Multi-Edge Machining Program Control for Feed Speed Adjustment
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Solution Overview
Problem
NC machine tools experience increased calculation load and slower machining times when using multi-edge tools, as existing systems fail to optimize feed speeds and machining conditions for varying numbers of effective edges, leading to potential tool damage.
Innovation Solution
A machining program generation device that calculates and sets optimal machining conditions for each region of a tool based on the number of effective edges, determining the tool's contact region with the workpiece and generating a program to adjust feed speeds and other conditions to prevent tool damage while shortening machining time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the same machining conditions are used for all regions of a multi-edge tool, then the machining process is simple to control, but the machining time increases and tool performance is not fully utilized
Solution Approach 1:
The tool is divided into multiple regions based on the number of effective cutting edges in each region. The machining program is segmented to apply different feed speeds and machining conditions to different regions, allowing optimization of machining time for each region while managing complexity through systematic regional classification.
Solution Approach 2:
Different machining conditions (feed speed, rotational speed) are applied to different regions of the tool based on their specific characteristics (number of effective edges). This local optimization ensures that each region operates at its optimal performance level, reducing overall machining time while preventing tool damage.
2Productivity
If high feed speed is used to shorten machining time, then productivity increases, but the risk of tool damage increases when machining with regions having fewer effective edges
Solution Approach 1:
The machining program dynamically adjusts feed speed and rotational speed based on the current region's number of effective edges. When the tool region with fewer effective edges is engaged, the system automatically reduces feed speed to prevent overload and tool damage, while maintaining high feed speeds in regions with more edges to maximize productivity.
Solution Approach 2:
Machining parameters (feed speed F-codes, rotational speed S-codes) are changed according to the active tool region. The system monitors which region is currently machining and adjusts parameters accordingly, ensuring that high feed speeds are only used when the tool region can handle the load, thus preventing tool damage while maintaining high productivity.
3Productivity
If the number of effective edges is not considered in machining conditions, then the programming is simpler, but the tool performance cannot be fully utilized and machining time increases
Solution Approach 1:
The tool is pre-divided into regions with different numbers of effective edges, and machining conditions are pre-calculated for each region. This preliminary preparation allows the NC device to simply select the appropriate pre-defined conditions based on the current region, utilizing full tool performance without requiring complex real-time calculations or programming.
4Reliability
If calculation of feed speed and rotational speed is performed successively during machining as in PTL 1, then adaptive control is achieved, but the calculation load on the NC machine tool increases and machining becomes slower
Solution Approach 1:
Instead of performing successive calculations during machining, the system pre-divides the tool into regions and pre-determines the optimal feed speed and rotational speed for each region. This eliminates the need for complex real-time calculations, reducing the NC device's calculation load and maintaining high machining speed while still achieving adaptive control through region-based parameter selection.
Data Source
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AI summary
This machining program generation device is provided with: a storage unit (27) that stores machining conditions for respective tool (41) regions determined on the basis of the number of effective edges in a multi-blade tool; a contact region calculation unit (25) that calculates a tool (41) region which comes into contact with a workpiece during machining on the basis of the shapes of the workpiece and the edge portion of the tool and of a tool path; and a machining program generation unit (29) that generates a machining program on the basis of the tool path and the machining conditions stored in the storage unit (27) in association with the tool region coming into contact with the workpiece.