Precision Gage for Accurate Tool Diameter Measurement
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Solution Overview
Problem
Cutting tools used in CNC machines often do not measure their precise designed size, leading to low-quality results and increased scrap workpieces due to the difficulty in accurately measuring tools with fine cutting edges and variable flute geometry.
Innovation Solution
A custom gage with precision manufactured diameters that allow accurate measurement of cutting tools to within 0.0002 inches, enabling precise positioning and evaluation of tool integrity, reducing multiple cycle runs and improving finished product accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If hand instruments are used to measure cutting tools, then the measurement process is simple, but the measurement precision is insufficient (cannot achieve 0.0002" accuracy)
Solution Approach 1:
A precision gage with a known accurate diameter serves as an intermediary reference standard. The gage is mounted in the tool holder alongside the cutting tool, and both are measured simultaneously using a simple indicator. This intermediary object enables accurate measurement without requiring complex measurement equipment.
Solution Approach 2:
The precision gage creates a reference copy of the desired measurement standard. By having a gage with a precisely known diameter mounted in the same tool holder as the cutting tool, the measurement system can compare the tool against this reference copy rather than requiring absolute measurement capabilities.
2Measurement precision
If electronic measurement means are used in CNC machines, then measurement capability is improved, but the ability to identify tool condition with multiple flutes is insufficient
Solution Approach 1:
The measurement approach is segmented into two independent parts: the precision gage mounted in one tool holder slot and the cutting tool mounted in another slot. This segmentation allows each to be measured independently, and the gage provides a reference that works regardless of the number of flutes on the cutting tool, solving the limitation of electronic systems with multi-flute tools.
3Ease of operation
If nominal size tools are used, then tool selection is simplified, but the actual tool size varies from design size leading to quality issues
Solution Approach 1:
The precision gage is pre-manufactured with an accurately known diameter and mounted in the tool holder before the cutting tool is installed. This preliminary establishment of a reference standard allows the operator to immediately determine the actual size of any cutting tool by comparison, without requiring complex measurement procedures.
Data Source
AI summary
A device used in a spindle or fixture to measure tool sizes. The device has two cylindrical shapes that have precision machined surfaces. The device's face has a precise size which is the same nominal size as that of a material removing tool. The device's shaft allows for concentric and precision fastening of the device to a spindle or a fixture. The nose of the device is located on the end of the larger of the two cylindrical shapes which is visible exposed when mounted and used. The end of the device is at the end of the smaller of the two cylindrical shapes which is hidden after mounting. The device allows more accurate programming of machine tools thus providing higher quality results on machined work pieces and reducing machining cycles.