Tool Reworking via 3D Virtual Model Contour Fitting
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Solution Overview
Problem
Current methods for machining tools are complex and inefficient, particularly in reworking worn tools, where excessive material removal is often necessary to ensure quality, and additive manufacturing processes lack precision, leading to suboptimal tool characteristics.
Innovation Solution
A method involving 3D scanning to create a virtual tool model, comparing it with stored data sets to select the appropriate machining parameters, and minimizing material removal by fitting a reference contour into the virtual model to produce a desired tool contour, using tools like lasers or EDM for precise machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional measuring methods are used to assess tool characteristics, then measurement accuracy is achieved, but the process complexity and time consumption increase significantly
Solution Approach 1:
The patent creates a digital 3D copy (virtual model) of the tool using laser scanning technology. This digital replica contains all geometric information needed for measurement and assessment, eliminating the need for complex physical measuring systems while maintaining measurement accuracy. The virtual model can be stored and reused for multiple assessment purposes.
Solution Approach 2:
The patent replaces traditional mechanical contact-based measuring systems with optical laser scanning technology. The laser scanner non-contactly captures the tool's 3D geometry by measuring light reflection patterns, substituting mechanical measurement mechanisms with optical fields and computational processing.
2Reliability
If excessive material is removed during tool reworking to ensure quality, then tool reliability is improved, but material loss and manufacturing costs increase
Solution Approach 1:
The patent performs a preliminary 3D scan of the tool to create an accurate virtual model before any reworking begins. This allows the system to plan and optimize the reworking process in advance, determining the minimum material removal needed to restore tool specifications, thereby preventing excessive material removal during actual machining.
Solution Approach 2:
The patent uses the virtual 3D model as a feedback reference during the reworking process. The actual tool geometry is continuously compared against the virtual model to monitor material removal, ensuring that only the necessary amount of material is removed while maintaining tool quality standards.
3Productivity
If traditional tool manufacturing methods are used, then production speed is maintained, but manufacturing precision and geometric accuracy deteriorate
Solution Approach 1:
The patent performs 3D scanning and virtual model creation as a preliminary step before manufacturing or reworking. This allows the complete tool geometry to be captured and analyzed in advance, enabling precise machining paths to be planned without requiring multiple iterative measurements during the manufacturing process, thus maintaining high productivity while achieving superior 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
This approach optimizes tool reworking by minimizing material removal, extending the life of expensive tools, maintaining precise geometric configurations, and allowing for precise coating applications, while improving the manufacturing efficiency of tools with imprecisely positioned cutting plates.
Implementation Method 1
The at least one measuring device (23) is embodied in such a manner that, with the use of the measuring unit (17), it is possible to detect the three-dimensional outer contour of the tool (16)
Implementation Method 2
machining by removing material... using tools like lasers or EDM for precise machining
Implementation Method 3
machining by removing material... using tools like lasers or EDM for precise machining
Data Source
AI summary
The invention relates to a device (15) and a method (V) for machining a tool (16) by removing material. The tool (16) is first of all measured in three dimensions using a measuring unit (17) and a three-dimensional virtual tool model (M) is produced therefrom. This virtual tool model (M) is compared with a reference contour (R) from a particular tool data record (WD). If a match was determined, a machining program (PR) assigned to the tool data record (WD) is selected and a desired contour (SK) is determined by fitting the reference contour (R) into the three-dimensional virtual tool model (M). The tool (16) can then be machined on the basis of this desired contour (SK).