Vibration Cutting Tool Wear Detection From Stroke Force Difference
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Solution Overview
Problem
Existing machine tools face challenges in accurately determining the degree of wear of tool distal ends during machining, often requiring frequent interruptions and resulting in reduced work efficiency.
Innovation Solution
A machine tool configuration that includes a spindle, rotation mechanism, tool, movement mechanism, vibration mechanism, and a determination means to assess tool wear by measuring the difference in force components during forward and return strokes in relative vibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are arranged to detect tool wear during machining, then tool wear monitoring accuracy is improved, but device complexity and space requirements increase
Solution Approach 1:
The patent replaces complex sensor-based detection systems with a mechanical measurement approach. By measuring the actual cutting depth and comparing it with the commanded cutting depth, the system infers tool wear without requiring additional sensors on the tool or workpiece. This substitution of mechanical measurement for electronic sensing reduces device complexity while maintaining monitoring accuracy
Solution Approach 2:
The system uses the existing movement mechanism and control system to perform wear detection. The same components that control tool positioning are utilized to measure actual cutting depth, eliminating the need for separate detection devices. The control system itself serves the dual function of both controlling machining and detecting tool wear
2Measurement precision
If machining is interrupted to check tool wear, then measurement precision is improved, but productivity decreases
Solution Approach 1:
The system enables continuous tool wear monitoring during machining operations by measuring actual cutting depth in real-time and comparing it with commanded values. This continuous detection eliminates the need to interrupt machining for wear checks, maintaining uninterrupted productive operation while accurately tracking tool wear progression
Solution Approach 2:
The system implements feedback by continuously comparing the commanded cutting depth with the actual measured cutting depth. The difference between these values indicates tool wear, providing real-time feedback that enables continuous monitoring without interrupting the machining process
3Reliability
If multiple sensors are added to improve wear detection reliability, then measurement precision is improved, but ease of operation deteriorates
Solution Approach 1:
The system achieves reliable wear detection using existing multi-functional components. The movement mechanism serves both to position the tool and to measure actual cutting depth. The control system performs both machining control and wear detection functions, eliminating the need for dedicated sensor systems and simplifying operation
Data Source
AI summary
A machine tool is provided, which cuts a workpiece W by concurrently vibrating and moving the workpiece and a tool relatively by using a movement mechanism and a vibration mechanism while rotating a spindle by using a rotation mechanism, and which includes a determination means for determining the degree of wear of a distal end of the tool from a difference between a force component during a forward stroke and a force component during a return stroke in relative vibration of the workpiece and the tool. The force component is a force component of a force that is received by the tool from the workpiece and that is in a direction parallel to the direction of movement by the movement mechanism.