The paper presents the development of a high-precision system for processing images of the physical model of the impeller obtained by the optical system in transmitted and reflected light. The paper presents the development of a high-precision system for processing images of the physical model of the impeller obtained by the optical system in transmitted and reflected light. The basis for increasing the accuracy of impeller geometry control is the assumption that there exist a correlation between the accuracy of the entire blade surface and the accuracy of the optically accessible zone of the blade if the conditions for shaping the blade surface are met in the optically accessible for measurements zone. In this work, the controlling trajectory for the measuring machine during the formation of a set of control images on the base of numerically relationships between the positioning coordinates of the cutter during 5-axis processing and conditions of the contact of the cutter . Thus, the image processing system allows to establish, based on a set of focal zones in images, the relationship between the coordinates of a physical object. The developed method allows for not only a significant increase in the measurement speed, but also for the identification and elimination of error in the contact of the cutter with the workpiece surface. A method for setting up a measuring machine is proposed, which ensures the required accuracy of product control during multi-coordinate high-speed milling. Based on the operation of the proposed system, the results of geometric accuracy measurements, linear and angular measurements and studies of the properties of machined surfaces of products equipped with slot of various shapes between blades are obtained.
Helical surfaces are important elements of solid end mills. Their production is carried out using multi-coordinate grinding. Shape errors and reduction in the quality of the screw surface appear due to abrasion, high pressure, and wear of the grinding wheel. Therefore, it is extremely important to measure geometric accuracy, to perform linear and angular measurements, and to study the properties of rake helical surfaces. The paper proposes improvements to monitoring of helical surfaces via the use of a new computer vision system for assessing microtexture on helical surfaces after multiaxis grinding on CNC machines. A computer vision system was developed to evaluate defects on helical surfaces after multi-coordinate grinding on CNC machines, and a comprehensive analysis of existing indicators for recognizing the defect was carried out in a guaranteed range of probability of finding a solution of 99.7% for the distribution density of grinds. To verify the developed method, the accuracy of surfaces obtained by using the one was compared with the measurements carried out using specialized equipment for the control of the accuracy of helical surfaces. A new system for monitoring the accuracy and defects of cutting edges, helical front and rear surfaces allows establishing the main geometric parameters of the cutting edges and cutting wedge such as flute angle and rake angle at the apex using key indicators of the difference in color intensity in the focal zone of the image. When developing this approach, it was found that areas with smaller curvature of the rake surface are more susceptible to the accumulation of helical flute pitch errors after grinding. Experimental studies of the system operation were conducted to provide empirical evidence on helical surfaces after multiaxis grinding on CNC machines, demonstrating excellent convergence and defect recognition accuracy. The accuracy of determining the results of the inclination angles of the microtexture surface after grinding at the control point is 2-2.5 degrees, which allows you to form a comprehensive solution for scanning the surface, which will allow you to apply a simple method of control using a camera in reflected light.
Solving the problem of reverse engineering as a key element of the production process and its technological preparation has a key role. This work demonstrates for the first time the possibility of preparing production and collecting key indicators, which allows you to recreate a digital twin of the technological process and display the technological aspects of the design as a result of collecting key indicators. Such indicators include the width of the cut layer, the cutting zone of a conical cutter during multi-axis positioning, obtained based on the results of processing a group of images of processed products. Actual technological indicators of the technological process can be identified and numerically formalized by assessing the shape of the helical surface on a class of parts obtained as a result of multi-coordinate processing, which proves the possibility of applied application of the method in the structure of the production process in real time. As a result, the use of a new algorithm will reduce the likelihood of receiving defective products and recreate the technological process based on processing a set of product images. The work constructs an analytical model for the automated creation of processing paths based on improved B-splines, which can significantly improve smoothness compared to numerical methods for generating paths. The actual technological indicators of the machining process can be identified and numerically formalized dependencies by determining the influence of the helical surface on the precise positioning of the end mill with compensation along each axis during 5-axis machining, obtained as a result of multi-axis machining, which proves the possibility of applied application of the method in the production process in the mode real time.
In designing a conical end mill with a helical front surface, the geometry of the grinding wheel has an influence on the shape of the back profile, as this study shows. For the first time, the influence of the generix of a conical circle's angle of inclination on various interference schemes has been studied. Through the combination of laser ablation and grinding, the underpoints of the helical surface were given their final shapes, indicating the standard sizes that would affect the execution's ability to be manufactured. This work will result in the engineering of a system for automated manufacturing of conical mills, as well as the development of control programs for CNC grinding and laser ablation machines. It will also enable the development of design support for cutting tool production. The work reveals analytical dependences of the value of the clearance angle, controlled at the point of the flank surface during the transition from the radius of the cutting edge to the profile section of the helical flute in the radial section, which is set from the coordinate of a parametrically defined point along the OX axis in the radial section. It has been established that the value of the radius of curvature of the cutting edge and the point of formation of the transition of the radius to the profile can significantly change the kinematic geometry of the cutter (up to nine degrees when the radius of the cutting-edge changes by 30 μmm).
In this paper, a new system for designing drills with a full parametric cycle of connection of the main parameters of the rear surface of the drill, based on the identified functional relationships between the parameters of the original tool surface and the kinematics of the movement of the drill tooth. For the first time, a mechanism for determining the shape of the back surface of a three-tooth drill with the possibility of regrinding by various methods has been established. This work will allow not only to develop design support for tool production, but also to create a system for the automatic production of three-tooth drills and writing control programs for CNC machines. The work is the first to propose an analytical mathematical model for solving the solve problem of profiling the helical groove of a twist drill and cutting edges, which is the main stage in the design of a new class of drills with a toroidal cutting surface. For the first time, a study of the field of change in the rake angle and the normal rake angle in the region of the generating surface was carried out. As a result, it was found that in the f range from [-1.2; 1] the normal rake angle γN for almost the entire length of the section takes values in the range [20°; 32°], with a displacement of the cutting edge f by a distance of 2.8 mm, it will be possible to obtain the geometry of the helical surface on the cutting surface in a constant range from 32° with a tolerance range of 2°.
A key functional role is served by the helical surfaces of carbide end mills that can be manufactured during diamond grinding wheel. Localized changes in the form of the helical surface can be caused by abrasion, high pressure, and grinding wheel wear. Therefore, it is extremely important to measure the physical samples of products with a helical surface according to the criterion of profile accuracy, rake angle and core diameter. A specialized inspection machine in reflected light can be used to obtain images across the helical groove. Manually extracting a number of defects from photos takes time. Using defect recognition algorithms, effective and quick quality control of a ground helical surface can be established. As a result, effective surface quality control can be achieved in the machine tool industry. In this study, an innovative approach to determine a defect's shape and location as well as an algorithm for removing it are presented. Both of these approaches are integrated into the technological process used to manufacture products with helical surfaces. With the goal to recognized create suggestions for image analysis using different image levels, the suggested approach provides logically smoothing histograms and limiting contrast as an image pre-processing, based on an analysis of images with useful and faulty parts. Achieved successful extraction of areas of adhesive, diffusion, abrasion and chips from the image through post-processing. The article presents a new approach to recognizing adhesive and diffusion defects on the helical surface of a mill after grinding. When developing this approach, it was revealed that areas with alternating profile changes are most susceptible to the formation of defects under conditions of increased heating of the working area, and specialized inductors for searching for defects in localized areas according to the criterion of pixel brightness intensity were proposed.
The studies will be carried out using optical metrology methods on a Walter Helicheck inspection machine in reflected light and a number of images were stored to form a statistical sample. Established new indicators and criteria for grinding efficiency based on image processing of the helical groove of the end mill. As a result, recommendations for the selection of optical control techniques were made for the first time at the intermediate stage of technological preparation for production, in real time, and after processing. In this work, for the first time, we prove the possibility of determining the camera displacement pith distance during continuous scanning of the profile of a helical surface in a radial section, the measurement accuracy and recreating a three-dimensional model of the object. As a result of the work of the new algorithm using the Haar-wavelet with new indicators, it was established that the actual one is located inside the focal zone, which proves the possibility of applied application of the method of monitoring the shape of helical flute of end mills using computer vision. The measurement accuracy of the helical flute increased from 4 to 12% along its profile.
A new approach to the automated design and control of ceramic end mills is proposed, which allows creating a group of structures for machining a range of products from various hard-to-cut materials in different modes. The method compares favorably with the existing ones by creating new cutting tool with increased performance, providing an increase in the resistance of mill to brittle fracture up to 2-3 times. The design approach includes a comprehensive measurement module for quality control of products with a reduction in the complexity of measurement up to 10 times in terms of time.
A method for microprocessing products with a shaped generatrix by remote the product from the image is proposed, which provides an increase in productivity without loss of quality. The method allows you to recreate an object based on image reconstruction with basic accuracy requirements and establish a rational trajectory of the turning tool on CNC machines. The method is implemented as follows: a cylindrical workpiece is fixed in the machine spindle, the plate is installed in the turning body cutter, a preliminary positioning of the cutter is performed and its fixation in the working area of the machine with a special trajectory of movement obtained on the basis of the recognized profile of the product during reverse engineering. As a result, the new method allows increasing the productivity of the treated surface up to 2 times, depending on the shape and accuracy of the object being reconstructed.
Cutting tools with shaped cutting surfaces are widely used in industry. Their use allows to improve cutting conditions and to increase productivity. The faceted cutting surface is formed by cutting edges of complex shape. Since, there does not exist a standard/conventional methods for controlling a specialized tool, the development of methods for controlling chips of a cutting wedge of a complex shape is of high importance. In this paper, an image processing algorithm that allows to search for the shape of the edge and find deviations in the form of a chip from the theoretical result has been developed. The algorithm helps to quickly transform from a digital image to the real scale of the cutting edges. The translation of the coordinate system of the measuring machine calibrate and control the angular position of the cutter during measurement. The approach to finding the coordinates of the cutting edge, developed in this article, includes an error elimination block with experimental verification of functional dependencies, which allows to quickly correct the angular position of the controlled tooth online. This can significantly increase the efficiency and speed of measuring end mills for adjusting the angular position and correction when controlling a multi-blade tool while evaluating the accuracy of the cutting edge and the magnitude of the chip on the back surface.
In mechanical engineering, cutting tool wear is a major factor in the functional and parametric failure of a cutting tool. The loss of tool performance causes failures in the production of suitable products, as well as machine downtime. In this connection, accurate measurement of wear of the cutting wedge at various stages of the technological process is extremely important. The article proposes a method for recognizing wear zones on the back surfaces of cutting inserts by image processing. Indicators have been formed for assigning a failure criterion for various quality factors. For the formation of a measurement system, a three-stage control method with the rationale for operational recommendations is proposed. The correlation of wear by image processing has been compared with the optical method currently applied in manual mode, which greatly reduces the efficiency of production quality control.
In this paper, a set of indicators for an effective assessment of the cutting ability of a grinding wheel was established based on the detection of the degree of filling and immersion of abrasive edges. It has been pointed out that a profile of a populated circle has a direct correlation with the average number of recognized faces. A new indicators for measuring zones with active edges and their distribution on the surface of a grinding wheel was developed, which can be identified by the models algorithms, is formed
The geometric parameters of sharpening the rake surface are very important for the efficient use of the drill. Therefore, it is important to know the correct sharpening angle of the drill in the radial direction. This is especially important at the stage of regrinding the drill, due to the incorrect installation of the drill into the fixture. In this paper, a new image processing algorithm is proposed that allows you to set indicators and factors that determine the correct choice of the angular position of the drill after regrinding. This algorithm can be of great industrial use due to the simplicity of implementation and minimization of the necessary equipment for setting up the measuring station. The presented model has an important application value and differs from the existing ones in that it can be applied for regrinding of drills with curvilinear cutting edges. This advantage is achieved by using a simpler construction of the drill’s flank surfaces. The proposed design ensures a rational distribution of the clearance angle value along the cutting part regardless of the original shape of the flank surface before the regrinding. Taking into account the limitations of the image processing algorithm and the theoretical model of the cutting part of a tri-flute drill, a rational ratio of the rake and clearance angles obtained by simulating the edge movement in cutting process. This approach allows a radical revision of the traditional recommendations for regrinding process of tri-flute drills. This is becomes possible to solve problems associated with regrinding drills with involute and multi-level flat flank surface. However, the validity of our work still needs to be carefully checked.
In this paper, a new method for determining the curvature of the drill's rake surface is developed. The new method is based on the identified functional relationships between the focus area in the image and the shape of drill’s rake surface. The revealed relationships allow for the determination of the curvature of the front surface of the drill, which can be used to determine the geometric parameters of the chip flute. The method is based on the analysis of images obtained in the process of measurement by a camera in reflected light. To implement the developed method, the drill was fixed in a collet chuck on a NC measuring machine, the camera is pointed at the front surface area, and a series of images with different focal lengths was taken. After processing the images obtained in reflected light, the shape of the rake surface of the drill in the radial section was determined. The accuracy of the proposed method is proved by comparison with the data obtained from the measuring machine
We propose a method for detecting the boundaries of the cutting edge and flank surface of helical drills.To implement the proposed method, the drill is installed in a rotating holder on the coordinate measuring machine and the rotation around the axis and simultaneous recording of video from the transmitted light camera to create a sample of images, the processing of which determines the profile boundary in the axial section of the drill. To evaluate the accuracy of this method, comparisons of the data obtained with the algorithm and the measuring machine are given. To find the gradient drop zones, the Canny's method was improved with discrete smoothing processing of a sequential set of images while changing the angular position of the drill. In this case, the new method is relevant for real-time image processing with a specified accuracy of up to 5 µm and 30 minutes for linear and angular measurements.
In this work, a new mathematical model for determining the mechanism of plunging the cutting edge of end mills with a stable passage of the cutting into the workpiece material has been developed. The new mathematical model describes the chip width as a function of the feed rate, the number of teeth and the cutter diameter. The present work shows that the theoretical value of the width of the cut layer can be used as a key parameter controlling the cutting force and as a key factor determining the plunging mechanism. A comparison of model results with experimental data has shown that modeled and experimental heights of microroughness in the stable cutting sections are in agreement within 0.05 μm that indicates the high accuracy of the developed mathematical model.
A new method for determining surface roughness based on improving the kinematics of the milling cutter movement during micro-cutting has the advantage of the precise spatial position of the micro cutter edge. A change in the components of the speed of movement and rotation during a complex movement of the cutter changes the mechanism of plunging of the cutting edge into the workpiece material. Based on the model developed in this work, the kinematic parameters of the cutter were determined, and new relationships between the cutter geometry and parameters of the technological process were discovered. The revealed new relationships made it possible to determine not only the mechanism of chip formation but also the dimensions of damages to the workpiece surface during plunger cutting.
A new approach to obtaining three-dimensional cutting edges on a tapered cutting surface is proposed based on an image obtained on a measuring machine in the control section. The method is developed based on forming a spline and evaluating the shape using a unique algorithm, which is in turn based on an analytical mathematical model. The developed method allows estimating the main geometric parameters of the cutting edge and analyzing the shape of the helical groove of the drill. In the experiments, the drill was installed on a rotary table capable of adjusting the position around its axis. The validity of the new approach was corroborated by physical tests and analysis of the set of images obtained using an optical measuring system.
Toroidal end mills have great industrial applications and have good prospects for increasing the volume of products produced with them. It complicates the process of measuring the cutting edges by changing the position of the cutting edges along the axis, which does not allow the geometry control at the same focal length. The method proposed in the article is an effective tool for carrying out automated measurements of the shapes of cutting edges. Application of the method is relevant for edge control in automated mode. To assess the accuracy of the proposed method, it was tested on a high precision measuring machine Walter Helicheck Plus. The new method allows for repeatability of measurements down to 1.5 μm, which meets the accuracy requirements for non-profiling areas of end mills. Suggested method is universal and can significantly reduce the laboriousness of measuring multi-flute cutters. The most important advantage of this method is the ability to determine the ranges in which there is a smooth cutting edge in all areas of the cutter's cutting edge.
The application of solid carbide tri-flute drills is important for machining high- precision holes. The main advantages of a tri-flute drill are high productivity, very good self-centering and relatively small deviation from the base axis of the hole. The profile of the helical chip groove in the radial section and the shape of the thinning of the drill are the most important factors controlling the cutting precision and overall performance. In this work, various types of groove shape have been investigated and a new method for designing and rationalizing the cutting part shape of a tri-flute drill has been developed. The key result of this paper is a new method of the design of the cutting edge with minimized change in the radius of curvature, which allows to more evenly distribute the force load in the cutting zone and, hence, to decrease the probability of the drill failure. A comprehensive study of the geometric parameters of the drill cutting edges allowed determining the necessary curvature with a minimum number of node points and accounting for the initial position of the transitional section and chisel edge angle. New relationships between the curvature of cutting edge and the shape of the chip groove derived in this work provide a theoretical foundation for the further development of practical recommendations for designing the high-performance tri-flute drills.
Solid ceramic mills with a toroidal cutting surface are playing an important, steadily growing role in manufacturing products made of heat-resistant materials. However, properties of these mills have a drawback such as the low strength and, hence, their design requires the absence of zones with high concentration of stresses to reduce the probability of the brittle fracture. In this paper, a new approach to the formation of the cutting edge of solid ceramic end mills has been developed. Unlike the existing approaches, which are based on the shape of the helical groove on the periphery, the new approach is based on the shape of the cutting edge on the toroidal cutting surface determining the shape of the helical surface of the cutter on the radial section. The new method allows finding ranges, in which constant angle cutting edges in the toroidal region exist, and developing multiple new designs of solid end mills with varying combinations of geometric parameters. One of the most important advantages of this method is the ability to determine the ranges, where a smooth cutting edge in all areas of the cutting part of the cutter exists. The derived analytical dependencies can be used to develop new designs of tools of a special shape with a rational combination of geometric parameters of cutting edges with accounting for the radii of the torus surface and the radius of the cutter.
The helical groove, which has a complex shape in the radial section, strongly affects the performance of solid ceramic mills. The accuracy of shaping is strongly affected by the size of the grinding wheel and the kinematic parameters of its movement and rotation relative to the workpiece. Although it is possible to obtain the aforementioned properties using the existing methods, there does not exist a general approach the determination the acceptable ranges of the diameter of the grinding wheel and radius of curvature of its profiling section. In this paper we have analyzed the main features of the design of the profiling sections of grinding wheels, have formed a set of initial parameters that most efficiently implement the trajectory of the shaping movement, which in turn constitutes a new general method of shaping for the helical surfaces of ceramic cutters, have analyzed the character of rolling of a set of profiling sections on a helical surface, have derived new analytical relationships determining impacts of the grinding wheel design and parameters controlling the trajectory of the grinding wheel movement on the shape of the cutter profile in the axial section, and have demonstrated advantages of the developed general approach in designing a new ceramic mill. The new method of shaping allows to unambiguously realize movements of the grinding wheel on various machine layouts and to exclude the displacement of the shaping point by replacing rotation with displacement. Further development of this method will make it possible to replace five- coordinate machines with four-coordinate ones when manufacturing milling cutters with a helical surface that can significantly reduce the production costs.
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