Numerical Controller for Multi-Tool Chip Division in Threading
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Solution Overview
Problem
Conventional threading and turning machining methods lead to continuous chip generation, causing chip entanglement and workpiece damage, and result in increased mechanical load, reducing machine and tool life, and prolonging machining time.
Innovation Solution
A numerical controller that controls the relative speeds and positions of multiple tools to divide chips during machining, using techniques such as tool front insertion, tool vibration, tool rear insertion, and combination techniques, to manage chip division without increasing machining time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If a swinging operation is added to divide chips during machining, then chip division is achieved, but mechanical load increases and machine/tool life is adversely affected
Solution Approach 1:
The patent divides the chip generation process into multiple segments by using multiple tools that cut at different positions along the workpiece. Each tool creates separate cutting zones, which naturally divides the chips into discrete sections rather than continuous entangled masses, eliminating the need for additional swinging operations.
Solution Approach 2:
The patent transitions from single-point cutting to multi-point cutting along the axial dimension of the workpiece. By distributing cutting actions across multiple tools positioned at different locations, the system divides chips in the axial direction without requiring radial swinging movements, thereby reducing mechanical load.
2Object-generated harmful factors
If a swinging operation is added to divide chips during machining, then chip division is achieved, but machining time increases
Solution Approach 1:
The patent maintains continuous machining action by having multiple tools operate simultaneously at different positions along the workpiece. This eliminates the need to stop or slow down the workpiece rotation to perform separate chip division operations, as chip division occurs continuously alongside the cutting process.
3Loss of time
If motor speed is increased to maintain machining time equal to normal threading, then machining time is maintained, but tool tip life decreases due to higher load
Solution Approach 1:
The total cutting workload is segmented across multiple tools, with each tool responsible for a portion of the threading operation. This distribution reduces the load on each individual tool tip, allowing maintenance of high machining speeds without compromising tool life, as no single tool tip is overloaded.
Solution Approach 2:
The patent combines the functions of multiple tools to work in unison on the same workpiece. By merging their cutting actions into a coordinated multi-tool operation, the system achieves the productivity of high-speed machining while distributing the mechanical stress across multiple tool tips, thereby preserving tool life.
Data Source
AI summary
The numerical controller of the invention receives input of a technique for operating a plurality of tools and an operation condition of the operation technique, calculates movement command data including speed information and position information on the plurality of tools, such that respective cutting paths of the plurality of tools intersect, based on the input operation method and operation condition, generates interpolation data based on the movement command data, and controls a motor for driving a machine based on the interpolation data.