Turning Controller Approach Angle Adjustment for Thrust Force Minimization
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Solution Overview
Problem
In turning operations, especially on fine shafts with high aspect ratios, the thrust force applied during cutting can significantly impact turning accuracy, and existing solutions struggle to effectively manage this force to maintain precision.
Innovation Solution
A turning controller system that includes a spindle, tool holding unit, Z-axis driver, X-axis driver, and B-axis driver, along with a control device that calculates and sets an approach angle to minimize the thrust force by inclining the tool holding unit around the B-axis, ensuring the thrust force applied to the workpiece is zero or minimal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional tool with fixed approach angle is used, then the tool structure is simple, but the thrust force cannot be minimized affecting turning accuracy
Solution Approach 1:
The tool holding unit is made dynamically adjustable in the B-axis direction, allowing the approach angle to be changed during different stages of the turning process. The B-axis driver enables real-time adjustment of the tool inclination angle to optimize thrust force minimization for different cutting depths, transforming a static tool structure into a dynamic one that adapts to process requirements.
Solution Approach 2:
The approach angle parameter is made variable rather than fixed. The control device calculates optimal approach angle values based on cutting depth and other parameters, then adjusts the tool holding unit's B-axis angle accordingly. This parameter change enables the system to minimize thrust force for different operating conditions while maintaining a relatively simple tool structure.
2Manufacturing precision
If the approach angle is adjusted to minimize thrust force, then turning accuracy is improved, but the control system complexity increases
Solution Approach 1:
The control device automatically calculates the optimal approach angle based on the working program and tool shape data, and autonomously generates B-axis command amounts for adjustment. This self-service capability eliminates the need for manual intervention or complex external control systems, as the controller itself performs the optimization calculations and executes the adjustments.
Solution Approach 2:
The system incorporates a feedback mechanism where the control device monitors the turning process parameters, calculates the optimal approach angle based on current cutting conditions, and adjusts the B-axis angle accordingly. This closed-loop control ensures thrust force minimization while maintaining a manageable control system architecture.
3Manufacturing precision
If a single approach angle is used for all cutting depths, then the tool design is simple, but turning accuracy deteriorates for fine shafts with high aspect ratios
Solution Approach 1:
The tool holding unit's B-axis angle is made dynamically adjustable to adapt to different cutting depths. For fine shafts with high aspect ratios, the system automatically selects smaller approach angles to minimize thrust force and prevent workpiece bending, while for larger workpieces, larger angles can be used. This dynamic adaptation resolves the contradiction between simple tool design and high precision requirements.
Data Source
AI summary
A turning controller includes a storage, a working program processing device, a command value setting processing device, an approach angle setting command amount calculator, and a command processing device. The storage is configured to store a working program and tool shape data. The working program processing device is configured to analyze the working program and to calculate and output command amounts. The command value setting processing device is configured to set an approach angle command value for defining an approach angle. The approach angle setting command amount calculator is configured to calculate, as an approach angle setting command amount, a B-axis command amount for controlling to cause the approach angle to have the approach angle command value based on the tool shape data. The command processing device is configured to output the approach angle setting command amount to the B-axis driver.