Numerical Control for Honing Feed Reversal Without Tool Stop
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Solution Overview
Problem
Existing synchronous control methods for honing processes result in large frictional forces when the tool rotation temporarily stops during direction reversals, leading to deterioration in the quality of the machined face.
Innovation Solution
A numerical control device that calculates the start and end points of reciprocation for the feed axis, conducts synchronous control of feed movement and tool rotation, and determines whether to reverse the feed direction based on predefined conditions before reaching the start or end points, thereby preventing tool rotation from stopping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If synchronous control is performed on feedrate and rotation speed of the tool, then the intersecting angle between grinding marks is kept constant, but the tool rotation temporarily stops when the feed direction is reversed, generating large frictional force and deteriorating the quality of the machined face
Solution Approach 1:
The numerical control device calculates the start point and end point of reciprocation in advance, and determines the reversal timing before the feed axis reaches these points. This preliminary determination allows the system to reverse the feed direction at optimal moments while maintaining tool rotation, preventing the harmful frictional force that would otherwise occur during direction reversals.
Solution Approach 2:
The invention ensures continuous tool rotation during the honing process by coordinating the feed axis reversal with the rotation phase. The controller maintains rotational movement throughout the reciprocation cycle, preventing stoppages that would generate friction and heat, thereby ensuring the useful action of honing continues uninterrupted while still achieving constant intersecting angles of grinding marks.
2Reliability
If the tool rotation is stopped and then restarted during feed direction reversal, then the synchronous control can be maintained, but large frictional force is generated between the tool and workpiece
Solution Approach 1:
The system calculates and determines the reversal timing before the feed axis reaches the start or end points of reciprocation. This advance determination allows the controller to coordinate feed direction reversal with the rotation phase, ensuring synchronous control is maintained while preventing tool rotation stoppage that would generate frictional force.
Solution Approach 2:
The invention maintains continuous tool rotation throughout the feed direction reversal process. By determining reversal timing in advance and coordinating it with the rotation phase, the system ensures that the useful action of rotating and honing the workpiece continues without interruption, eliminating the frictional force that would result from stopping and restarting rotation.
3Productivity
If the feed axis reaches the start point or end point before reversal, then the reciprocation cycle is completed, but the tool rotation stops causing deterioration of machined face quality
Solution Approach 1:
The numerical control device calculates the start point and end point of reciprocation in advance and determines the reversal timing before the feed axis reaches these points. This preliminary calculation allows the system to reverse direction at optimal moments during the reciprocation cycle, maintaining both productivity and preventing tool rotation stoppage that would deteriorate machined face quality.
Solution Approach 2:
The invention ensures that tool rotation continues throughout the entire reciprocation cycle by coordinating feed axis reversal with the rotation phase. The controller determines reversal timing in advance and executes it before the feed axis reaches the start or end points, ensuring continuous rotational movement that maintains machined face quality while completing the reciprocation cycle efficiently.
Data Source
AI summary
This numerical control device includes a calculation unit that calculates, from a machining program, a start point and an end point of a reciprocating movement of a feed shaft; a control unit that synchronous controls, between the start point and the end point calculated by the calculation unit, a feed movement of the feed shaft and a relative rotational movement between a tool and a workpiece; and a determination unit that determines whether a condition for reversing the feed direction of the feed shaft has been satisfied before the feed shaft reaches the start point or the end point during synchronous control. When the determination unit determines that the condition for reversing the feed direction of the feed shaft has been satisfied, the control unit reveres the feed direction of the feed shaft before the feed shaft reaches the start point, or the end point.