Cutting Edge Track Planning for Accurate Rotation-Symmetric Machining
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Solution Overview
Problem
Existing methods for machining a workpiece with a rotation symmetry plane, such as the side surface of a column, lack accuracy and efficiency, particularly in maintaining the desired surface roughness and target shape.
Innovation Solution
A method involving a three-dimensional orthogonal coordinate system to determine the track of a linear or curved cutting edge, ensuring the cutting edge is in contact with the rotation symmetry plane, where the cutting edge's inclination matches the target inclination, allowing for precise machining by dividing the cutting edge into regions that successively contact the workpiece.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If existing methods are used to machine rotation symmetry planes, then machining can be performed, but machining accuracy and surface roughness are insufficient
Solution Approach 1:
The cutting edge is divided into multiple regions (first region, second region, etc.) along its length. Each region is responsible for machining a specific portion of the rotation symmetry plane. This segmentation allows precise control of the track for each region, ensuring that the inclination of each segment matches the target inclination at different positions, thereby improving both machining accuracy and surface quality.
Solution Approach 2:
The patent dynamically adjusts the track of the cutting edge based on its position and orientation. The track is calculated to ensure that at any given position, the inclination of the cutting edge matches the target inclination of the rotation symmetry plane. This dynamic adjustment of the cutting path allows the cutting edge to adapt to varying surface geometries, improving machining precision and surface roughness.
2Productivity
If a linear cutting edge is fed transverse to the axial line of rotation, then efficient machining can be achieved, but the surface roughness and shape accuracy deteriorate
Solution Approach 1:
Instead of moving the cutting edge in a simple transverse direction (one-dimensional approach), the patent introduces a three-dimensional track calculation that incorporates radial, axial, and tangential components. The cutting edge follows a complex spatial path defined by equations involving radial distance R, axial position Z, and angular position φ. This multi-dimensional approach maintains machining efficiency while achieving superior shape accuracy and surface quality.
3Productivity
If the cutting edge inclination does not match the target inclination, then machining can proceed quickly, but the machined surface deviates from the target shape
Solution Approach 1:
The track calculation incorporates feedback mechanisms where the inclination of the cutting edge is continuously adjusted based on the target inclination at each position. The system calculates the required track to ensure that the cutting edge inclination matches the target inclination, and this information feeds back into the track determination process. This feedback loop ensures both shape accuracy and reasonable machining speed.
Data Source
AI summary
A method for manufacturing a machine component includes determining a track of a cutting edge and feeding the cutting edge along the track. The determining a track includes calculating a coordinate (X(t), Y(t), Z(t)) of a first end portion of the cutting edge in accordance with X(t)=(Rsh(t)cos ϕ(t)−Xchip(t)), Y(t)=(Rsh(t)sin ϕ(t)−Ychip(t)), and Z(t)=(Zsh(t)−Zchip(t)), where a variable t assumes (N+1) values not smaller than 0 and not greater than 1. ϕ(t) represents an angle formed by a straight line connecting a point of cutting projected on an XY plane and an origin of the XY plane to each other with respect to an X axis, and ϕ(t) satisfies a conditiontanϕ(t)=tanβ·tanθs-tanθ·tan2θ+tan2β-tan2θstanθ·tanθs+tanβ·tan2θ+tan2β-tan2θs.