Machined Surface Evaluation Using Visible Area Maps

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Solution Overview

Problem

Current methods for evaluating and machining workpiece surfaces focus primarily on surface roughness but fail to effectively address visible characteristics that affect the appearance of machined surfaces, leading to undesired lines and patterns.

Innovation Solution

An object surface evaluation method that creates a visible area map by setting surface properties and normal direction change rates as axes, allowing for the display and adjustment of machining conditions to minimize visible shape changes, thereby improving the machined surface's appearance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If surface roughness is reduced to improve machining accuracy, then manufacturing precision is improved, but visible lines and patterns may still appear on the machined surface

Engineering Contradiction:

Improvesurface roughnessVSAvoidvisible lines and patterns

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The invention changes the evaluation parameters from traditional surface roughness alone to a combination of surface roughness and normal direction change rate. By introducing the normal direction change rate as an additional parameter, the system can identify and control the geometric features that cause visible lines and patterns, thereby resolving the contradiction between achieving low surface roughness and eliminating visible defects.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention adds a new dimension to surface evaluation by incorporating the normal direction change rate, which represents the rate of change of the surface normal vector. This additional dimensional parameter allows the evaluation system to detect geometric irregularities that are not captured by traditional surface roughness measurements alone, enabling better control over visible surface characteristics.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Manufacturing precision

If traditional surface roughness evaluation methods are used, then manufacturing precision can be controlled, but the appearance characteristics visible to human observers cannot be effectively evaluated

Engineering Contradiction:

Improvesurface roughness controlVSAvoidappearance evaluation accuracy

Core Design Contradiction:

Manufacturing precisionVSMeasurement precision

Solution Approach 1:

The invention introduces the normal direction change rate as an intermediary parameter that bridges the gap between traditional surface roughness measurement and human visual perception. This intermediary parameter captures the geometric information that directly influences appearance, allowing the evaluation system to assess both manufacturing precision and visual quality through a unified measurement approach.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The invention replaces the subjective human visual inspection system with an objective computational evaluation system that uses normal direction change rate calculations. By substituting mechanical/optical measurement with computational geometry analysis, the system achieves precise quantification of appearance characteristics that correlate with human perception.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If machining conditions are optimized for surface roughness, then manufacturing precision is improved, but visible appearance defects cannot be prevented

Engineering Contradiction:

Improvesurface finish qualityVSAvoidvisible patterns and lines

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The invention implements a feedback mechanism where the normal direction change rate is calculated from the machined surface geometry and used to adjust machining conditions. By continuously monitoring and feedbacking the normal direction change rate, the system can identify machining parameters that produce visible patterns and adjust them to eliminate such defects while maintaining surface roughness quality.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The invention enables preliminary evaluation of machining conditions by calculating the normal direction change rate from the tool path and workpiece geometry before actual machining occurs. This allows the system to predict potential visible defects and adjust machining parameters in advance, preventing the formation of unwanted surface patterns before they occur.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS11507051B2Object surface evaluation method, evaluation device, workpiece machining method using said evaluation method, and machine tool

Publication Date: 2022.11.22 MAKINO MILLING MASCH CO LTD

AI summary

A parameter indicating a surface property of an object surface is plotted on the horizontal axis, a normal direction change rate of the shape of the object surface is plotted on the vertical axis, the minimum normal direction change rate visible to a person is associated with the parameter indicating the surface property of the object surface to create a visible area map, the relationship between the parameter indicating the surface property of a machining surface of a workpiece, and the maximum value of the normal direction change rate of the shape of the machining surface of the workpiece is displayed on the visible area map, and the object surface is evaluated.