NC Tool Selection for Multi-Edge Tool Life and Cycle Time
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Solution Overview
Problem
The use of multi-edge tools in machining operations often results in increased cycle times due to the need for tool replacement when one edge reaches its end-of-life, leading to inefficiencies and increased costs.
Innovation Solution
A numerical control device that prefetches machining program blocks, decodes tool and edge type selection commands, and selects tools to minimize tool replacements based on remaining edge lives, allowing continuous machining without replacing the entire tool.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a multi-edge tool is used and one edge reaches end-of-life, then the tool must be replaced entirely, but this increases cycle time and reduces productivity
Solution Approach 1:
The tool is divided into multiple independent edges, each with its own life cycle. The system monitors and manages each edge separately, allowing replacement of only the exhausted edge rather than the entire tool. This segmentation enables continuous utilization of remaining functional edges, reducing idle time and maintaining productivity.
Solution Approach 2:
The system performs preliminary monitoring of edge life status before complete exhaustion occurs. By tracking cumulative hours and remaining life of each edge in advance, the system can proactively manage tool replacement timing and switch to alternative edges or tools optimally, preventing unexpected downtime and cycle time extensions.
2Reliability
If tool replacement is performed when one edge expires, then tool life is managed properly, but the number of replacements increases and costs increase
Solution Approach 1:
Instead of discarding the entire tool when one edge expires, the system recovers and continues using the remaining functional edges. The tool body and unused edges are preserved and reused, minimizing material waste and reducing the frequency of complete tool replacements, thereby lowering costs.
Solution Approach 2:
The system changes the management parameter from whole-tool replacement to edge-level replacement. By monitoring individual edge parameters (cumulative hours, remaining life) separately and making replacement decisions based on edge-specific conditions rather than tool-wide conditions, the system optimizes resource utilization and reduces waste.
3Reliability
If the entire tool is replaced when one edge expires, then tool reliability is maintained, but device complexity increases due to frequent replacements
Solution Approach 1:
The tool is designed with multiple edges that can perform the same machining function. This multi-functionality allows any functional edge to replace an exhausted one, providing redundancy and flexibility. The system can switch between edges without requiring different tool types, simplifying the replacement process while maintaining machining consistency.
Data Source
AI summary
A numerical control device is intended for a machine tool that machines a workpiece using a multi-edge tool including a plurality of edges of different specifications, the numerical control device including: a tool information memory that stores edge type numbers in association with tool type numbers; a tool type-edge type selection command decoding unit that prefetches a plurality of blocks of a machining program, decodes a tool type selection command for selecting one of the tool types and/or an edge type selection command for selecting one of the edge types in the plurality of prefetched blocks, and generates internal information including the tool type selection command and/or the edge type selection command that have been decoded; and a tool selection unit that selects one tool with which the number of times of tool replacement is minimized during execution of at least the plurality of prefetched blocks.