Milling Path Phase Synchronization for Uniform Surface Finish
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Solution Overview
Problem
Milling processes often result in irregular surface structures due to asynchronous spindle position and feed rate, leading to uneven surface quality and potential defects in products like injection molding.
Innovation Solution
Control the speed and phase position of the spindle along the machining path by varying spindle speed and feed rate, ensuring synchronized phase positions across adjacent paths, which can be achieved through precise control of a position-controlled electric motor and angular position determination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If constant spindle speed is used during milling, then the machining process is simple to control, but the surface quality becomes uneven due to asynchronous spindle position and feed rate
Solution Approach 1:
The patent applies dynamics by transitioning from constant spindle speed to variable spindle speed that is synchronized with the feed rate. The spindle speed is dynamically adjusted along the machining path to maintain a constant relationship between spindle rotation and tool engagement position, thereby achieving uniform surface quality while keeping the control system manageable through coordinated motion control.
2Measurement precision
If feed rate is varied during machining, then positioning accuracy is improved, but the spindle position and path feed become asynchronous, causing random phase positions
Solution Approach 1:
The patent applies parameter changes by dynamically adjusting the spindle speed parameter in response to feed rate variations. When the feed rate changes during machining, the spindle speed is proportionally adjusted to maintain the synchronization between spindle rotation and tool engagement position. This ensures that phase positions remain consistent across adjacent milling paths while allowing flexible feed rate control for precise positioning.
3Manufacturing precision
If spindle speed is controlled to maintain phase position, then surface uniformity is improved, but the control system complexity increases
Solution Approach 1:
The patent applies feedback by continuously monitoring the relationship between spindle speed and feed rate, and automatically adjusting the spindle speed to maintain constant phase positioning. The control system uses the programmed feed rate as feedback to dynamically calculate and adjust the required spindle speed, ensuring uniform surface quality without requiring overly complex control architecture.
Data Source
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AI summary
The invention relates to a method for machining a workpiece by means of a milling tool arranged on a rotatable spindle, the spindle being moved relative to the workpiece or the workpiece being moved relative to the spindle along a machining path and, at the same time, the spindle rotating about a spindle axis. In said method, an improvement in the surface quality is achieved by controlling the rotational speed and/or the phase position of the rotation of the spindle along the machining path, the machining path comprising linear parallel tracks and the phase position of the spindle along the machining path being substantially the same on adjacent tracks, the phase position being controlled by varying the rotational speed of the spindle and/or the advancing speed of the spindle relative to the workpiece along the machining path.