A new method and practical recommendations for measuring geometric accuracy, linear and angular measurements of helical surfaces of end mill for HSM

Abstract

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.