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<h1 id="measurement">Measurement</h1>
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<p>How a physical quantity gets from a real cutter or a real cut into the model. These are protocols
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rather than theory: follow them and the simulation is fed a measured number instead of a default.</p>
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<p>Ordered from the cutter on the bench, through the instrument that watches it, to the cutter in the
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cut and the experiment that has to be designed before it.</p>
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<ul>
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<li><a href="radial-angle-measurement.html">Radial Angle Measurement</a> — Reading the radial rake and radial relief angles off a cutting-plane scan</li>
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<li><a href="smart-tool-holder.html">Smart Tool Holder</a> — The moment arm and installation angle that decide whether the holder's torque is scaled right at all</li>
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<li><a href="smart-holder-training.html">Smart Holder Training</a> — The three cut shapes and the conditions that let a smart tool holder train milling coefficients</li>
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<li><a href="training-cut-set-design.html">Designing a Training Cut Set</a> — The two degeneracies that leave a coefficient unrecoverable whatever the data quality, and the helix and feed spread that remove them</li>
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<h2 id="see-also">See Also</h2>
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<ul>
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<li><a href="../milling-physics/index.html">Milling Physics</a> — the model these measurements feed</li>
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<article data-uid="Technique-RadialAngleMeasurement">
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<h1 id="radial-rake-angle-and-radial-relief-angle-measurement-on-the-cutting-plane">Radial Rake Angle and Radial Relief Angle Measurement on the Cutting Plane</h1>
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||||
<p>The method for measuring angles on the tool cutting plane scan is illustrated below:</p>
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<p><img src="radial-angle-measurement-img/clip-cutter-angle-scheme.jpg" alt="Tool angle measurement"></p>
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||||
<h2 id="radial-rake-angle-α">Radial Rake Angle (α)</h2>
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<ol>
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<li>Sweep along the tool rotation direction to find the trailing point A of the cutting edge</li>
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||||
<li>Connect point A to the center O</li>
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||||
<li>The angle ∠OAA' between line OA and the first polyline endpoint A' on the cutting side of the edge is the rake angle α</li>
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||||
</ol>
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||||
<h2 id="radial-relief-angle-β">Radial Relief Angle (β)</h2>
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<ol>
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<li>Find the contact point B between the tool and the envelope circle</li>
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<li>Construct the tangent line Lt to the envelope circle at point B</li>
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||||
<li>BB' is the first line segment on the relief side of the tool</li>
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||||
<li>Pick an arbitrary point B'' on Lt in the relief direction</li>
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||||
<li>The angle ∠B'BB'' between BB' and Lt is the relief angle β</li>
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</ol>
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<h2 id="see-also">See Also</h2>
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||||
<ul>
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||||
<li><a class="xref" href="../milling-physics/relief-face-avoidance.html">Relief Face Avoidance</a> — the minimum relief angle the measured β has to clear</li>
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<li><a class="xref" href="../milling-physics/cutter-geometry.html">Cutter Geometry</a> — the cutter description these angles are part of</li>
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%
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G40 G17 G49 G54 G80
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G43 Z10. H01
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G00 G90 X-20. Y10.
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;@MachiningResolution_mm=0.0625;
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;@SetNcResolutionFeedPerTooth();
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X25. F10. ;@LineSelection("lineB",AnchorMode.FirstTouch,AnchorMode.LastTouch);
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S1500 M03
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G91 G28 Z0.
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G43 Z10. H02
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G01 G90 X10. Y30. M08
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G01 Z-4. F20. ;@LineSelection("drillA",AnchorMode.FirstTouch,AnchorMode.LastTouch);
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Z10.
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X20.
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G01 Z-4. F10. ;@LineSelection("drillB",AnchorMode.FirstTouch,AnchorMode.LastTouch);
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Z10.
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M09
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M05
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<h1 id="smart-tool-holder-coefficient-training">Smart Tool Holder Coefficient Training</h1>
|
||||
|
||||
<p>By cutting the following shapes and collecting three-direction torques with a smart tool holder, you can train milling coefficients through HiNC projects.</p>
|
||||
<h2 id="overview">Overview</h2>
|
||||
<p><img src="smart-holder-training-img/training-path-diagram.png" alt="Smart Tool Holder Coefficient Training Path Diagram"></p>
|
||||
<ul>
|
||||
<li>T1 End mill D10 4 flutes</li>
|
||||
<li>T2 Drill bit, diameter unrestricted</li>
|
||||
</ul>
|
||||
<p>Click to download <a href="smart-holder-training-img/train.nc">NC code</a>.</p>
|
||||
<div class="NOTE">
|
||||
<h5>Note</h5>
|
||||
<p><strong>Adjusting Machining Method</strong></p>
|
||||
<ul>
|
||||
<li>Speed and feed can be changed according to material conditions, but feed per tooth must be in multiples.</li>
|
||||
<li>Slower spindle speed allows the smart tool holder to collect more data per unit time.</li>
|
||||
<li>The wall thickness between the two slots in <a href="#shape-i">Shape I</a> needs to be thin enough so that <a href="#shape-ii">Shape II</a> cutting is discontinuous per revolution.</li>
|
||||
</ul>
|
||||
</div>
|
||||
<h2 id="shape-i">Shape I</h2>
|
||||
<p>Shape I consists of three red slots, which are preparatory shapes, no need to collect smart tool holder data.</p>
|
||||
<ul>
|
||||
<li>ae10; ap1; S1500; F600</li>
|
||||
</ul>
|
||||
<h2 id="shape-ii">Shape II</h2>
|
||||
<p>Shape II penetrates through the thin walls between the three red slots, need to collect smart tool holder data.</p>
|
||||
<ul>
|
||||
<li>lineA: T1; ap1; S50; F20 (frt0.1)</li>
|
||||
<li>lineB: T1; ap1; S50; F10 (frt0.05)</li>
|
||||
</ul>
|
||||
<h2 id="shape-iii">Shape III</h2>
|
||||
<p>Shape III is drilling, need to collect smart tool holder data.</p>
|
||||
<ul>
|
||||
<li>drillA: T2; dp4; S50; F20</li>
|
||||
<li>drillB: T2; dp4; S50; F10</li>
|
||||
</ul>
|
||||
<h2 id="see-also">See Also</h2>
|
||||
<ul>
|
||||
<li><a href="training-cut-set-design.html">Designing a Training Cut Set</a> — what a set of passes has to span before the coefficients are recoverable at all</li>
|
||||
<li><a href="smart-tool-holder.html">Smart Tool Holder</a> — the moment arm and installation angle a training run assumes are already right</li>
|
||||
<li><a class="xref" href="../machine-capability/cam-floating-point-drift.html">CAM Floating-Point Drift</a> — a measurement error source to rule out before trusting a training run</li>
|
||||
<li><a class="xref" href="../milling-physics/milling-physics-coordinates.html">Milling Physics Coordinates</a> — the spindle-rotation frame the holder's torques are reported in</li>
|
||||
</ul>
|
||||
|
||||
</article>
|
||||
|
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<article data-uid="Technique-SmartToolHolder">
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<h1 id="smart-tool-holder">Smart Tool Holder</h1>
|
||||
|
||||
<p>A smart tool holder is a machine tool accessory equipped with sensors that can monitor force and torque data in real time during machining. To ensure simulation accuracy, the following parameters must be configured correctly:</p>
|
||||
<h2 id="sensor-configuration">Sensor Configuration</h2>
|
||||
<h3 id="moment-arm-height">Moment Arm Height</h3>
|
||||
<ul>
|
||||
<li>The sensor height setting has a significant impact on simulation accuracy</li>
|
||||
<li>This height defines the moment arm distance for the torque measured by the sensor</li>
|
||||
<li>If not set correctly, a constant scaling error will appear in the torque calculation</li>
|
||||
</ul>
|
||||
<h3 id="coordinate-system-alignment">Coordinate System Alignment</h3>
|
||||
<ol>
|
||||
<li><p><strong>Basic Principle</strong></p>
|
||||
<ul>
|
||||
<li>The cutting edge should be aligned with the sensor's X-axis</li>
|
||||
<li>Ensure the sensor XY coordinate system is consistent with the simulation XY coordinate system</li>
|
||||
<li>The impact of coordinate system misalignment is relatively smaller compared to the moment arm setting</li>
|
||||
</ul>
|
||||
</li>
|
||||
<li><p><strong>Installation Angle Adjustment</strong></p>
|
||||
<ul>
|
||||
<li>If perfect alignment is not possible, measure the offset angle</li>
|
||||
<li>Enter the measured angle in the “Installation Angle” field</li>
|
||||
<li>The maximum possible deviation is 45 degrees</li>
|
||||
</ul>
|
||||
</li>
|
||||
</ol>
|
||||
<h2 id="factors-affecting-accuracy">Factors Affecting Accuracy</h2>
|
||||
<h3 id="coordinate-transformation-effects">Coordinate Transformation Effects</h3>
|
||||
<ul>
|
||||
<li>An installation angle deviation can cause up to a √2 factor difference in values</li>
|
||||
<li>This difference is inherently a result of coordinate transformation, not a measurement accuracy issue</li>
|
||||
<li>Even with the same smart tool holder, different installation angles will produce different measurement data</li>
|
||||
</ul>
|
||||
<h3 id="best-practices">Best Practices</h3>
|
||||
<ol>
|
||||
<li>Prioritize accurate moment arm height configuration</li>
|
||||
<li>Align the cutting edge with the sensor X-axis as closely as possible</li>
|
||||
<li>If perfect alignment is not achievable, always measure and set the correct installation angle</li>
|
||||
</ol>
|
||||
<p>Only with these parameters correctly configured will the simulated micro-waveforms match the actual sensor measurements.</p>
|
||||
<h2 id="see-also">See Also</h2>
|
||||
<ul>
|
||||
<li><a href="smart-holder-training.html">Smart Holder Training</a> — the cut shapes and conditions that turn a correctly configured holder into trained milling coefficients</li>
|
||||
<li><a class="xref" href="../milling-physics/milling-physics-coordinates.html">Milling Physics Coordinates</a> — the frame the holder's forces and torques are reported in</li>
|
||||
<li><a href="../../manual/setup/cutter.html">Cutter</a> — where the holder's settings are entered in the application</li>
|
||||
</ul>
|
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{"items":[{"name":"Overview","href":"index.html","topicHref":"index.html"},{"name":"Radial Angle Measurement","href":"radial-angle-measurement.html","topicHref":"radial-angle-measurement.html"},{"name":"Smart Tool Holder","href":"smart-tool-holder.html","topicHref":"smart-tool-holder.html"},{"name":"Smart Holder Training","href":"smart-holder-training.html","topicHref":"smart-holder-training.html"},{"name":"Designing a Training Cut Set","href":"training-cut-set-design.html","topicHref":"training-cut-set-design.html"}]}
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<article data-uid="Technique-TrainingCutSetDesign">
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<h1 id="designing-a-training-cut-set">Designing a Training Cut Set</h1>
|
||||
|
||||
<p>Training recovers the six milling coefficients by fitting simulated force against measured force
|
||||
over a set of passes. Whether a given set of cutters and passes can determine those coefficients at
|
||||
all is a property of the design rather than of the data quality: two specific degeneracies leave a
|
||||
coefficient unrecoverable however clean the samples are. Each has its own fix, and neither fix
|
||||
substitutes for the other.</p>
|
||||
<h2 id="the-two-degeneracies">The Two Degeneracies</h2>
|
||||
<table>
|
||||
<thead>
|
||||
<tr>
|
||||
<th>What goes wrong</th>
|
||||
<th>How it shows up in the result</th>
|
||||
<th>What removes it</th>
|
||||
</tr>
|
||||
</thead>
|
||||
<tbody>
|
||||
<tr>
|
||||
<td><strong>The bending-moment plane null.</strong> In rotation-averaged Mx/My one particular combination of the edge and normal shear coefficients is exactly unobservable</td>
|
||||
<td>Shear coefficients come back orders of magnitude too large, and their signs flip between runs on the same data</td>
|
||||
<td><strong>Helix diversity</strong> — at least two clearly different helix angles among the cutters trained together</td>
|
||||
</tr>
|
||||
<tr>
|
||||
<td><strong>Slope–intercept collinearity</strong> between the shear and ploughing coefficients, which enter the fit as the slope and the intercept of the same line</td>
|
||||
<td>The correlation still looks good. Shear comes back low by roughly a tenth, ploughing high by around a half</td>
|
||||
<td><strong>A spread of feed per tooth</strong> across the passes — a range of chip loads, not a range of depths</td>
|
||||
</tr>
|
||||
</tbody>
|
||||
</table>
|
||||
<p>A set that fixes one and not the other still fails, and it fails in the manner of the one left
|
||||
unfixed. Both are properties of the cut set as a whole, so both are decided before any metal is cut.</p>
|
||||
<h2 id="why-the-helix-angle-is-the-lever">Why the Helix Angle Is the Lever</h2>
|
||||
<p>The unobservable direction is a combination of the edge and normal shear coefficients weighted by
|
||||
the cosine and sine of the helix angle. Changing the helix angle does not remove that direction —
|
||||
it <strong>rotates</strong> it. Two helix angles far enough apart therefore give two different null directions
|
||||
whose only common point is zero, so the pooled fit has no null at all, and the edge coefficient
|
||||
becomes identifiable from the measurement alone: no torque channel, no prior value, no externally
|
||||
supplied phase.</p>
|
||||
<p>A single helix angle of zero is the worst case, and misleadingly so, because it aligns the null
|
||||
exactly with the edge-coefficient axis. A cut set built that way returns an edge coefficient that
|
||||
is null-space fill rather than a value the data demands, while the normal coefficient beside it
|
||||
comes out as the most accurate number on the page.</p>
|
||||
<div class="IMPORTANT">
|
||||
<h5>Important</h5>
|
||||
<p>At a single helix angle the individual edge and normal shear values are not meaningful on their
|
||||
own, even when the correlation coefficient is high. A training run is judged by the force it
|
||||
reproduces over time — see <a class="xref" href="../validation/cutting-force.html">Cutting Force and Torque</a> —
|
||||
not by the magnitude of any one coefficient.</p>
|
||||
</div>
|
||||
<h2 id="flute-count-is-not-a-lever">Flute Count Is Not a Lever</h2>
|
||||
<p>Adding more passes with the same symmetric multi-flute cutter buys nothing, at any feed. That
|
||||
sample subspace is degenerate, and more of it stays degenerate: a set made only of symmetric
|
||||
four-flute passes cannot derive its own cutter phase, and the fit collapses rather than degrading.
|
||||
What buys identifiability is spread — in helix angle, and in feed per tooth.</p>
|
||||
<p>Symmetric off-the-shelf cutters are nonetheless sufficient. Custom single-flute grinding is not
|
||||
required for either fix; a pair of stock two-flute cutters ground at different helix angles carries
|
||||
the same identifiability, and is what a shop can actually obtain.</p>
|
||||
<h2 id="engagement-side-cuts-rather-than-slots">Engagement: Side Cuts Rather Than Slots</h2>
|
||||
<p>The useful excitation comes from passes whose radial engagement is small enough that at most one
|
||||
helix flute is in contact at a time — the engagement arc narrower than the angular pitch between
|
||||
flutes. A full slot holds several flutes in the cut at once and averages away the very variation
|
||||
the fit needs. Stepping a shallow side cut along the edge of the stock produces a set where no pass
|
||||
is ever a slot.</p>
|
||||
<p>Adding depth of cut is not a substitute. Depth moves the load without changing the chip load, so it
|
||||
does nothing for the slope–intercept collinearity that the feed-per-tooth spread exists to break.</p>
|
||||
<h2 id="see-also">See Also</h2>
|
||||
<ul>
|
||||
<li><a href="smart-holder-training.html">Smart Holder Training</a> — the shipped cut shapes these constraints apply to</li>
|
||||
<li><a class="xref" href="../milling-physics/cutter-geometry.html">Cutter Geometry</a> — where the helix angle this design turns on is described and entered</li>
|
||||
</ul>
|
||||
|
||||
</article>
|
||||
|
||||
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