Machine Tool Controller Using Spindle-Synced Feed Stops for Chip Shredding
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Solution Overview
Problem
Conventional oscillating cutting methods face challenges in adjusting oscillation frequency and amplitude to match changing machining conditions, leading to potential overload on cutting tools and reduced tool life, with excessive calculations required when not using tables for control parameters.
Innovation Solution
A controller for machine tools that generates movement commands and intermittent stop instructions to manage the relative motion between cutting tools and works, allowing for chip shredding without oscillation by stopping the cutting tool's movement in synchronization with spindle axis rotation or predetermined cycles, triggered by external signals or rotation angles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If oscillating cutting is employed to shred chips, then chip shredding is achieved, but the cutting tool is subjected to mechanical overload and reduced tool life
Solution Approach 1:
The patent extracts the oscillation function from the cutting tool and transfers it to the workpiece. The workpiece is oscillated while the cutting tool remains stationary, eliminating the mechanical overload on the cutting tool while still achieving chip shredding through the relative oscillating motion.
Solution Approach 2:
Instead of oscillating the cutting tool as in conventional methods, the patent inverts the approach by oscillating the workpiece. This reversal eliminates the harmful acceleration and deceleration forces from the cutting tool while maintaining the beneficial chip shredding effect through relative motion.
2Adaptability or versatility
If oscillation frequency and amplitude are adjusted to match changing machining conditions, then machining adaptability is improved, but control complexity increases
Solution Approach 1:
The patent replaces the mechanical oscillation control system with a programmable control system. Instead of mechanically adjusting oscillation frequency and amplitude, the control system generates oscillation commands based on machining conditions, simplifying the mechanical structure while maintaining adaptability.
Solution Approach 2:
The patent implements dynamic adjustment of oscillation parameters through program control. The oscillation frequency and amplitude can be changed by modifying control program parameters, allowing adaptive response to machining conditions without complex mechanical adjustment mechanisms.
3Reliability
If intermittent stopping is used for chip shredding without oscillation, then cutting tool reliability is improved, but productivity may be reduced
Solution Approach 1:
The patent implements periodic oscillation of the workpiece during the cutting process. This continuous periodic motion achieves chip shredding without requiring complete stops, maintaining productivity while protecting the cutting tool from overload. The oscillation creates periodic variations in cutting conditions that shred chips effectively.
Data Source
AI summary
To provide a controller for a machine tool capable of shredding chips without use of oscillation during machining by cutting. A controller is for a machine tool used for machining by cutting of a work as a cutting target by means of coordinated motion of multiple axes including at least a spindle axis. The controller comprises: a movement command generation unit that outputs a movement command for cutting the work by moving a cutting tool and the work relative to each other in a machining direction; and a stop determination unit that outputs a stop instruction for intermittently stopping the relative move in the machining direction to the movement command generation unit. The movement command generation unit outputs a movement command for stopping the relative move between the cutting tool and the work in the machining direction based on the stop instruction. The stop determination unit outputs the stop instruction for a period when the spindle axis rotates 360 degrees or more.