Ultrasonic with rotating tool center point and kinematics

Michael Cahill; Michael Bechtold; Rob Bechtold

doi:10.1117/12.2602370

28 October 2021 Ultrasonic with rotating tool center point and kinematics

Michael Cahill, Michael Bechtold, Rob Bechtold

Proceedings Volume 11889, Optifab 2021; 118891A (2021) https://doi.org/10.1117/12.2602370
Event: SPIE Optifab, 2021, Rochester, New York, United States

Abstract

Hard ceramic and glass material with tough mechanical properties and complex geometries can present a significant challenge in manufacturing. Slower processing times, excessive tool wear, and increased setup times are common with these materials and geometries. To overcome these challenges OptiPro has developed OptiSonic, an ultrasonic assisted machining technology. OptiSonic utilizes a custom tool holder that is designed to produce oscillations, in microns of amplitude, when loaded into a rotating spindle. A software package, IntelliSonic is used for setting up and controlling the ultrasonic motion during operation. Initially, the software is used to characterize each tool to find its optimal resonant peak to operate. Then, while grinding, IntelliSonic continuously adjusts the frequency to maintain optimal grinding efficiency during the operation. OptiSonic has shown, through testing, a reduction of force while machining. The combination of OptiSonic, kinematics, and RTCP (rotating tool center point) allows for full 5-axis simultaneous motion for grinding which allows operators to keep a more consistent wear band on the tool and aid in setup, operation, and part quality. After machine kinematic alignment is completed, the RTCP in the CNC control can make compensations without having to generate new tool paths. Also, the same tool paths can be shared between machines that have kinematics enabled. This can lead to a significant time reduction in setting up and adjusting tool paths.

Conference Presentation

Citation Download Citation

Michael Cahill, Michael Bechtold, and Rob Bechtold "Ultrasonic with rotating tool center point and kinematics", Proc. SPIE 11889, Optifab 2021, 118891A (28 October 2021); https://doi.org/10.1117/12.2602370

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