Helical Cutting Tool Edge Measurement Using Continuous Light Tracing
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Solution Overview
Problem
Existing methods for measuring the condition of helical cutting tools during their working lifetime are inefficient and do not allow for frequent, high-resolution assessments, leading to potential use of damaged or worn tools in manufacturing processes.
Innovation Solution
A non-contact tool setting apparatus is used to measure the position of helical edges on a cutting tool installed in a machine tool, determining translational and rotational motion to trace a light beam along the edge, collecting beam intensity data, and analyzing it to assess tool condition in real-time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional point-by-point measurement techniques are used, then the measurement process is simple, but the measurement resolution and completeness of tool condition assessment are insufficient
Solution Approach 1:
The patent transitions from point-by-point measurement to continuous trace measurement by adding rotational motion dimension. The light beam traces the helical edge by combining translational movement with synchronized rotational movement of the tool, creating a two-dimensional measurement path that captures complete tool condition data along the entire helical edge.
Solution Approach 2:
The patent implements continuous measurement along the helical edge by maintaining an unbroken light beam trace. The synchronized rotation and translation ensure the light beam continuously follows the helical contour without interruption, providing uninterrupted tool condition data throughout the measurement process.
2Reliability
If tool removal for inspection is performed, then detailed examination is possible, but machine downtime increases and tool damage risk increases
Solution Approach 1:
The measurement system is integrated directly into the machine tool, allowing the tool to be measured while remaining installed in the spindle. The tool essentially measures itself through the non-contact light beam method, eliminating the need for removal and external inspection equipment.
Solution Approach 2:
The system enables continuous in-process measurement during tool operation, allowing tool condition to be monitored before actual damage occurs. This preliminary detection capability prevents the need for reactive tool removal and inspection after damage has already happened.
3Reliability
If frequent tool inspections are conducted, then tool condition is better monitored, but measurement time and productivity are reduced
Solution Approach 1:
The continuous trace measurement method captures tool condition data along the entire helical edge in a single uninterrupted operation. This eliminates the need for multiple discrete measurement points and repeated measurement cycles, significantly reducing total measurement time while maintaining comprehensive monitoring.
Solution Approach 2:
The patent replaces mechanical contact measurement methods with non-contact optical measurement using a light beam. This substitution eliminates mechanical wear, reduces measurement force, and enables faster measurement speeds without affecting tool or measurement system integrity.
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
Enables quick and reliable in-process measurement of helical cutting tools, increasing the frequency of wear and damage checks, reducing the risk of using substandard tools and improving manufacturing quality.
Implementation Method 1
a transmitter for emitting a light beam and a receiver for receiving the light beam, the receiver generating a beam intensity signal describing the intensity of received light
Data Source
Figure 1~2(c)
Figure 3A~3E
Figure 4(A)~6(B)
AI summary
A method is described for assessing a condition of a helical cutting tool (20;50) having at least a first helical edge (44) using a machine tool (4). The helical cutting tool is installed in a spindle (22) of the machine tool, such that it can cut features in a workpiece (8). The machine tool also comprises a non-contact tool setting apparatus (2) having a transmitter (10) for emitting a light beam (12) and a receiver (14) for receiving the light beam, the receiver generating a beam intensity signal describing the intensity of received light. The described method comprises the steps of (i) measuring a position of one or more points on the first helical edge, (ii) using the measurements of step (i) to determine the translational and rotational motion of the helical cutting tool relative to the light beam that is required to trace the light beam along the first helical edge, (iii) imparting the translational and rotational motion calculated in step (ii) to thereby trace the light beam along the first helical edge, (iv) collecting beam intensity data describing the beam intensity signal that is generated by the receiver as the light beam is traced along the first helical edge during step (iii), and (v) using the beam intensity data collected in step (iv) to assess the condition of the first helical edge. A corresponding machine tool for implementing the method is also described.