Undeformed Chip Thickness Measurement in Micro-milling
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Solution Overview
Problem
Accurate measurement of undeformed chip thickness in micro-milling is inefficient due to the need to measure tool runout and wear, which complicates the process and reduces efficiency.
Innovation Solution
A method and system that acquire a surface topography picture of the flute bottom after micro-milling, extract tool marks, calculate spacing distances, and reconstruct instantaneous undeformed chip thickness based on equivalent cutting radius differences between cutter teeth, allowing measurement without prior assessment of tool runout and wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If tool runout and wear are measured in advance to determine undeformed chip thickness, then measurement accuracy is improved, but measurement efficiency deteriorates due to complex measurement流程
Solution Approach 1:
The patent extracts only the necessary information (tool marks on workpiece surface) from the measurement process, eliminating the need to measure tool runout and wear separately. By focusing on the final effect (tool marks) rather than intermediate parameters (tool conditions), the method achieves accurate undeformed chip thickness measurement without the complex preliminary measurements traditionally required.
Solution Approach 2:
The patent uses the tool marks left on the workpiece surface as a copy or trace of the tool's cutting action. Instead of directly measuring the tool's physical conditions (runout and wear), the method measures the indirect evidence (tool marks) that reflect the actual cutting process, thereby obtaining undeformed chip thickness information more efficiently.
2Reliability
If multiple parameters (tool runout, tool wear, feed per tooth) are measured to calculate undeformed chip thickness, then measurement comprehensiveness is improved, but measurement complexity increases
Solution Approach 1:
The patent merges the measurement of multiple parameters into a single measurement of tool marks on the workpiece surface. The tool marks inherently contain information about feed per tooth, tool runout, and tool wear effects, allowing all these parameters to be considered simultaneously through one measurement process rather than separate measurements.
Solution Approach 2:
The workpiece surface itself serves as the measurement carrier, with tool marks automatically formed during the cutting process. The cutting process creates its own measurement trace (tool marks) that can be directly measured to determine undeformed chip thickness, eliminating the need for separate measurement instruments and procedures for tool runout and wear.
Data Source
AI summary
The invention provides a measurement method and system of undeformed chip thickness in micro-milling. This method includes the steps of: S1: acquiring a surface topography picture of the bottom of a flute after micro-milling; S2: extracting a tool mark at the central line of the flute from the surface topography picture; S3: calculating a spacing distance between adjacent tool marks and calculating the difference of equivalent cutting radius between adjacent cutter teeth based on the spacing distance between adjacent tool marks; and S4: reconstructing the instant undeformed chip thickness in micro-milling based on the difference of equivalent cutting radius between adjacent cutter teeth. The measurement method and system of undeformed chip thickness in micro-milling allow undeformed chip thickness measurement in micro-milling without measuring the tool runout and wear in advance, which significantly shortens the measurement flow and improves the measurement efficiency while effectively ensuring the measurement accuracy.