Numerical Controller Cutting In-Out Motion Insertion
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Solution Overview
Problem
Existing lathe-turning machining technologies face challenges in effectively separating chips and circulating coolant, leading to tool damage and reduced machining accuracy due to continuous chip contact and inefficient coolant circulation.
Innovation Solution
A numerical controller is developed with cutting in/out motion and circular motion inserting functions that analyze operation conditions to insert these motions at specific timings and speeds, preventing interference with the machining path and ensuring efficient chip separation and coolant circulation without additional mechanical components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If low-frequency vibration is applied to workpiece and cutting tool to separate chips and circulate coolant, then chip separation and coolant circulation are improved, but ball screws cause backlash and require increased amplitude and feeding speed
Solution Approach 1:
The patent applies low-frequency vibration to the workpiece and/or cutting tool to achieve chip separation and coolant circulation. The vibration causes the cutting tool to oscillate during machining, creating gaps that allow chips to separate and coolant to flow through the machining zone effectively.
Solution Approach 2:
The patent dynamically adjusts the vibration amplitude and feeding speed to compensate for backlash in ball screws. By coordinating the vibration parameters with the feeding mechanism speed, the system maintains effective cutting conditions while accounting for the mechanical imperfections of the ball screw system.
2Reliability
If forward movement, suspension, and reverse movement are executed to prevent continuous chip generation, then chip separation is improved, but cutting tool may contact processed surface and be damaged
Solution Approach 1:
The patent implements periodic forward and reverse movements of the cutting tool during machining. This periodic action creates intervals where chips are separated from the workpiece, preventing continuous chip generation and accumulation. The tool moves forward to cut, then reverses to allow chip separation, creating a rhythmic machining pattern.
3Reliability
If actuator mechanism is attached to cutting tool holder to cause circular or elliptic motion, then chip separation and coolant circulation are improved, but cost of machine tool increases
Solution Approach 1:
The patent employs mechanical vibration of the workpiece and/or cutting tool to achieve chip separation and coolant circulation without requiring additional actuator mechanisms on the cutting tool holder. The vibration is generated through the existing machining system components, eliminating the need for expensive piezoelectric elements or other actuator attachments.
Solution Approach 2:
The patent utilizes the existing mechanical components of the lathe machine tool to generate the necessary vibration and motion for chip separation. The system serves itself by using its own structure and motion capabilities rather than requiring external add-on devices, thereby reducing overall system cost.
Data Source
AI summary
Disclosed is a numerical controller that has a cutting in/out motion inserting function and configured to control a machine tool that performs lathe-turning machining in which a cutting tool moves in contact with a rotating workpiece. The numerical controller includes a cutting in/out motion inserting unit that generates a program to perform cutting in/out motion, based on operation conditions analyzed by a cutting in/out motion operation conditions analysis unit and inserts the generated program of performing the cutting in/out motion to a program to perform the lathe-turning machining.