Evaluation Workpiece Geometry for Machine Tool Performance Testing
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Solution Overview
Problem
Existing methods for evaluating the performance of machine tools do not effectively assess the influence of various factors such as machining programs, numerical controllers, servo controllers, tools, and machining conditions, leading to inefficiencies and inaccuracies in machining processes.
Innovation Solution
The development of an evaluation work piece with specific features like vertical level differences, direction reversing parts, corner parts, flat surface parts, boundary parts, and curved surface parts, along with a corresponding machining program and data structure, allows for comprehensive evaluation of these factors by simulating various machining scenarios and measuring outcomes like striped patterns and surface roughness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a simple grooving surface is used for displacement evaluation, then the evaluation process is simple, but it cannot evaluate the influence of various factors such as machining program, numerical controller, servo controller, tool, and machining condition
Solution Approach 1:
The evaluation work piece is divided into multiple distinct parts (vertical level difference part, direction reversing part, corner part, flat surface part, boundary part, curved surface part), each designed to evaluate specific machining factors. This segmentation allows comprehensive evaluation of various influences while maintaining a structured and manageable evaluation process.
Solution Approach 2:
The evaluation work piece serves multiple evaluation functions simultaneously - it can evaluate displacement, vibration, backlash, surface quality, and the influence of different control systems and machining conditions. This multi-functionality enables a single work piece to comprehensively assess various factors affecting machining quality.
2Adaptability or versatility
If multiple evaluation parts are included in the evaluation work piece, then comprehensive evaluation of machining factors is achieved, but the complexity of the work piece structure increases
Solution Approach 1:
Multiple evaluation parts are merged into a single integrated evaluation work piece structure. This combination allows comprehensive evaluation capabilities while reducing the need for multiple separate work pieces, thereby managing structural complexity through consolidation.
Solution Approach 2:
Different parts of the evaluation work piece have distinct local characteristics (vertical level differences, curved surfaces, flat surfaces, corner geometries) tailored to evaluate specific machining aspects. This local differentiation enables targeted evaluation of various factors while maintaining overall structural coherence.
3Measurement precision
If traditional displacement evaluation method is used, then only displacement in Z-axis direction can be evaluated, but it cannot evaluate vibration, backlash, and surface quality
Solution Approach 1:
The evaluation work piece is designed to perform multiple evaluation functions beyond simple displacement measurement. The inclusion of vertical level difference parts, curved surface parts, and flat surface parts enables evaluation of vibration, backlash, surface quality, and displacement simultaneously, expanding the evaluation scope while maintaining measurement precision.
Solution Approach 2:
The work piece is segmented into specialized parts for different evaluation purposes - displacement evaluation parts, vibration evaluation parts, surface quality evaluation parts. This segmentation allows each part to optimize its specific evaluation function while contributing to comprehensive assessment capabilities.
Data Source
AI summary
An evaluation work piece includes at least one of a part (B) or (G), and at least one of a part (A), (C), (D), (E), or (F). (A) is a vertical level difference part. (B) is a direction reversing part at which a direction of movement of a tool in a height direction is reversed when the tool is used for machining of a three-dimensional object including a curved surface. (C) is a corner part at which a direction of movement of the tool changes. (D) is a flat surface part. (E) is a boundary part between a flat surface and a curved surface with a changing curvature. (F) is a curved surface part having a curved surface with a changing curvature. (G) is a curved surface part at which command points are aligned regularly between adjacent tool paths on a curved surface. At least one of the part (B) or (G) is included in a cut spherical body part. A reference surface for a three-dimensional measuring machine is arranged around the cut spherical body part. At least one of the part (A), (C), (D), (E) or (F) is arranged outside the reference surface.