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 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.
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.
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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