Cutting Insert Edge Machining Using 3D Boundary Surface Detection
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Solution Overview
Problem
The existing methods for post-processing cutting inserts on cutting tools after soldering are labor-intensive and prone to errors, requiring manual data entry and precise positioning, which complicates the achievement of specified tolerances and quality standards.
Innovation Solution
A method that utilizes 3-dimensional surface analysis to automatically determine the cutting edge boundary surfaces of the cutting tool, allowing for precise material removal without manual data entry, using CAD data or surface scanners to generate the 3-dimensional cutting tool surface and control the movement and material removal devices accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual data entry and positioning methods are used for post-processing cutting inserts, then the process can be completed with simple equipment, but the process becomes labor-intensive and prone to errors
Solution Approach 1:
The patent replaces manual mechanical positioning and data entry operations with an automated optical measurement system. A measuring device with a sensor scans the cutting inserts and cutting tool body to automatically capture geometric data, eliminating the need for manual coordinate input and positioning. The control unit processes this data to generate machining paths automatically.
Solution Approach 2:
The cutting tool itself provides the measurement references through its geometric features (datum surfaces, centers). The system uses self-contained geometric relationships on the cutting tool and inserts to automatically determine positions and orientations without requiring external reference measurements or manual data entry about tool geometry.
2Extent of automation
If automated 3D surface analysis is implemented, then measurement accuracy and automation are improved, but device complexity increases
Solution Approach 1:
The measuring device is designed as a multi-functional system that can measure various cutting tool types and insert configurations using the same basic hardware platform. The sensor and control unit handle different geometric features (surfaces, edges, centers) and generate machining paths for different material removal operations, reducing the need for multiple specialized devices.
Solution Approach 2:
The control unit serves as an intermediary that bridges the simple optical measurement task and the complex machining operation. It automatically processes the raw geometric data from the sensor, calculates the cutting insert positions and orientations, determines the material removal paths, and controls the machining device, thereby hiding the computational complexity from the operator.
3Manufacturing precision
If precise positioning of cutting inserts is required to meet tolerances, then cutting edge quality is improved, but the time required for positioning and measurement increases
Solution Approach 1:
The system performs preliminary automated measurement and analysis of the cutting inserts and tool body geometry before machining begins. The measuring device scans and records all relevant geometric features, and the control unit pre-calculates the machining paths based on the actual measured positions, ensuring that when machining starts, all positioning decisions are already made and optimized.
Solution Approach 2:
The patent replaces time-consuming manual measurement and calculation operations with automated optical scanning and computational processing. The sensor rapidly captures 3D geometric data of the cutting inserts and tool body, and the control unit immediately processes this data to generate precise machining paths, significantly reducing the setup time compared to manual methods.
4Ease of manufacture
If material removal is performed based on manual measurements, then equipment simplicity is maintained, but errors in data entry lead to poor quality
Solution Approach 1:
The patent replaces manual measurement and data entry operations with an automated optical measurement system. A sensor on the measuring device scans the cutting inserts and tool body to automatically capture their actual geometric positions and shapes. The control unit uses this measured data to generate accurate machining paths, eliminating human error in data entry while maintaining relatively simple machining equipment.
Data Source
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AI summary
A method for machining a cutting tool (1, 21) and a machining device (50) for carrying out the method are proposed. The cutting tool (1, 21) has a cutting tool body (2, 22) and at least one cutting insert (3, 4, 5, 23) attached to the cutting tool body (2, 22), with at least one cutting edge (10, 30). A three-dimensional surface of the cutting tool (1, 21) is defined. From this surface, cutting edge boundary surfaces (11a, 12a, 31a, 32a) are determined, which form a surface of the cutting insert (3, 4, 5, 23) and are arranged adjacent to a cutting edge (10, 30) of the cutting insert (3, 4, 5, 23). The machining device (50) is controlled by means of these cutting edge boundary surfaces (11a, 12a, 31a, 32a) and removes material in a targeted manner from the cutting insert (3, 4, 5, 23).