In this study, a new method for identifying the key indicators and dependencies in processing images of helical surfaces of conical cutters at the main stages of the production cycle, which is based on the relationships between the shape of the cutting edges, the angle of inclination of the helical flute, clearance angle, color intensity and image brightness, has been developed. Design and geometric parameters were exported from the simulations with the model created by the automated system for designing conical cutters, which determines the dimensions, shape and geometric parameters of the cutting part of the tool. The identified dependencies allow determining the active zone and the transfer coefficient at the interface between the rear surface and the measuring machine and a stable connection is carried out with a group of cutting part parameters obtained from the results of the CAD system. A high-resolution image of the flank surface boundary zone is scanned with an optical camera on a specialized machine, and the improved method was used to quantitatively calculate the boundary The controlled measurements of a set of point coordinates and geometric parameters of the helical surface of a conical cutter forms a system for a comprehensively studying the designs of conical cutters and the physical mechanisms of their production using image analysis based on the developed indicator interpretation system, which is a foundation for a unified digital cyber-physical production system to be developed. The combination of improved performance or expanded functional capabilities with increased rigidity and reliability, which enables the processing of a wider range of structural designs of part surfaces, is the primary competitive advantage of the new generation of cutting tools with unique working surface geometries. These tools are designed and manufactured using a developed cyberphysical system from contemporary tool materials. With the least amount of frames, the new method's application enables the quickest possible identification of findings that are appropriate for monitoring the back surface of the cutting tool class under consideration.
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.
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).
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.
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.
Shaped plates with a special shape of texture on the front surface are widely used in the production of products of complex shapes from heat-resistant materials. An important stage of technological preparation for the formation of a system for the automated production of plates using laser ablation is the assignment of recommendations for the shape of the front surface. The technical result is ensured by the rational shape of the front surface of the replaceable multifaceted plate, which meets the requirements of manufacturability and increased performance when using it. Placement on the front surface of a microrelief, which is formed by a set of holes in the form of a group of micro-holes with a radius of 20-40 μm, a depth of 20-40 μm, which ensures the placement and retention of a suspension based on molybdenum disulfide during drilling, and the coordinates of the centers of the holes are determined by new analytical dependencies. This technological solution will significantly increase the speed of writing programs to control machines for laser ablation.
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