Workpiece Surface Display for Ball End Mill Dimple Prediction
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Solution Overview
Problem
Existing systems fail to accurately display the spherical dimples formed on a workpiece surface by a ball end mill, making it difficult for users to predict the surface pattern after machining and leading to incomplete or streaked machining marks.
Innovation Solution
A workpiece machined surface display method and device that specifies the shape and position of dimples to be formed by a cutting blade, generates a tool path based on these specifications, and displays dimple images on a monitor, allowing users to visualize the machining marks before actual machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If conventional machining display systems are used, then the tool path can be displayed, but the actual spherical dimple patterns formed on the workpiece surface cannot be accurately visualized
Solution Approach 1:
The patent creates a virtual copy of the actual dimple pattern by simulating the machining process. A 3D model of the workpiece is generated, and the ball end mill cutting action is simulated to produce a virtual dimple pattern that replicates the actual surface topology. This virtual copy allows users to visualize and evaluate the surface pattern before actual machining occurs.
Solution Approach 2:
The system performs preliminary simulation of the machining process to predict the dimple pattern before actual machining. By calculating the tool path and simulating the ball end mill cutting action in advance, the system allows users to evaluate and adjust machining parameters to avoid incomplete or streaked dimples before committing to actual machining operations.
2Ease of operation
If ball end mill is used to cut workpiece surface, then machining can be performed, but spherical dimples are formed which are difficult to predict and evaluate before machining
Solution Approach 1:
The system provides visual feedback by displaying the predicted dimple pattern on the workpiece surface model. Users can see the expected surface pattern, including the size, shape, and distribution of dimples, before machining. This feedback loop allows users to adjust machining parameters such as feed rate, spindle speed, and tool path to achieve the desired surface pattern.
Solution Approach 2:
The patent introduces a simulation model as an intermediary between the machining parameters and the actual workpiece surface. This virtual model acts as a mediator that translates machining parameters into predicted surface patterns, allowing users to evaluate the outcome without directly machining the actual workpiece.
3Device complexity
If conventional display methods showing only groove shapes are used, then tool path visualization is provided, but actual dimple shapes and surface patterns cannot be grasped
Solution Approach 1:
The patent transitions from 2D groove line representations to 3D surface topology visualization. By generating a 3D model of the workpiece and simulating the dimple pattern on the surface, the system provides depth and dimensional information that accurately represents the actual surface topology, allowing users to grasp the true shape and distribution of dimples.
Data Source
Figure 1
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Figure 4A~4B
AI summary
The invention is a workpiece machining surface display method by means of which a machining mark generated when a workpiece machining surface (60) is machined by a rotary tool (54) comprising a cutting edge (54a) is displayed on a display device (2). Said workpiece machining surface display method contains: a first step in which the shape and position of an indentation (61) generated by the cutting edge (54a) shaving the workpiece machining surface (60) are predicted; and a second step in which an indentation image (610) representing the shape of the indentation (61) that has been predicted in the first step is displayed in association with the predicted position.