Plate-like Material Machining for Uniform Thickness
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Solution Overview
Problem
Conventional methods for achieving a flat and uniform thickness in plate-like materials with two- or three-dimensional deformation, such as ceramic sintered or metal plates, are inefficient and costly due to reliance on operator instincts and manual spacer insertion, leading to increased machining costs and reduced yield.
Innovation Solution
A method and apparatus that measure the height differences across a plate-like material's surface, adjust the inclination of a virtual plane to minimize machining costs, and use a biaxial rotary-type machining table to perform surface treatments like cutting, grinding, and electrical discharging, optimizing the machining process by calculating the smallest height difference to achieve uniform thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If operator sets material directly on processing machine based on instincts, then operation simplicity is maintained, but manufacturing precision of flatness and uniform thickness deteriorates
Solution Approach 1:
The system performs preliminary measurement of the plate-like material's surface shape and thickness distribution before machining. The measurement unit measures the actual shape of the plate-like material, and the setting unit automatically sets the processing machine parameters based on these measurements, eliminating the need for operator estimation and manual spacer insertion.
Solution Approach 2:
A computer-based control unit acts as an intermediary between measurement and machining operations. The control unit processes measurement data and automatically generates machining parameters, serving as a mediator that translates physical measurements into precise machining instructions without human intervention.
2Manufacturing precision
If excessive grinding is performed to ensure flatness, then manufacturing precision is improved, but loss of substance increases and productivity decreases
Solution Approach 1:
The system measures the actual shape and thickness distribution of the plate-like material before machining begins. This preliminary measurement allows the control unit to calculate the minimum necessary machining amount at each location, removing only the exact amount of material needed to achieve the target flatness and thickness specifications.
Solution Approach 2:
The system dynamically adjusts machining parameters based on measured data. The control unit varies the machining depth and tool path according to the actual surface topology, transforming the machining process from a fixed-depth operation to an adaptive process that removes material only where necessary.
3Manufacturing precision
If excessive grinding is performed to ensure flatness, then manufacturing precision is improved, but productivity decreases due to increased operation time
Solution Approach 1:
The measurement unit quickly captures the surface shape data before machining, allowing the control unit to pre-calculate the optimal machining path and parameters. This eliminates trial-and-error adjustments during machining and reduces the total operation time while maintaining precision.
Solution Approach 2:
The system uses feedback from the measurement unit to continuously optimize the machining process. The control unit adjusts machining parameters in real-time based on actual surface measurements, ensuring that each pass removes the minimum necessary material while maintaining the required flatness tolerance.
4Ease of operation
If manual spacer insertion is used to maintain flatness, then ease of operation is maintained, but manufacturing precision of uniform thickness deteriorates
Solution Approach 1:
The system replaces the manual mechanical method of spacer insertion with an automated optical/electrical measurement and control system. The measurement unit uses optical sensors to detect surface topology, and the control unit automatically translates this data into precise machining instructions, eliminating the need for physical spacers and manual adjustment.
Solution Approach 2:
The control unit serves as an intermediary that processes measurement data and automatically determines the optimal machining parameters for achieving uniform thickness. This digital mediator replaces the physical spacers and operator judgment with algorithm-based parameter optimization.
Data Source
AI summary
Provided is a surface treatment method for performing machining such as cutting work, grinding, and electrical discharging to a plate-like material with two- or three-dimensional deformation to realize a uniform thickness. This method includes the steps of mounting the plate-like material on a surface plate, setting a coordinate axis in a plane direction of the plate-like material to be X, Y and setting a coordinate axis in a height direction of the plate-like material to be Z, virtualizing a surface containing an origin of the measured Z direction, measuring a height Z1-n from the origin in an arbitrary plane position, and inclining and cutting the plate-like material so that an absolute value of a difference between a maximum value Zmax and a minimum value Zmin of the obtained height data will be minimum. Although a ceramic sintered plate such as a sputtering target or a metal plate prepared by metal rolling or forging, in most instances, is subject to two- or three-dimensional deformation as a result of thermal stress or machining stress during the manufacturing process, this invention is able to obtain a flat plate-like material having a uniform thickness and minimal machining costs from a plate-like material with two- or three-dimensional deformation.