Cutting Tool Vibration Sensing for Material-Independent Impact Extraction
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Solution Overview
Problem
Existing cutting processing apparatuses face difficulties in accurately extracting the impact amount during cutting of materials with lower hardness than stainless steel, as the transmitted vibration is small, making it challenging to detect and measure the impact accurately.
Innovation Solution
A cutting processing apparatus with a sensor positioned near the fixing portion of the cutting object, aligned to detect vibrations in the direction of maximum cutting resistance, and a control circuit that extracts the sum total of impact amounts at processing frequencies and their multiples, allowing for stable measurement and feedback control of processing speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the sensor is positioned at the main shaft support portion to detect vibration, then the impact amount can be extracted for hard materials like stainless steel, but the detection becomes difficult for soft materials like aluminum or copper due to small transmitted vibration
Solution Approach 1:
The patent introduces a new intermediary component - a sensor mounting portion provided on the tool holder that directly contacts the cutting tool. This intermediary structure serves as a dedicated vibration transmission path from the cutting tool to the sensor, bypassing the main shaft support portion. The sensor mounting portion acts as a mediator that enhances vibration signal transmission specifically for soft materials while maintaining compatibility with hard material processing
Solution Approach 2:
The patent applies local quality by creating a specialized sensor mounting portion with specific structural characteristics optimized for vibration detection. This local structure on the tool holder has different properties from the main shaft support portion, specifically designed to enhance sensitivity to small vibrations generated during cutting of soft materials like aluminum and copper
2Measurement precision
If the sensor is placed near the cutting object fixing portion to improve detection for soft materials, then vibration detection sensitivity increases, but the sensor may detect unwanted vibrations from the fixing structure
Solution Approach 1:
The patent segments the vibration detection system into two distinct parts: the sensor mounting portion on the tool holder and the main shaft support portion. This segmentation isolates the sensor's vibration detection function from the fixing structure, allowing the sensor to detect cutting vibrations without interference from fixing structure vibrations. The tool holder acts as a separate vibration transmission path
Solution Approach 2:
The tool holder serves as an intermediary structure that transmits vibration from the cutting tool to the sensor while isolating the sensor from vibrations generated by the fixing structure. This intermediary positioning allows the sensor to be near the cutting action without directly contacting the fixing portion, thus avoiding unwanted vibration signals
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration enables accurate detection of vibrations and impact amounts during cutting, reducing the influence of material hardness on impact measurement and allowing for precise control of processing speed based on cutting resistance, thereby improving processing efficiency.
Implementation Method 1
a sensor that detects vibration during cutting processing of the cutting object and outputs a monitoring signal
Data Source
AI summary
Provided is a cutting processing apparatus that can reduce effects of the material of a cutting object in extraction of an impact amount during cutting of the cutting object. The cutting processing apparatus includes a cutting tool, a chuck portion, a feed mechanism, a fixing portion that fixes the cutting object, a stage that moves the fixing portion at a processing speed in a direction substantially orthogonal to a rotation axis of the chuck portion, a sensor that is arranged in the vicinity of a position on the fixing portion at which the cutting object is fixed, detects vibration of the cutting tool during cutting processing of the cutting object, and outputs a monitoring signal, and a control circuit that converts time waveform data of the monitoring signal to frequency waveform data and extracts an impact amount during cutting processing of the cutting object from the frequency waveform data.