Machined Surface Visibility Mapping for Human-Perceived Finish

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Solution Overview

Problem

Current methods for evaluating object surfaces, particularly machined surfaces, do not adequately account for characteristics visible to humans, limiting their application in actual workpiece machining.

Innovation Solution

An object surface evaluation method and device that calculates surface roughness and normal direction change rate to create a visible area map, allowing for the adjustment of tool and machining conditions to make unwanted surface features less visible to humans.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If surface roughness is reduced to improve machining accuracy, then manufacturing precision is improved, but the appearance quality visible to humans may still deteriorate due to visible lines and patterns

Engineering Contradiction:

Improvesurface roughnessVSAvoidvisibility of lines and patterns

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The patent changes the evaluation parameters from traditional surface roughness alone to a composite evaluation including normal direction change rate and visible area ratio. This allows optimization of surface quality based on human visual perception characteristics rather than just numerical roughness values, resolving the contradiction between manufacturing precision and appearance quality.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces conventional mechanical surface measurement methods with an optical evaluation system that calculates visible area ratios based on light reflection characteristics. This substitution enables assessment of surface appearance as perceived by humans, addressing the limitation of traditional roughness measurements that do not correlate with visual quality.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If traditional surface roughness evaluation methods are used, then manufacturing precision can be controlled, but the evaluation does not reflect characteristics visible to humans

Engineering Contradiction:

Improvesurface roughness controlVSAvoidhuman-visible surface characteristics

Core Design Contradiction:

Manufacturing precisionVSLoss of information

Solution Approach 1:

The patent merges traditional surface roughness evaluation with human visual perception characteristics by combining multiple evaluation parameters (surface roughness, normal direction change rate, visible area ratio) into a comprehensive surface quality assessment system. This integration preserves manufacturing precision control while adding human-visible characteristics to the evaluation.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent introduces computational models of human visual perception as an intermediary between physical surface properties and evaluation results. By using calculated visible area ratios based on light reflection models, the system translates physical surface characteristics into human-perceivable quality metrics without losing information.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Manufacturing precision

If machining conditions are optimized for surface roughness, then manufacturing precision is improved, but application to actual workpiece machining with human-visible requirements becomes limited

Engineering Contradiction:

Improvesurface finish qualityVSAvoidapplication to actual machining

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The patent creates a dynamic and flexible evaluation system that can adapt to different machining scenarios and human visual requirements. The visible area map and综合评价 index allow customization of surface quality criteria based on specific application needs, enhancing versatility while maintaining manufacturing precision control.

Inventive Principle:

Principle #15Dynamics

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables the evaluation and machining of surfaces based on human-visible characteristics, allowing for the reduction of visually detectable imperfections and the optimization of machining parameters for desired surface finishes.

Implementation Method 1

the evaluation device calculates a normal direction change rate of the object surface... it is possible to make portions of the object surface machined by a machine which would otherwise be visible to a person not easily visibly detectable by a person

Methodology Applied

Scientific EffectLight reflection: Reflection

Data Source

PatentEP3582039B1Object surface evaluation method, evaluation device, workpiece machining method using said evaluation method, and machine tool

Publication Date: 2023.03.22 MAKINO MILLING MASCH CO LTD

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AI summary

A parameter indicating a surface property of an object surface is plotted on the horizontal axis, a normal direction change rate of the shape of the object surface is plotted on the vertical axis, the minimum normal direction change rate visible to a person is associated with the parameter indicating the surface property of the object surface to create a visible area map, the relationship between the parameter indicating the surface property of a machining surface of a workpiece, and the maximum value of the normal direction change rate of the shape of the machining surface of the workpiece is displayed on the visible area map, and the object surface is evaluated.