Machine Tool Spindle Tilt Compensation for Flat Surface Machining
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Solution Overview
Problem
Machining large workpieces with small-diameter milling tools on general-purpose machine tools often results in level differences due to spindle tilt and mounting errors, making it difficult to achieve a flat surface without steps or irregularities.
Innovation Solution
A machine tool configuration that includes a spindle tilt angle calculating unit and a coordinate system rotation unit, which uses measured values from a contact element to adjust the spindle's tilt and rotate the XY-plane, ensuring orthogonal alignment between the spindle and the workpiece surface, thereby minimizing level differences during machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a small-diameter milling tool is used on a general-purpose machine tool to machine large workpieces, then the machine tool size and cost are reduced, but level differences and steps occur on the machined surface due to spindle tilt and mounting errors
Solution Approach 1:
The patent applies preliminary action by measuring the spindle tilt angle and thermal displacement before machining begins. The system pre-calculates compensation values for the control device based on these measurements, allowing the machining process to proceed with corrected parameters that account for the spindle's actual orientation and thermal effects, thereby preventing level differences on the machined surface
Solution Approach 2:
The patent implements feedback by continuously monitoring the spindle's position and thermal displacement during machining operations. The control device uses this feedback information to dynamically adjust machining parameters and compensate for deviations, ensuring consistent flatness across the entire workpiece surface even when using multiple machining paths
2Area of stationary object
If multiple machining paths are used to cover the entire workpiece surface, then the workpiece can be fully machined, but level differences occur between paths due to spindle inclination
Solution Approach 1:
The control device receives feedback regarding the spindle's actual position and orientation during each machining path operation. Based on this feedback, the system calculates and applies compensation values that adjust the tool path parameters, ensuring that all machining paths converge to the same reference level and eliminating steps between paths
Solution Approach 2:
The patent changes machining parameters dynamically by adjusting the control commands based on measured spindle tilt angles and thermal displacement. The system modifies tool path coordinates, feed rates, and depth of cut parameters to compensate for spindle inclination, allowing multiple machining paths to produce consistent surface levels
Data Source
AI summary
A machine tool includes one tip arranged on the spindle at a position that faces the table, a cutting edge position storing unit that stores therein multiple measured values that are obtained by performing measurement of the position of the tip at least two times in a state where the spindle is set at at least one phase and the tip is positioned at an identical point, a spindle tilt angle calculating unit that calculates a tilt angle of the spindle with respect to an XY-plane, based on the multiple measured values, and a coordinate system rotation unit that rotates the XY-plane about at least one of X-axis and Y-axis, based on the tilt angle of the spindle calculated by the spindle tilt angle calculating unit.