Turning Tool With In-Situ Distance Sensing for Machined Surface Measurement
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Solution Overview
Problem
In machining using an automatic lathe, the inability to measure workpiece dimensions during the process leads to increased machining time and cost due to the need to temporarily draw the tool away from the workpiece for measurement, which complicates adjusting for cutting edge abrasion and affects dimensional accuracy.
Innovation Solution
A turning tool equipped with a measurement device, including distance sensors, that allows for in-situ measurement of machined surfaces without requiring the tool to be drawn away from the workpiece, reducing measurement time and enabling real-time adjustment for improved accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the tool is drawn apart from the workpiece to measure the machined surface, then measurement can be performed, but machining time is lengthened and machining cost increases
Solution Approach 1:
The measurement device is integrated directly onto the tool body, merging the cutting function and measurement function into a single tool unit. This allows the tool to both machine and measure without being drawn apart, eliminating the time loss associated with tool repositioning while maintaining measurement capability
Solution Approach 2:
A distance sensor serves as an intermediary measurement device that can measure the machined surface through non-contact means while the tool remains in its machining position. This intermediary device enables measurement without requiring the tool to be drawn apart, resolving the contradiction between measurement access and time efficiency
2Measurement precision
If the tool is drawn apart from the workpiece to measure the machined surface, then measurement can be performed, but machining cost increases
Solution Approach 1:
By combining cutting and measurement functions in one integrated tool, the system eliminates the need for separate measurement operations that increase machining time and cost. The merged tool performs both functions simultaneously, improving productivity and reducing cost
Solution Approach 2:
The tool performs self-measurement by incorporating the measurement device on its own body, enabling it to autonomously measure the machined surface without requiring separate measurement equipment or additional operational steps, thereby reducing machining cost
3Device complexity
If dimensions are not measured during machining, then machining process is simpler, but adjustment for cutting edge abrasion becomes difficult
Solution Approach 1:
The measurement device provides real-time feedback on the machined surface dimensions during the machining process. This feedback enables immediate detection of cutting edge abrasion and allows for timely adjustment of machining parameters or tool replacement, maintaining manufacturing precision without significantly increasing process complexity
Solution Approach 2:
The measurement device is positioned to measure the machined surface before the tool is withdrawn, enabling preliminary detection of dimensional accuracy and cutting edge condition. This preliminary measurement allows for proactive adjustment before precision is compromised
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 solution shortens measurement time, reduces machining costs, and enhances dimensional accuracy by allowing for immediate correction of cutting edge wear, thereby preventing product tolerance issues and improving overall manufacturing efficiency.
Implementation Method 1
a measurement device attached to the tool body, and measures a distance from the tool body to an object
Data Source
AI summary
A turning tool includes a tool body extending along a tool axis and having a base on a tip of the tool body, a cutting insert detachably attached to the base, and a measurement device attached to the tool body. The measurement device has a first distance sensor which measures a distance to an object located radially outward of the tool axis.