Tool Wear Segmentation for NC Program Generation
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Solution Overview
Problem
Existing methods for machining with NC machine tools do not effectively utilize tool portions that are still usable due to wear, as they focus on correcting tool paths without considering which parts of the tool can be used, leading to inefficient tool usage and increased costs.
Innovation Solution
A processing program generation method and device that acquire usage history information of each tool portion, set a target portion for use based on this information, and generate a processing program to utilize the remaining usable parts of the tool for machining, thereby optimizing tool usage and reducing waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If tool path correction is performed based on cumulative wear calculation, then machining precision is maintained, but tool utilization efficiency deteriorates because worn portions cannot be effectively reused
Solution Approach 1:
The tool is divided into multiple portions along its length, and wear is calculated separately for each portion based on the cumulative machining history. This segmentation allows the system to identify which specific portions are still usable and which have reached wear limits, enabling selective reuse of viable portions rather than discarding the entire tool.
Solution Approach 2:
The patent applies different quality assessments to different portions of the tool based on their individual wear states. By evaluating each portion's remaining life and machining capability locally, the system can determine optimal reuse strategies for each segment, maximizing overall tool utilization while maintaining machining precision in the portions that can still be used.
2Manufacturing precision
If the entire tool is discarded when any portion becomes worn, then machining quality is ensured, but tool cost increases due to ineffective utilization
Solution Approach 1:
Instead of discarding the entire tool when wear occurs, the patent recovers and continues to use the portions that have not yet reached their wear limits. By tracking wear history for each portion and identifying usable segments, the system recovers value from partially worn tools, reducing tool replacement frequency and costs while maintaining machining quality through selective use of viable portions.
3Productivity
If usage history tracking is implemented for each tool portion, then tool utilization is optimized, but system complexity increases
Solution Approach 1:
The system automatically tracks and accumulates machining history data for each tool portion without requiring manual intervention. The NC device itself serves to record and process usage information, eliminating the need for external tracking systems or manual logging, thereby optimizing tool utilization while minimizing the added system complexity.
Solution Approach 2:
The patent implements a feedback mechanism where the NC device continuously monitors machining parameters and updates wear calculations for each tool portion based on actual usage. This automated feedback loop enables dynamic optimization of tool utilization by identifying usable portions in real-time, while the integration with existing NC systems keeps the complexity increase manageable.
Data Source
AI summary
A processing program generation method for generating a processing program (PR) for a work machine on the basis of use-results information for a tool (4) attached to a work machine (2), wherein the use-results information for each part of the tool (4) is obtained, a target use part of the tool (4) is set on the basis of the obtained use-results information, and the processing program (PR) is generated in a manner such that a workpiece (W) is processed using the set target use part of the tool (4).