The system may further include an interpolation module configured to interpolate tool path motions with new tool orientations.

[0021] As used herein, the term "interpolation module" may refer to a component within the dynamic tool orientation adjustment system that generates intermediate tool positions and orientations between defined points along the tool path. The interpolation module may create a smooth and continuous motion profile for the tool, ensuring precise control over the tool's movement and orientation throughout the machining process.

[0022] The interpolation module may perform interpolation by using various mathematical algorithms to calculate the intermediate positions and orientations of the tool between known points on the tool path. In some aspects, the interpolation module may employ methods such aslinear interpolation, circular interpolation, or spline interpolation, depending on the complexity of the tool path and the desired smoothness of the tool motion.

[0023] For example, the interpolation module may use parametrized lines and / or arcs or a cubic spline interpolation method to generate a smooth curve that passes through all the known points on the tool path. This method may allow for continuous first and second derivatives at each point, resulting in a smooth and natural-looking tool motion. The cubic spline interpolation may be represented by a piecewise function:wherein SL(x) is the spline function for the i-th interval, andand d, are coefficients determined by the interpolation conditions.

[0024] In practice, the interpolation module may work as follows: (1) receive a set of discrete tool positions and orientations from the tool path generator; (2) apply the chosen interpolation algorithm to calculate intermediate positions and orientations; (3) generate a dense set of points representing the interpolated tool path; (4) coordinate with the feed rate calculator to assign appropriate feed rates to each interpolated segment; and (5) provide the interpolated tool path data to the NC code generator for execution on the machine.

[0025] The interpolation module may also consider the dynamic tilting of the tool when performing interpolation. As the tool orientation changes to avoid collisions or optimize cutting conditions, the interpolation module may adjust the interpolation parameters accordingly. This may ensure that the tool follows a smooth and efficient path while maintaining the desired orientation throughout the machining process.

[0026] In some implementations, the interpolation module may use adaptive interpolation techniques. These techniques may adjust the density of interpolated points based on the complexity of the tool path segment. For example, in areas with sharp turns or complex geometries, the module may generate more intermediate points to maintain accuracy, while in straight or simple curved sections, fewer points may be used to reduce computational load.

[0027] The interpolation module may also work in conjunction with the collision detection module to ensure that the interpolated tool path remains collision-free. If a potential collision is detected along an interpolated segment, the module may recalculate the interpolation with adjusted parameters to avoid the collision while maintaining a smooth tool path.

[0028] The tool orientation control may further include an initial orientation setter configured to set the initial tool orientation, an orientation range definer configured to define the tool orientation range, and a clearance value specifier configured to specify the clearance values. The tool orientation adjuster may be further configured to dynamically tilt the tool within the tool orientation range based on the clearance values. The system may further include a tool pathoptimizer configured to generate an optimized tool path based on the tool path motions and recalculated feed rates. The system may also include an NC code generator configured to generate NC code based on the optimized tool path. The feed rate calculator may be further configured to recalculate the feed rates based on a desired chip thickness and a current tool orientation. Additionally, the feed rate calculator may be further configured to perform a second interpolation based on changes in the tool orientation with respect to a motion direction from a start to an end of each motion.

[0029] According to another aspect of the present disclosure, a method for dynamic tool orientation adjustment in NC lathe roughing machining is provided. The method includes receiving, by a tool orientation control, an initial tool orientation and a tool orientation range, defining clearance values for safe tool rotation, and generating an initial tool path based on a workpiece geometry. The method further includes detecting potential collisions along the tool path, dynamically tilting a tool within the tool orientation range in response to detected potential collisions, and recalculating feed rates for each motion based on the new tool orientations.

[0030] According to other aspects of the present disclosure, the method may include one or more of the following features. The method may further include interpolating tool path motions with new tool orientations. The method may also include setting, by an initial orientation setter, the initial tool orientation, defining, by an orientation range definer, the tool orientation range, and specifying, by a clearance value specifier, the clearance values. Dynamically tilting the tool may be based on the clearance values specified by the clearance value specifier. The method may also include generating, by a tool path optimizer, an optimized tool path based on the tool path motions and recalculated feed rates, and generating, by an NC code generator, NC code based on the optimized tool path. Recalculating the feed rates may be based on a desired chip thickness and a current tool orientation. The method may further include performing, by a feed rate calculator, a second interpolation based on changes in the tool orientation with respect to a motion direction from a start to an end of each motion.

[0031] According to yet another aspect of the present disclosure, a non-transitory computer-readable medium storing instructions is provided. When executed by a processor, the instructions cause the processor to perform a method for dynamic tool orientation adjustment in NC lathe roughing machining. The method includes receiving an initial tool orientation and a tool orientation range, defining clearance values for safe tool rotation, and generating an initial tool path based on a workpiece geometry. The method further includes detecting potential collisions along the tool path, dynamically tilting a tool within the tool orientation range in response to detected potential collisions, and recalculating feed rates for each motion based on the new tool orientations.

[0032] According to other aspects of the present disclosure, the method performed by the non-transitory computer-readable medium may include one or more of the following features.The method may further include interpolating tool path motions with new tool orientations. The method may also include setting, by an initial orientation setter, the initial tool orientation, defining, by an orientation range definer, the tool orientation range, and specifying, by a clearance value specifier, the clearance values. Dynamically tilting the tool may be based on the clearance values specified by the clearance value specifier. The method may also include generating, by a tool path optimizer, an optimized tool path based on the tool path motions and recalculated feed rates, and generating, by an NC code generator, NC code based on the optimized tool path. Recalculating the feed rates may be based on a desired chip thickness and a current tool orientation. The method may further include performing, by a feed rate calculator, a second interpolation based on changes in the tool orientation with respect to a motion direction from a start to an end of each motion.

[0033] The foregoing general description of the illustrative embodiments and the following detailed description thereof are merely exemplary aspects of the teachings of this disclosure and are not restrictive.BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Non-limiting and non-exhaustive examples are described with reference to the following figures.

[0035] FIG. 1 illustrates a block diagram of a dynamic tool orientation system TOS for optimizing numerical control lathe roughing machining, according to aspects of the present disclosure.

[0036] FIG. 2 depicts an isometric view of a dynamic tool orientation adjustment system with a circular disc and tool holder, according to an embodiment.

[0037] FIG. 3 shows an isometric view of a dynamic tool orientation adjustment system with a segmented circular component, according to aspects of the present disclosure.

[0038] FIG. 4 illustrates an isometric view of a CNC lathe machining setup with a dynamic tool orientation adjustment system, according to an embodiment.

[0039] FIG. 5 is a flowchart of a method for dynamic tool orientation adjustment in NC lathe roughing machining, according to aspects of the present disclosure.

[0040] FIG. 6 depicts a flowchart of another method for dynamic tool orientation adjustment in NC lathe roughing machining, according to an embodiment.

[0041] FIG. 7 shows a system diagram of a Dynamic Tool Orientation System for use with an NC lathe, according to aspects of the present disclosure.

[0042] FIG. 8 illustrates a block diagram of a Tool Orientation Control system for optimizing NC lathe roughing machining, according to an embodiment.DETAILED DESCRIPTION

[0043] The following description sets forth exemplary aspects of the present disclosure. It should be recognized, however, that such description is not intended as a limitation on thescope of the present disclosure. Rather, the description also encompasses combinations and modifications to those exemplary aspects described herein.

[0044] The present disclosure relates to a dynamic tool orientation TOR adjustment system for numerical control [NC] lathe NCL roughing machining. This system addresses limitations in conventional fixed-axis turning operations by allowing real-time adjustments to tool orientation TOR during machining processes. The system optimizes tool TOL reach, cutting efficiency, and overall machining performance across varying workpiece WPG geometries.

[0045] The dynamic tool orientation TOR adjustment system comprises several interconnected components that work together to enhance NC lathe NCL roughing operations. These components include modules for setting initial tool TOL orientations, defining orientation ranges, specifying clearance values CSV, detecting collisions, adjusting tool TOL orientations, interpolating ITP tool TOL paths, and recalculating feed rates FDR. By integrating these functions, the system provides a comprehensive approach to optimizing machining processes.

[0046] One key aspect of the system is its implementation as instructions stored on a non-transitory computer-readable medium. These instructions are executed by a processor to perform the dynamic tool orientation TOR adjustment method. This software-based approach allows for flexible integration with existing NC lathe NCL systems (in Figure 1 depicted only schematically) and enables rapid updates and improvements to the tool orientation TOR adjustment algorithms.

[0047] The system continuously monitors the machining process, detecting potential collisions and dynamically adjusting tool TOL orientations within predefined ranges. This realtime adaptation minimizes the need for multiple manual operations, reducing setup times and improving overall machining efficiency. Additionally, the system recalculates feed rates FDR based on the adjusted tool TOL orientations, ensuring optimal cutting conditions throughout the machining process.

[0048] By providing dynamic tool orientation TOR adjustment capabilities, the system enables more efficient machining of complex geometries, potentially reducing cycle times and improving part quality. This approach represents a significant advancement in NC lathe NCL roughing machining technology, offering benefits in terms of productivity, tool TOL life, and machining flexibility.

[0049] The dynamic tool orientation TOR adjustment system for numerical control (NC) lathe NCL roughing machining provides a comprehensive solution for optimizing machining processes. Figure 1 illustrates an isometric view of the system, showcasing its main components and functionality.

[0050] The system includes a tool orientation control TOC configured to manage various aspects of the machining process. A user interface UIF allows operators to input parametersand control the system. The operator may submit tool TOL clearance CLR and / or a tool orientation TOR range RNG via the user interface UIF.

[0051] The tool orientation control TOC receives an initial tool orientation TO1 and a tool orientation TOR range RNG. The initial tool orientation TO1 represents the starting position of a tool TOL, while the tool orientation TOR range RNG defines the allowable adjustment limits for the tool TOL during operation.

[0052] A workpiece WPC is virtually and / or actually positioned for machining, and a tool path generator TPG of the tool orientation control TOC generates an initial tool path TPT based on the workpiece WPC geometry. The system defines clearance values for safe tool TOL rotation, ensuring that the tool TOL maintains a safe distance SDT from the workpiece WPC during orientation adjustments.

[0053] The system incorporates a collision detection module CDM designed to detect potential collisions along the tool path TPT. This module continuously monitors the relationship between the tool TOL and other machine components and the workpiece WPC, identifying any risk of interference or contact.

[0054] To address potential collisions, the system employs a tool orientation adjuster TOA. This component dynamically tilts the tool TOL within the predefined tool orientation TOR range RNG in response to detected potential collisions. By adjusting the tool orientation TOR in realtime, the system maintains optimal cutting conditions while avoiding unwanted contact with the workpiece WPC.

[0055] An interpolation module IPM works in conjunction with the tool orientation adjuster TOA to interpolate tool path TPT motions with new tool orientations. This process ensures smooth transitions between different tool TOL positions, maintaining consistent cutting performance throughout the machining operation.

[0056] The system also features a feed rate calculator FRC that recalculates feed rates FDR for each interpolated motion based on the new tool orientations. This dynamic adjustment of feed rates FDR optimizes cutting conditions, taking into account factors such as chip thickness CTN and the current tool axis orientation TAO. This interaction finally results in an optimized tool path OTP.

[0057] Figure 1 illustrates a block diagram of a dynamic tool orientation system TOS for optimizing numerical control lathe roughing machining. The tool orientation TOR system TOS comprises several interconnected components that work together to dynamically adjust tool orientation TOR and optimize machining processes. The lower part of Figure 1 illustrates 4 scenarios SON of machining processed during optimizing of tool TOL motion according to the method.

[0058] The tool orientation TOR system TOS includes a user interface UIF connected to a tool path generator TPG. The tool path generator TPG communicates with a collision detectionmodule CDM, which analyzes potential collisions PTC along the generated tool path TPT. The collision detection module CDM performs continuous collision checks CLC, evaluating the tool path TPT for potential interference with the workpiece WPC. This proactive approach allows the system to anticipate and prevent collisions before they occur during actual machining and / or during virtual planning or machining simulation, wherein actual machining may include virtual planning or machining simulation and / or digital twinning. A tool orientation adjuster TOA receives input from the collision detection module CDM and modifies the orientation of the tool TOL as needed. A feed rate calculator FRC determines appropriate feed rates FDR based on the adjusted tool path TPT.

[0059] The dynamic tool orientation system TOS is connected to a numerical control lathe NCL, which interfaces with a workpiece WPC for machining operations. The tool orientation TOR system TOS also includes a tool orientation control TOC, which comprises an initial orientation setter IOS, an orientation range definer ORD, and a clearance value specifier CVS. These values of the initial orientation setter IOS, the orientation range definer ORD, and the clearance value specifier CVS may be provided via the user interface UIF or alternatively automatically generated by these modules at the process start and / or during the process. These components work together to set the initial tool orientation TO1 , define the tool orientation TOR range RNG, and specify clearance values CSV for safe tool TOL movement.

[0060] A tool path optimizer TPO contains an interpolation module IPM that interpolates the tool path TPT with new tool orientations NTO. The tool orientation TOR system TOS also includes a collision avoidance system CAS that uses data from the tool path optimizer TPO to avoid potential collisions during machining. A numerical control code generator NCG generates the necessary numerical control code NCC for the optimized tool path OTP and orientation adjustments.

[0061] The feed rate calculator FRC considers factors such as chip thickness CTN and current tool orientation CTO when determining appropriate feed rates FDR. The tool orientation control TOC manages the tool axis orientation TAO and ensures a safe distance SDT is maintained during machining operations.

[0062] The components of the tool orientation TOR system TOS interact through a series of connections, with data flowing from the user interface UIF through the various modules before reaching the numerical control lathe NCL. This modular structure allows for efficient processing of tool path TPT data and real-time adjustments during machining operations on the workpiece WPC.

[0063] By integrating these components and functionalities, the dynamic tool orientation TOR adjustment system enhances the efficiency and precision of numerical control lathe roughing machining operations. The system's ability to adapt tool TOL orientations TOR andfeed rates FDR in real-time contributes to improved machining outcomes and reduced cycle times.

[0064] Figure 2 illustrates a detailed view of a dynamic tool orientation TOR adjustment system for numerical control lathe roughing machining. The system includes a tool orientation adjuster TOA. The tool orientation adjuster TOA enables the range RNG of possible tool TOL orientations for the machining operation.

[0065] A triangular tool TOL is positioned within the circular disc. The tool TOL comprises three cutting edges CED. The cutting edge is the respectively primary point of contact between the tool TOL and the workpiece WPC during machining operations. The tool TOL is shown in a specific orientation, representing an initial tool orientation TO1. The initial tool orientation TO1 serves as the starting position for the tool TOL before any dynamic adjustments are made during the machining process.

[0066] The workpiece WPC is a rotational symmetric part with four different diameters to be machined.

[0067] Several lines extend from the tool TOL holder across the rectangular blocks. These lines represent the tool path TPT or cutting trajectory during the machining operation. The tool path TPT illustrates how the tool TOL moves across the workpiece WPC during the roughing process.

[0068] The dynamic tool orientation TOR adjustment system allows for the tool TOL holder TOL to be repositioned. This flexibility enables optimization of the cutting angle and tool TOL reach based on the geometry of the workpiece WPC.

[0069] The tool orientation adjuster TOA enables the repositioning of the tool TOL. This adjustment capability allows for dynamic changes to the tool orientation TOR during the machining process, optimizing the cutting parameters based on the specific geometry of the workpiece WPC.

[0070] In some implementations, the tool TOL includes a cutting insert CIT manufactured using advanced ceramic materials. For example, the cutting insert is made from silicon nitride or cubic boron nitride instead of traditional carbide materials. These advanced ceramic materials offer superior heat resistance and hardness, extending tool TOL life and allowing for higher cutting speeds in the dynamic orientation adjustment process. These tools TOL benefit in particular from the disclosure as they can be arranged optimally to the workpiece obtaining beneficial feed rates and best chipping.

[0071] The use of advanced ceramic materials for the cutting insert enhances the performance of the dynamic tool orientation TOR adjustment system according to the disclosure. The increased hardness and heat resistance of these materials allow for more aggressive cutting parameters, reducing machining time while maintaining tool TOL longevity.Additionally, the superior wear resistance of silicon nitride or cubic boron nitride inserts contributes to more consistent machining results over extended periods of use.

[0072] Figure 3 illustrates the same situation as depicted in Figure 2 with a different tool TOL orientation putting a different cutting edge CED into the feed enabling to machine the intended contour.

[0073] Figure 4 illustrates an isometric view of a dynamic tool orientation TOR adjustment system for numerical control lathe roughing machining. The system comprises an NC lathe NCL and a workpiece WPG positioned for machining operations.

[0074] The NC lathe NCL is shown as a large machine structure with a spindle SPL and chuck assembly CKA visible. The workpiece WPC is depicted as a cylindrical object secured in the chuck of the NC lathe NCL, ready for machining.

[0075] A tool orientation adjuster TOA is visible near the workpiece WPC. This component allows for dynamic adjustment of the cutting tool's orientation during the machining process. The tool orientation adjuster TOA is capable of rotating and tilting the cutting tool TOL to optimize its position relative to the workpiece WPC.

[0076] A tool path TPT is represented by a series of lines or curves around the workpiece WPC. This tool path TPT indicates the planned trajectory of the cutting tool TOL during the machining operation. The tool path TPT shows how the cutting tool TOL will move to remove material from the workpiece WPC.

[0077] The dynamic tool orientation TOR adjustment system allows for real-time modifications to the tool's position and angle as it follows the tool path TPT. This capability enables the system to adapt to varying geometries of the workpiece WPC, potentially improving machining efficiency and reducing cycle times.

[0078] The integration of the tool orientation adjuster TOA with the NC lathe NCL and the precisely defined tool path TPT demonstrates how the system can handle complex machining operations while dynamically adjusting the tool orientation TOR to optimize the cutting process.

[0079] The setup incorporates advanced sensor technology (not depicted), such as laserbased distance sensors or ultrasonic sensors, to enhance the precision and responsiveness of the dynamic tool orientation TOR adjustment system. These sensors continuously monitor the spatial relationship between the cutting tool TOL and the workpiece WPC, allowing for highly accurate detection of potential collisions or interference.

[0080] This advanced sensing technology enables the system to make rapid and accurate adjustments to the tool orientation TOR, maintaining optimal cutting conditions while avoiding collisions. The result is a higher level of precision in tool TOL positioning and collision CLS avoidance, leading to improved machining accuracy, reduced cycle times, and enhanced overall efficiency of the turning operation.

[0081] Figure 5 illustrates a flowchart for a method 800 of dynamic tool orientation adjustment for optimized NC lathe roughing machining. The method 800 comprises several steps that work together to enhance the efficiency and precision of the machining process.

[0082] The method 800 begins with step 802, where a tool orientation control receives an initial tool orientation and a tool orientation range. This step establishes the starting position of the tool and defines the allowable range for orientation adjustments during the machining operation.

[0083] In step 804, the method 800 defines clearance values for safe tool rotation. These clearance values ensure that the tool maintains a safe distance from the workpiece during orientation adjustments, preventing collisions and maintaining optimal cutting conditions.

[0084] Step 806 involves generating an initial tool path based on a workpiece geometry. This step takes into account the specific shape and features of the workpiece to create an efficient cutting path for the tool.

[0085] The method 800 then proceeds to step 808, which involves detecting potential collisions along the tool path. This step continuously monitors the relationship between the tool and the workpiece to identify any risk of interference or contact.

[0086] In response to detected potential collisions, step 810 dynamically tilts the tool within the tool orientation range. This adjustment allows the tool to maintain optimal cutting conditions while avoiding unwanted contact with the workpiece.

[0087] Step 812 of the method 800 involves interpolating tool path motions with new tool orientations. This process ensures smooth transitions between different tool positions, maintaining consistent cutting performance throughout the machining operation.

[0088] Following the interpolation, step 814 recalculates feed rates for each interpolated motion based on the new tool orientations. This dynamic adjustment of feed rates optimizes cutting conditions, taking into account factors such as chip thickness and the current tool axis orientation.

[0089] The method 800 continues with step 816, which performs a second interpolation based on the tool orientation change. This additional interpolation further refines the tool path and ensures precise control over the tool's movement.

[0090] In step 818, the method 800 determines the optimal feed rate for each sub-motion. This step takes into account the specific cutting conditions and tool orientation for each segment of the tool path, maximizing efficiency and precision.

[0091] Finally, step 820 generates optimized NC code with dynamic adjustments. This step produces the machine-readable instructions that incorporate all the optimizations and adjustments made throughout the method 800.

[0092] The method 800 for dynamic tool orientation adjustment is implemented as instructions stored on a non-transitory computer-readable medium and executed by aprocessor. This implementation allows for flexible integration with existing NC lathe systems and enables rapid updates and improvements to the tool orientation adjustment algorithms.

[0093] Figure 6 illustrates a flowchart for a method 900 of dynamic tool orientation adjustment for optimized NC lathe roughing machining. The method 900 provides an alternative approach to the method 800 shown in Figure 5, offering specific advantages in terms of realtime adaptation and efficiency.

[0094] The method 900 begins with a step 902, which involves creating an initial machining path. This step establishes the starting trajectory for the tool based on the workpiece geometry and machining requirements.

[0095] Following the creation of the initial path, a step 904 continuously monitors for potential collisions. This ongoing surveillance ensures that the system can respond promptly to any risks that may arise during the machining process.

[0096] The method 900 then proceeds to a step 906, which checks for detected collision risks. If a collision risk is detected, the method 900 moves to a step 908. In the step 908, the tool orientation adjusts within a predefined range. An orientation range definer defines this range, allowing for controlled and safe adjustments of the tool position.

[0097] After adjusting the tool orientation, a step 910 recalculates the optimal feed rate for the new orientation. This recalculation considers factors such as the desired chip thickness and the current tool orientation, ensuring efficient material removal while maintaining tool life.

[0098] The method 900 then updates the machining path with the new orientation and feed rate in a step 912. This update ensures that the machining process continues with the optimized parameters.

[0099] If no collision risk is detected in the step 906, or after updating the machining path in the step 912, the method 900 proceeds to a step 914. The step 914 continues the machining process with the current parameters.

[0100] The method 900 includes a step 916, which checks if the machining operation is complete. If the operation is not complete, the method 900 loops back to the step 904 to continue monitoring for potential collisions. This iterative process ensures continuous optimization throughout the entire machining operation.

[0101] When the machining operation is complete, the method 900 concludes with a step 918, ending the machining process.

[0102] A key advantage of the method 900 over the method 800 is its continuous monitoring and real-time adjustment capabilities. While the method 800 focuses on initial path generation and subsequent adjustments, the method 900 emphasizes ongoing collision detection and immediate response.

[0103] The method 900 incorporates several additional components to enhance its functionality. An initial orientation setter sets the initial tool orientation TO1 , providing a startingpoint for the machining process. A clearance value specifier specifies clearance values, which guide the dynamic tilting of the tool based on these specified values.

[0104] A tool path optimizer generates an optimized tool path based on the interpolated tool path motions and recalculated feed rates. This optimization ensures that the machining process remains efficient throughout its duration.

[0105] An NC code generator generates NC code based on the optimized tool path, translating the optimized parameters into machine-readable instructions for the NC lathe.

[0106] A feed rate recalculator performs a second interpolation based on changes in the tool orientation with respect to a motion direction from a start to an end of each interpolated motion. This additional interpolation refines the feed rate calculations, further optimizing the machining process.

[0107] The method 900 provides a more adaptive and responsive approach to dynamic tool orientation adjustment, allowing for continuous optimization throughout the machining process. This real-time adaptation capability enhances the efficiency and precision of NC lathe roughing machining operations.

[0108] The Dynamic Tool Orientation System architecture, as illustrated in Figure 7, comprises several interconnected components that work together to optimize NC lathe roughing machining operations. The system includes a Dynamic Tool Orientation System 1000, which serves as the central control unit for managing tool path generation and adjustment.

[0109] A User Interface 1002 connects to a Tool Path Generator 1004, allowing operators to input parameters and control the system. The Tool Path Generator 1004 creates initial tool paths based on the workpiece geometry and user-defined parameters.

[0110] The system incorporates a Collision Detection Module 1006 that analyzes potential collisions in the generated path. This module continuously monitors the spatial relationship between the tool and the workpiece, identifying any risk of interference or contact.

[0111] A Tool Orientation Adjuster 1008 receives input from the Collision Detection Module 1006 and modifies the tool orientation as needed. This component dynamically tilts the tool within the predefined tool orientation range in response to detected potential collisions.

[0112] The system includes a Feed Rate Calculator 1010 that determines appropriate feed rates based on the adjusted tool path. The Feed Rate Calculator 1010 recalculates feed rates for each interpolated motion based on the new tool orientations. This recalculation takes into account factors such as the desired chip thickness and the current tool orientation, ensuring optimal cutting conditions throughout the machining process.

[0113] To further refine the feed rate calculations, the Feed Rate Calculator 1010 performs a second interpolation. This additional interpolation is based on changes in the tool orientation with respect to the motion direction from the start to the end of each interpolated motion. Byconsidering these orientation changes, the system achieves more precise control over the cutting process and maintains consistent chip formation.

[0114] The Dynamic Tool Orientation System 1000 incorporates a Tool Path Optimizer that generates an optimized tool path based on the interpolated tool path motions and recalculated feed rates. This optimization ensures that the machining process remains efficient throughout its duration, taking into account the dynamic adjustments made to tool orientation and feed rates.

[0115] An NO Code Generator is integrated into the system to translate the optimized tool path into machine-readable instructions for the NC lathe. This component generates the NC code based on the optimized tool path, incorporating all the dynamic adjustments and optimizations made during the process.

[0116] The Dynamic Tool Orientation System 1000 connects to an NC Lathe 1012, which interfaces with a Workpiece 1014 for machining operations. This connection allows the system to directly control the lathe based on the optimized tool path and generated NC code.

[0117] The components of the Dynamic Tool Orientation System interact through a series of connections, with data flowing from the User Interface 1002 through the various modules before reaching the NC Lathe 1012. This integrated architecture enables real-time adaptation of machining parameters, optimizing the NC lathe roughing process while avoiding collisions and maintaining efficient operation.

[0118] Figure 8 illustrates a block diagram of a Tool Orientation Control system for optimizing NC lathe roughing machining. The system comprises several interconnected modules that work together to enhance machining efficiency and precision.

[0119] The Tool Orientation Control TOC serves as the central control unit for managing tool path generation and adjustment. The Tool Orientation Control TOC includes an Initial Orientation Setter IOS configured to set the initial tool orientation TO1. This Initial Orientation Setter IOS establishes the starting position of the tool before any dynamic adjustments are made during the machining process.

[0120] An Orientation Range Definer ORD within the Tool Orientation Control TOC defines the tool orientation range RNG. This range RNG represents the allowable adjustment limits for the tool during operation, ensuring that the tool remains within safe and effective parameters.

[0121] The Tool Orientation Control TOC also incorporates a Clearance Value Specifier CVS configured to specify the clearance values CLR. These clearance values CLR define safe distances where the rotation of the tool should begin and end, preventing unintended collisions and ensuring reliable machining.

[0122] A Tool Path Optimizer TPO generates an optimized tool path based on the workpiece WPC geometry and the parameters set by the Tool Orientation Control TOC. The Tool Path Optimizer TPO includes an Interpolation Module IPM that interpolates tool path motions with new tool orientations. In some implementations, the Interpolation Module IPMemploys parametrized lines or arcs or it may employ a spline interpolation or NURBS (Non-Uniform Rational B-Spline) interpolation for smoother tool movements and more accurate feed rate calculations, especially for complex part geometries.

[0123] The system includes a Collision Detection Module CDM that analyzes potential collisions CLS along the tool path PTH. This Collision Detection Module CDM continuously monitors the spatial relationship between the tool TOL and the workpiece WPC, identifying any risk of interference or contact.

[0124] A Tool Orientation Adjuster TOA receives input from the Collision Detection Module CDM and modifies the tool orientation TOR as needed. The Tool Orientation Adjuster TOA dynamically tilts the tool TOL within the predefined tool orientation range RNG in response to detected potential collisions CLS.

[0125] The system incorporates a Feed Rate Recalculator FRR that determines appropriate feed rates FDR based on the adjusted tool path PTH. The Feed Rate Recalculator FRR recalculates feed rates FDR for each interpolated motion based on the new tool orientations TOR, taking into account factors such as the desired chip thickness CTN and the current tool axis orientation TAO.

[0126] A Collision Avoidance System CAS uses the data from the Tool Path Optimizer TPO and the Collision Detection Module CDM to prevent potential collisions CLS during machining. The Collision Avoidance System CAS ensures that the tool TOL maintains a safe distance SDT from the workpiece WPC during orientation adjustments.

[0127] An NC Code Generator NCG translates the optimized tool path PTH into machine-readable instructions for the NC lathe. The NC Code Generator NCG incorporates all the dynamic adjustments and optimizations made during the process into the final NC code.

[0128] The Tool Orientation Control TOC system includes a User Interface UIF that allows operators to input parameters and control the system. In some implementations, the User Interface UIF incorporates graphical handles that allow to define tool orientations or alternatively it may incorporate a graphical slider interface for setting the orientation range RNG, providing an intuitive way for users to define the allowable tool orientations.

[0129] The Tool Orientation Control TOC can be integrated with Computer-Aided Design (CAD) software to allow for automatic suggestion of initial tool orientation ranges based on the 3D model of the part to be machined. This integration potentially reduces setup time and improves first-run accuracy of the machining process.

[0130] In some implementations, the Tool Orientation Control TOC implements a machine learning algorithm that suggests optimal ranges based on part geometry and historical data from previous machining operations. This feature enhances the system's ability to adapt to different workpiece WPC geometries and optimize machining parameters overtime.

[0131] The components of the Tool Orientation Control TOC system interact through a series of connections, with data flowing from the User Interface UIF through the various modules before reaching the NC Code Generator NCG. This integrated architecture enables real-time adaptation of machining parameters, optimizing the NC lathe roughing process while avoiding collisions CLS and maintaining efficient operation.

[0132] A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the disclosure. Accordingly, other implementations are within the scope of the following claims.

Claims

CLAIMS1. A system (TOS) for tool orientation adjustment in numerical control [NC] lathe roughing machining, the system comprising:a tool orientation control (TOC) configured to:receive an initial tool orientation (TO1);generate an initial tool path (PTH) based on a workpiece (WPC) geometry;receive a tool orientation range (RNG); anddefine clearance values (CLR) for safe tool rotation;a collision detection module (CDM) configured to detect potential collisions (CLS) along the tool path (PTH);a tool orientation adjuster (TOA) configured to dynamically tilt the tool (TOL) within the tool orientation range (RNG) in response to detected potential collisions (CLS), wherein dynamically tilting means that the tool (TOL) tilts while the machine is in feed and the tool (TOL) is moving along the tool path (PTH); anda feed rate calculator (FRC) configured to recalculate feed rates (FDR) for each motion based on new tool orientations.

2. The system (TOS) of claim 1 , further comprising:an interpolation module (IPM) configured to interpolate tool path motions with the new tool orientations.

3. The system (TOS) of claim 1 , wherein the tool orientation control (TOC) further comprises:an initial orientation setter (IOS) configured to set the initial tool orientation (TO1); an orientation range definer (ORD) configured to define the tool orientation range (RNG); anda clearance value specifier (CVS) configured to specify the clearance values (CLR).

4. The system of claim 3, wherein the tool orientation adjuster (TOA) is further configured to dynamically tilt the tool (TOL) within the tool orientation range (RNG) based on the clearance values (CLR).

5. The system of claim 1, further comprising:a tool path optimizer (TPO) configured to generate an optimized tool path (TPT) based on the tool path (TPT) motions and recalculated feed rates (FDR).

6. The system of claim 5, further comprising:an NC code generator (NCG) configured to generate NC code based on the optimized tool path (TPT).

7. The system of claim 1 , wherein the feed rate calculator (FRC) is further configured to recalculate the feed rates (FDR) based on a desired chip thickness (CTN) and a current tool orientation (TOR).

8. The system of claim 7, wherein the feed rate calculator (FRC) is further configured to perform a second interpolation based on changes in the tool orientation (TOR) with respect to a motion direction from a start to an end of each motion.

9. A method for dynamic tool orientation adjustment by a tool orientation control (TOC) in numerical control [NC] lathe roughing machining, the method comprising:receiving an initial tool orientation (TO1) by the tool orientation control (TOC); generating an initial tool path (PTH) based on a workpiece (WPC) geometry; receiving a tool orientation range (RNG) by the tool orientation control (TOC); defining clearance values (CLR) for safe tool rotation;detecting potential collisions (CLS) along the tool path (PTH);dynamically tilting a tool (TOL) within the tool orientation range (RNG) in response to detected potential collisions (CLS), wherein dynamically tilting means that the tool (TOL) tilts while the machine is in feed and the tool (TOL) is moving along the tool path (PTH); and recalculating feed rates (FDR) for each motion based on new tool orientations.

10. The method of claim 9, further comprising:interpolating tool path motions with the new tool orientations.

11. The method of claim 9, further comprising:setting, by an initial orientation setter (IOS), the initial tool orientation (TO1); defining, by an orientation range definer (ORD), the tool orientation range (RNG); and specifying, by a clearance value specifier (CVS), the clearance values (CLR).

12. The method of claim 11 , wherein the dynamically tilting of the tool (TOL) is based on the clearance values (CLR) specified by the clearance value specifier (CVS).

13. The method of claim 9, further comprising:generating, by a tool path optimizer (TPO), an optimized tool path based on tool path motions and recalculated feed rates (FDR).

14. The method of claim 13, further comprising:generating, by an NC code generator (NCG), NC code based on the optimized tool path.

15. The method of claim 9, wherein the recalculating of the feed rates (FDR) is based on a desired chip thickness (CTN) and a current tool orientation (TOR).

16. The method of claim 15, further comprising:performing, by a feed rate calculator (FRC), a second interpolation based on changes in the tool orientation (TOR) with respect to a motion direction from a start to an end of each motion.

17. A non-transitory computer-readable medium storing instructions that, when executed by a processor, cause the processor to perform a method for dynamic tool orientation adjustment in numerical control [NC] lathe roughing machining, the method comprising:receiving an initial tool orientation (TO1) and a tool orientation range (RNG); defining clearance values (CLR) for safe tool rotation;generating an initial tool path (PTH) based on a workpiece (WPC) geometry; detecting potential collisions (CLS) along the tool path (PTH);dynamically tilting a tool (TOL) within the tool orientation range (RNG) in response to detected potential collisions (CLS), wherein dynamically tilting means that the tool (TOL) tilts while the machine is in feed and the tool (TOL) is moving along the tool path (PTH); and recalculating feed rates (FDR) for each motion based on new tool orientations.

18. The non-transitory computer-readable medium of claim 17, wherein the method further comprises:interpolating tool path motions with the new tool orientations.

19. The non-transitory computer-readable medium of claim 17, wherein the method further comprises:setting, by an initial orientation setter (IOS), the initial tool orientation (TO1); defining, by an orientation range definer (ORD), the tool orientation range (RNG); and specifying, by a clearance value specifier (CVS), the clearance values (CLR).

20. The non-transitory computer-readable medium of claim 19, wherein the dynamically tilting of the tool (TOL) is based on the clearance values (CLR) specified by the clearance value specifier (CVS).

21. The non-transitory computer-readable medium of claim 18, wherein the method further comprises:generating, by a tool path optimizer (TPO), an optimized tool path based on the interpolated tool path motions and recalculated feed rates (FDR).

22. The non-transitory computer-readable medium of claim 21, wherein the method further comprises:generating, by an NC code generator (NCG), NC code based on the optimized tool path.

23. The non-transitory computer-readable medium of claim 18, wherein the recalculating of the feed rates (FDR) is based on a desired chip thickness (CTN) and a current tool orientation (TOR), andwherein the method further comprises performing, by a feed rate recalculator (FRR), a second interpolation based on changes in the tool orientation (TOR) with respect to a motion direction from a start to an end of each interpolated motion.

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