Machining Path Section Analysis for Overcutting Detection

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Solution Overview

Problem

The existing CAD and CAM systems often result in broken surfaces and overcutting defects in machining processes due to poor design patterns and calculation errors, leading to quality issues and time-consuming path adjustments.

Innovation Solution

A method for analyzing overcutting defects in machining processes without actual location information feedback from machine tool controllers, involving the calculation of path and tangent vectors, sectional planes, and intersection points to estimate overcutting amounts and correct machining codes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If CAM converts the design pattern into machining code, then the machining path is generated, but calculation errors cause the cutting depth to be too large resulting in overcutting defects

Engineering Contradiction:

Improvemachining path generation efficiencyVSAvoidcutting depth accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by performing overcutting detection and analysis before actual machining operations. The system calculates path vectors, tangent vectors, and sectional planes to identify potential overcutting defects in advance, allowing correction of machining code before it is executed on the machine tool, thus preventing precision errors while maintaining generation efficiency

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces mechanical feedback systems with a computational geometry-based detection system. Instead of relying on physical measurement and feedback from machine tools, the system uses mathematical calculations involving vectors, planes, and intersection points to detect overcutting defects, eliminating the need for actual location information feedback while improving precision

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If technicians constantly change the machining path to fix defects, then product quality improves, but a lot of time is wasted on path adjustments

Engineering Contradiction:

Improveproduct qualityVSAvoidtime for path adjustments

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The system performs preliminary detection and analysis of overcutting defects before machining, identifying problematic nodes and calculating correction values in advance. This allows technicians to fix all potential quality issues in one preprocessing step rather than repeatedly adjusting paths after observing defects, significantly reducing the time lost to iterative corrections

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system enables self-service by automatically detecting overcutting defects and calculating correction values without requiring manual intervention or feedback from machine tool controllers. The machining path planning device independently identifies problems and provides correction solutions, eliminating the need for technicians to constantly monitor and adjust paths during machining operations

Inventive Principle:

Principle #25Self-service

3Manufacturing precision

If overcutting amount is in the micron level, then machining precision is high, but it is very difficult to observe with the naked eye

Engineering Contradiction:

Improvemicron-level cutting accuracyVSAvoidovercutting detection difficulty

Core Design Contradiction:

Manufacturing precisionVSDifficulty of detecting and measuring

Solution Approach 1:

The patent replaces visual inspection with a computational detection system that uses mathematical calculations to measure overcutting amounts. By calculating the distance between the specified node and the connection line of intersection points, the system can precisely detect micron-level overcutting that is invisible to the naked eye, converting an undetectable physical quantity into a calculable geometric parameter

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system introduces geometric calculations as an intermediary between the machining process and defect detection. Instead of directly observing physical overcutting, the system uses path vectors, tangent vectors, and sectional planes as intermediaries to indirectly measure and detect micron-level defects through mathematical relationships, making the undetectable visible through computation

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS11654522B2Method for analyzing overcutting defect of machining process

Publication Date: 2023.05.23 IND TECH RES INST

AI summary

A method for analyzing an overcutting defect of a machining process comprises steps as following. A machining code is executed to generate a cutting face, wherein the cutting face comprises a plurality of machining paths. A specified machining path is defined from the plurality of machining paths and a specified node is set on the specified machining path. A sectional plane passing through the specified node is calculated. A plurality of intersection points between the sectional plane and the other machining paths which are different from the specified machining path are obtained. A first adjacent intersection point a second adjacent intersection point are specified from the intersection points. A connection line located between the first adjacent intersection point and the second adjacent intersection point is obtained. A distance between the specified node and connection line is calculate and the distance is defined as an overcutting amount of the specified node.