NC Tool Offset Compensation for Continuous Precision Machining
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Solution Overview
Problem
Conventional techniques for machining with machine tools face issues such as manual tool offset changes leading to defective parts, inaccurate tool wear estimation, manual compensation processes, and reduced productivity due to the need for stopping machining to adjust tool offsets.
Innovation Solution
A numerical controller for machine tools that automatically compensates the tool offset amount based on pre-stored wear data at appropriate timing, such as the end or start of machining, thereby eliminating manual intervention and ensuring accurate tool positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual tool offset adjustment is performed during machining, then tool wear compensation can be made, but defective parts may be produced and productivity is reduced
Solution Approach 1:
The system pre-calculates and stores the tool wear amount and offset compensation values before machining begins. By preparing the compensation data in advance based on tool life predictions and wear characteristics, the system eliminates the need for manual offset adjustments during machining, thus maintaining both precision and productivity.
Solution Approach 2:
The numerical control device automatically performs offset compensation without requiring operator intervention. The system self-manages the tool wear compensation process by automatically applying pre-calculated offset values to the machining program, eliminating manual stopping and adjustment operations.
2Manufacturing precision
If tool offset is changed during machining to compensate for wear, then tool wear can be compensated, but inappropriate steps occur in the workpiece
Solution Approach 1:
The complete tool offset compensation is prepared in advance before machining starts. The system calculates the total wear amount based on tool life predictions and prepares all necessary offset adjustments beforehand, preventing any intermediate changes during machining that could cause workpiece defects.
Solution Approach 2:
The tool wear compensation is divided into discrete segments corresponding to different tool life stages. The system segments the machining process into phases with predetermined offset values, applying each segment's offset at the appropriate time rather than making continuous adjustments during machining.
3Productivity
If operator manually inputs tool wear amount during machining, then productivity is maintained, but estimation accuracy is insufficient
Solution Approach 1:
The system incorporates feedback mechanisms that monitor actual tool wear and compare it with predicted wear values. This feedback loop enables continuous refinement of wear estimation algorithms, improving accuracy while maintaining automated operation and productivity.
Solution Approach 2:
The system replaces manual operator estimation with automated computational methods. Numerical algorithms calculate tool wear based on machining parameters, tool material properties, and workpiece characteristics, substituting human judgment with precise computational estimation.
4Extent of automation
If offset compensation is calculated using preset estimated values, then automated compensation is achieved, but it does not exactly match actual tool wear
Solution Approach 1:
The system uses feedback from actual machining results and tool wear measurements to continuously refine and update the preset estimated values. By comparing predicted wear with actual wear, the system adjusts its estimation parameters to improve accuracy while maintaining automated operation.
Solution Approach 2:
The system dynamically changes the parameters used in wear estimation based on accumulated machining data. By adjusting wear rates, tool life predictions, and compensation factors based on actual performance, the system adapts preset values to match actual tool wear more accurately.
Data Source
AI summary
The present invention is to allow for an automatic correction of an offset amount of a tool used in actual workpiece processing at an appropriate timing. The present invention provides a numerical control device for a machine tool including: an execution unit for executing a processing program; a storage unit for storing, for each tool used in each processing program, a wear amount of the each tool when executing the processing program, as a tool offset amount; a monitoring unit for monitoring the timing of the work processing end or work processing start; and a changing unit for changing, for each processing program, the present tool offset amount at the timing of the work processing end or work processing start monitored by the monitoring unit, on the basis of the tool offset amount of the processing program stored in the storage unit.