S-Shape Detection Test Piece for Five-Axis Milling Precision
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Solution Overview
Problem
Current detection methods for five-axis numerical control milling machines, such as the NAS979 frustum test piece, fail to comprehensively assess the dynamic precision and multi-axis coordinated precision, leading to issues like unsmooth machining profiles and poor surface quality, as they cannot accurately reflect the machine's open and close angle states or evaluate new numerical control functions like RTCP precision.
Innovation Solution
An 'S' shaped detection test piece with a ruled surface edge strip and rectangular base, forming 'S' curves in different planes, which have varying included angles, allowing for comprehensive detection of dynamic precision, surface quality, and post-processing program validation without requiring specialized tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the NAS979 frustum test piece is used for detection, then the detection method is simple and direct, but the comprehensive precision detection capability is insufficient
Solution Approach 1:
The patent transitions from the traditional frustum test piece to an S-shaped test piece with spatial curves in multiple planes. This dimensional change enables the test piece to detect not only basic geometric precision but also multi-axis coordinated precision, dynamic precision, and surface quality across different machining states (open and close angles), thereby comprehensively resolving the contradiction between detection simplicity and comprehensive capability.
2Ease of operation
If the frustum test piece is used, then the detection process is straightforward, but it cannot reflect the machine tool precision in open and close angle states
Solution Approach 1:
The S-shaped test piece incorporates dynamic geometric features including spatial curves, varying included angles, and intersections that require the machine tool to transition between open and close angle states during machining. This dynamic design enables the test piece to evaluate the machine tool's precision across different angular positions and motion states, directly addressing the limitation of the static frustum test piece.
3Reliability
If the NAS979 test piece is used, then the detection method is established and standardized, but new numerical control functions like RTCP precision cannot be evaluated
Solution Approach 1:
The S-shaped test piece is designed with multiple functional features including spatial curves, intersections, and varying angles that can evaluate various numerical control functions simultaneously. It can detect basic geometric precision, multi-axis coordinated precision, dynamic precision, RTCP (Remote Tool Center Point) precision, and surface quality, making it a universal test piece that maintains standardization while adapting to evaluate modern numerical control functions.
4Productivity
If the frustum test piece detection is performed, then the acceptance process is complete, but the machining profile smoothness and surface quality cannot be ensured
Solution Approach 1:
The S-shaped test piece performs preliminary evaluation of machining quality by detecting profile smoothness, surface quality, and multi-axis coordinated precision before actual production machining. The spatial curves and intersections in the test piece design allow for early detection of potential machining issues, enabling corrective actions to be taken before production parts are machined, thus ensuring manufacturing precision while maintaining acceptance efficiency.
Data Source
AI summary
The present invention relates to an “S” shaped detection test piece for comprehensively detecting the precision of the numerical control milling machine and the detection method thereof. The detection test piece consists of an “S” shaped equal thickness edge strip (1) and a rectangular base (2), respectively forming two “S” shaped curves in two different planes and the projections of which in the base plane (3) cross each other and have open and close angle (α) states formed at the intersection. The tube vernier calipers is directly used in the detection method to measure the thickness of the “S” shaped edge strip (1) and analyze and decide the five-axis coordinated precision according to the thickness of the upper and lower parts and different areas of edge strip (1); and the RTCP function of machine tool, the validity of post-processing programs and the spatial motion precision of machine tool are further analyzed and decided according to smoothness of the tool path of the combining site of the detection base plane (3) and the edge strip (1) and smoothness of the edge strip profile.