Multi-Tool Numerical Control for Continuous Chip Breaking
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Solution Overview
Problem
Existing chip breaking methods for lathe machines either increase machining time or reduce tool and machine life due to non-cutting times and increased mechanical load from oscillation cutting.
Innovation Solution
A numerical controller that synchronizes the relative speeds and positions of multiple tools to alternately shift their cutting points back and forth, allowing chip breaking without extending machining time or reducing tool and machine life, by controlling the movement of tools on a lathe machine to break chips during continuous cutting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If chip breaking is performed by temporarily feeding the tool in the reverse direction, then chips are broken, but machining time increases due to non-cutting time
Solution Approach 1:
The patent combines chip breaking function with oscillation cutting function into a single integrated operation. The controller simultaneously controls multiple tools to oscillate and break chips without requiring separate reverse feeding motion, thereby eliminating non-cutting time while maintaining effective chip breaking
Solution Approach 2:
The patent enables continuous cutting action by coordinating multiple tools to oscillate in a manner that maintains constant material removal. The tools alternate cutting and non-cutting phases seamlessly, ensuring the workpiece is continuously machined without idle reverse feeding movements
2Reliability
If oscillation amplitude and oscillation frequency are increased to break chips, then chip breaking effectiveness improves, but mechanical load increases reducing machine and tool life
Solution Approach 1:
The patent divides the chip breaking task among multiple tools rather than relying on a single tool with high oscillation parameters. Each tool performs cutting at moderate oscillation levels, collectively achieving effective chip breaking while distributing mechanical load across multiple tools and the machine structure
Solution Approach 2:
The patent dynamically controls the oscillation parameters of multiple tools in coordination. The controller adjusts oscillation amplitude and frequency of each tool based on real-time cutting conditions, maintaining optimal chip breaking effectiveness while preventing excessive mechanical load on any single tool or machine component
3Duration of action of stationary object
If oscillation amplitude and oscillation frequency are reduced to suppress vibrations, then machine and tool life is preserved, but machining time increases
Solution Approach 1:
The patent merges the functions of multiple tools with coordinated oscillation control to achieve both low-vibration cutting and efficient chip breaking. The combined action of multiple tools compensates for lower individual oscillation parameters, maintaining productivity while preserving machine and tool life
Data Source
AI summary
A numerical controller configured for simultaneous control such as to cut a workpiece in order in the direction of a rotary axis by a plurality of tools, in a machine having a plurality of cutter holders fitted individually with the tools and capable of lathe turning, generates movement command data for locating the plurality of tools so as to cut the workpiece with the same depth of cut and controlling respective relative speeds and relative positions of the plurality of tools so that respective cutting points of the tools move back and forth in order; generates interpolation data based on the movement command data; and controls a motor for driving the machine, based on the interpolation data.