Threading Tool Phase Control for Faster Vibration-Synchronized Cutting
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Solution Overview
Problem
In machine tools for threading, the stoppage of reciprocal vibration during the approach phase increases machining time due to the need to set precise phase relationships between the workpiece rotation and cutting tool vibration at the point of contact.
Innovation Solution
A control system that manages the machine tool's feeding, vibration, and rotation mechanisms, allowing the reciprocal vibration to be stopped during the approach phase and then synchronized with the rotation phase at the moment of contact, ensuring efficient cutting processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the reciprocal vibration is stopped during the approach phase to avoid unnecessary vibration, then the manufacturing precision is improved, but the machining time increases due to the need to set precise phase relationships
Solution Approach 1:
The control device preliminarily sets the phase relationship between workpiece rotation and cutting tool vibration before the cutting operation begins. By pre-configuring the phase offset during the approach phase, the system ensures that when vibration starts at the moment of contact, the cutting tool is already in the optimal phase position, eliminating the need for time-consuming phase adjustments during machining
Solution Approach 2:
The system dynamically controls the vibration phase by introducing a variable phase offset that is calculated based on the relationship between workpiece rotation speed and cutting tool vibration frequency. This dynamic phase adjustment allows the system to maintain optimal cutting conditions while minimizing the approach time
2Productivity
If the reciprocal vibration continues during the approach phase to reduce machining time, then the productivity is improved, but unnecessary vibration is generated when the cutting tool is not yet in contact with the workpiece
Solution Approach 1:
The control device implements periodic vibration action that is precisely timed to start at the moment of contact between the cutting tool and workpiece. By synchronizing the vibration cycle with the cutting operation, the system ensures that vibration occurs only when needed, eliminating unnecessary vibration during the approach phase while maintaining high productivity through optimized cycle timing
Data Source
AI summary
A machine tool and a control device for the machine tool for shortening the machining time of a workpiece in a case where the relative and reciprocal vibration of workpiece holder and tool post in the radial direction of the workpiece is stopped during a period from an initial point until when the workpiece and the cutting tool come into contact with each other is provided. In the machine tool, when threading the workpiece to form a threaded portion on the workpiece by relatively moving the workpiece and the cutting tool in the feed direction while relatively rotating the workpiece and the cutting tool 130 to perform multiple times of cutting processes along the same cutting path in a predetermined spiral form, the cutting tool is brought closer toward the workpiece in the feed direction from a predetermined initial point at which the workpiece and the cutting tool are separated from each other, the workpiece and the cutting tool come into contact with each other, and the threading is started with the contact. During the period from the initial point until when the workpiece and the cutting tool come into contact with each other, a controller stops the vibration of the cutting tool, and, in continuous cutting processes in the multiple times of cutting processes in the threading, the control means sets a phase position of the tool post in the vibration direction and stops the reciprocal vibration so that, when the workpiece and the cutting tool come into contact with each other, each of the continuous cutting processes has a predetermined phase in the reciprocal vibration relative to a rotation phase of the workpiece at the start of the threading.