Jig Grinding Toolpath Correction for Sub-2 Micrometer Geometry
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Solution Overview
Problem
Traditional material removal processes, such as jig grinding, face limitations in achieving sub-micron accuracy due to systematic errors in CNC machine tool systems, leading to geometry errors in machined workpieces.
Innovation Solution
A CNC machine tool system performs error compensation by creating a corrected toolpath trajectory using metrology data from a first machined workpiece, allowing for improved accuracy in subsequent machining of a second workpiece, with errors corrected to better than 2 micrometers through the use of a rotary tool with at least one cutting edge, such as a grinding wheel or milling tool.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional material removal processes are used, then manufacturing capability is achieved, but manufacturing precision deteriorates due to systematic errors
Solution Approach 1:
The patent implements feedback by measuring the actual geometry of a first workpiece, comparing it to the desired geometry to determine systematic errors, and using these measured errors to create a corrected toolpath trajectory for subsequent machining operations. This closed-loop feedback mechanism continuously improves manufacturing precision by eliminating systematic errors.
Solution Approach 2:
The patent applies preliminary action by first machining a reference workpiece to identify systematic errors before production machining begins. The error compensation data derived from this preliminary workpiece is then used to correct the toolpath trajectory for all subsequent workpieces, preventing the repetition of systematic errors.
2Manufacturing precision
If error compensation is implemented, then manufacturing precision improves, but device complexity increases
Solution Approach 1:
The patent achieves universality by integrating measurement and machining functions into a single system. The same CNC machine tool performs both the initial machining and the subsequent corrected machining, while also serving as the platform for error measurement and compensation calculation. This multi-functionality reduces the need for separate dedicated measurement equipment.
Solution Approach 2:
The patent uses copying by creating a digital model of the systematic errors from the first workpiece measurement and applying this error model to correct the toolpath trajectory. Instead of physically adjusting the machine, the error compensation is implemented through modified numerical control data that replicates the correction across all subsequent operations.
3Manufacturing precision
If corrected toolpath trajectory is used, then manufacturing precision improves, but loss of time increases due to additional measurement and correction steps
Solution Approach 1:
The patent applies preliminary action by performing the time-consuming measurement and error analysis on a single first workpiece before production begins. This one-time preliminary effort establishes the error compensation model that is then reused for all subsequent workpieces, minimizing the time impact on overall production.
Solution Approach 2:
The patent maintains continuity of useful action by implementing error compensation as an integrated part of the machining process rather than as a separate post-processing step. The corrected toolpath trajectory is automatically generated and applied, allowing the machining operation to proceed continuously with improved precision without significant interruption to the production flow.
Data Source
AI summary
According to one example, a CNC machine tool system may perform error compensation for improving the accuracy of the geometry (or form) of a machined workpiece to, for example, better than 2 micrometers. To do so, a first machined workpiece may be created using the CNC machine tool system. The CNC machine tool system may create the machined workpiece by jig grinding. Following the creation of the first machined workpiece, metrology of the workpiece error may then be performed on the machined workpiece. The metrology of the workpiece error may be used to create a corrected toolpath trajectory for re-machining. This corrected toolpath trajectory may then be utilized by the CNC machine tool system to machine a second machined workpiece having a geometry (or form) with an accuracy of, for example, better than 2 micrometers.