In precision engineering, helical surfaces on critical parts of equipment have become widespread. The article proposes an new method and practical recommendations for measuring geometric accuracy, linear and angular measurements, and studying the characteristics of helical surfaces and specialized equipment for monitoring the accuracy of helical surfaces. The uniqueness of the approach lies in the formation of key indicators of classification and filtering of a set of specialized measurement techniques based on scanning and digital image processing. A new method is proposed that makes it possible to adjust the measurement of the coordinates of the profile points of the helical surface in the radial section according to the shape of the focal area on the helical surface obtained by a reflected light camera. The work established new indicators of the effectiveness of tool control for high-speed multi-axis milling based on recommendations for the selection of methods and means of monitoring and control at the stage of technological preparation of production in real time. Criteria and indicators have been formed to eliminate errors at any stage in the process of digital control of images of the helical surface of a cutting tool for high-speed machining. The method consists in determining the law of preserving the shape of the profile, its further rotation and comparison with the original control profile by identifying a new relationship between the focal length and the profiling shape. The shape of the profiling curve is described depending on the angle of inclination of the helical flute, diameter, segmentation of the image in the focal zone and the magnitude of the error when measuring the profile in real time relative to the base profile. In this regard, the work justifies the practical adaptation of the search results for key measurement schemes in comparison with other existing methods for helical surfaces with an rake angle of the tangent to the profile in the axial section. The new level of production creates greater demand for product quality efficiency in a unified digital environment. As an advanced solution, the work proposes a method for compensating for errors in the shape of the focus area. This method allows you to compensate for the error in real time without stopping for readjustment. More accurate results allowed for an increase in accuracy up to 10 times compared to existing methods.
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.
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