Radius End Mill Contour Correction for Arc Center Accuracy
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Solution Overview
Problem
Conventional workpiece machining devices using radius end mills face challenges in achieving high-precision cutting due to positional deviations and shape errors, particularly at the arc center of the radius end mill, which cannot be corrected, leading to errors on the cutting surface.
Innovation Solution
A workpiece machining method and device that detect positional deviations between the real and ideal contour lines of a radius end mill, calculate correction values to align the arc centers, and correct the machining points using these values to reduce cutting errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a radius end mill is used for workpiece machining, then cutting capability is improved, but positional deviation at the arc center causes cutting errors
Solution Approach 1:
The system performs preliminary measurement of the radius end mill's actual contour line before machining, calculates the deviation from the ideal contour line, and pre-calculates correction values for the arc center position. This preliminary action allows the system to compensate for manufacturing errors before actual cutting begins, resolving the contradiction between using a radius end mill for cutting and maintaining precision.
Solution Approach 2:
The system measures the actual contour line of the radius end mill, compares it with the ideal contour line, and uses the detected deviation as feedback to calculate and apply correction values to the machining coordinates. This closed-loop feedback mechanism eliminates cutting errors caused by arc center positional deviation while preserving the cutting capability of the radius end mill.
2Ease of operation
If the end mill is fixed to the tool holding unit, then the machining operation can be performed, but defective chucking causes positional deviation
Solution Approach 1:
The system measures the actual position of the radius end mill after it is fixed to the tool holding unit, detects any positional deviation from the ideal position, and uses this feedback information to calculate correction values that compensate for defective chucking, thereby maintaining positioning accuracy while enabling the machining operation.
Solution Approach 2:
The system changes the machining parameters (coordinates) by applying correction values that compensate for positional deviation caused by defective chucking. By modifying the machining parameters based on actual measurements, the system maintains positioning accuracy despite variations in the chucking process.
3Device complexity
If the arc center position is not corrected, then the machining process is simple, but cutting errors occur on the workpiece
Solution Approach 1:
The system performs preliminary measurement and calculation of arc center deviation before machining, storing correction values for later use. This preliminary action adds minimal complexity to the overall process while effectively preventing cutting errors, as the correction values are calculated once and applied throughout the machining operation.
Solution Approach 2:
The system replaces complex mechanical adjustment mechanisms with a computational approach, using measurement data and coordinate transformation algorithms to correct arc center position. This substitution of mechanical correction with computational correction maintains simplicity while achieving high cutting surface accuracy.
Data Source
AI summary
A workpiece machining device includes a positional deviation correction unit configured to correct a positional deviation of a radius end mill by detecting a positional deviation between a real contour line and an ideal contour line of the radius end mill. The positional deviation correction unit calculates a first correction value configured to make a center of a first arc section formed into an arc shape at a corner portion of the ideal contour line and a center of a second arc section formed into an arc shape at a corner portion of the real contour line to be identical to each other in a plane perpendicular to the rotational axis, and corrects a machining point by the radius end mill using the first correction value.