Tool Contour Correction for Accurate Multi-Point Machining
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Solution Overview
Problem
Conventional workpiece machining devices face issues with positional deviations and shape errors due to defective chucking and tool wear, leading to inaccurate machining, especially when multiple points are involved, which existing correction methods fail to address.
Innovation Solution
A workpiece machining method and device that utilizes a control unit to detect and correct positional deviations and shape errors by calculating contour errors and distance effect coefficients, adjusting the machining path using a laser measuring instrument and NC program corrections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a tool is fixed to a tool holding unit by chucking, then the tool can be positioned relative to the workpiece for machining, but positional deviation occurs due to defective chucking or initial shape errors
Solution Approach 1:
The patent applies preliminary action by measuring the tool's actual shape and position before machining begins, detecting deviations from the ideal shape, and pre-calculating correction values that are stored and applied during subsequent machining operations. This advance preparation eliminates positioning errors that would otherwise occur during actual machining.
Solution Approach 2:
The patent implements feedback by using a laser measuring instrument to continuously monitor the tool's shape and position, comparing measured values against ideal values, and using the detected deviations to calculate and apply correction values. This closed-loop feedback system ensures machining accuracy despite initial positioning errors or tool wear.
2Adaptability or versatility
If conventional correction methods are used for tool wear, then tool deterioration can be compensated, but corrections cannot be performed for shape errors or positioning errors when the tool touches multiple points
Solution Approach 1:
The patent achieves universality by creating a comprehensive correction system that handles multiple types of errors (shape errors, positioning errors, and wear) and multiple machining scenarios (one-point and multi-point contact) through a unified approach. The laser measuring instrument and correction calculation unit can detect and correct various error types, making the system versatile across different machining conditions.
Solution Approach 2:
The patent replaces mechanical measurement and correction methods with optical measurement using a laser measuring instrument. This substitution enables non-contact, high-precision detection of tool shape and position, allowing accurate measurement and correction of errors that would be difficult or impossible to detect with conventional mechanical methods.
3Manufacturing precision
If the tool touches one point for machining, then correction for wear can be applied, but corrections cannot be applied when the tool touches multiple points
Solution Approach 1:
The patent applies preliminary action by pre-measuring the tool's complete three-dimensional shape and position using laser scanning before machining begins. This comprehensive advance measurement captures all potential error sources, enabling the system to calculate appropriate correction values for any machining scenario, whether one-point or multi-point contact, thereby expanding applicability while maintaining precision.
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 high-accuracy machining by correcting contour errors and avoiding unwanted contact with the workpiece, ensuring precise tool positioning and improved machining accuracy even when transitioning between multiple machining points.
Implementation Method 1
a tool shape measuring device that measures the shape of the tool by radiating laser light from the side-surface direction of the tool and receiving the reflected light
Implementation Method 2
measures the shape of the tool by radiating laser light from the side-surface direction of the tool and receiving the reflected light
Data Source
AI summary
A machining device includes: a positional deviation detection unit configured to calculate a correction value for correcting a positional deviation between an ideal contour line and an actual contour line in each of a plurality of angular directions based on a center of a hemispherical shape of a tool; a distance effect coefficient calculation unit configured to calculate a first distance effect coefficient indicating a degree of influence of the positional deviation when machining a second machining point, according to a distance between the tool and the second machining point in a case where a machining point machined by the tool transitions from one-point machining including a first machining point in the workpiece to two-point machining including the first machining point and the second machining point; and a positional deviation correction unit configured to correct the positional deviation of the tool.