Cutting method and cutting apparatus

Abstract

A tool-main-spindle, whose cutting angle can be changed, is translated by an X-axis moving mechanism portion on an X-axis provided in a plane perpendicular to an axis of a work, and is translated on a Y-axis by a Y-axis moving mechanism portion. Cutting of the work is performed by setting the cutting angle of the tool-main-spindle to an angle of the cutting tool at which the work has large dynamic rigidity, and causing an axis of a cutting tool to cross the work axis, and cutting the work with the cutting tool toward the axis of the work by cooperatively operating the X-axis moving mechanism portion and the Y-axis moving mechanism portion.

Claims

1. A cutting apparatus for cutting a work, the cutting apparatus including a cutting tool having a longitudinal axis located in a plane perpendicular to a rotational axis of the work such that the cutting tool is oriented toward the rotational work axis, the cutting apparatus comprising: an angle changing unit for changing a cutting angle of the longitudinal axis of the cutting tool relative to the work in the plane perpendicular to the rotational axis; an angle detecting unit for detecting an angular position about the rotational axis of the work at which the work has largest dynamic rigidity; an angle setting unit for controlling the angle changing unit; and a cutting control unit for controlling cutting, wherein the angle setting unit controls the angle changing unit so that the cutting angle of the cutting tool becomes equal to the angle of the angular position at which the work has largest dynamic rigidity as detected by the angle detecting unit; and the cutting control unit performs cutting of the work with the cutting tool while maintaining the cutting angle set by the angle setting unit.

2. The cutting apparatus according to claim 1, wherein the cutting tool is mounted to a tool-main-spindle that is positioned in the plane perpendicular to the rotational axis of the work, wherein the angle changing unit includes a first moving unit for causing movement of the cutting tool along a first axis provided in the plane perpendicular to the rotational axis of the work, a second moving unit for causing movement of the cutting tool along a second axis different from the first axis and which second axis is provided in the plane perpendicular to the rotational axis of the work, and a tool-main-spindle pivoting portion provided in the tool-main-spindle for enabling the cutting angle to be changed, the angle setting unit controls the cutting angle of the cutting tool mounted to the tool-main-spindle so that the cutting angle of the cutting tool mounted to the tool-main-spindle becomes equal to the angle of the angular position at which the work has largest dynamic rigidity as detected by the angle detecting unit, and controls the first moving unit and the second moving unit so that the longitudinal axis of the cutting tool crosses the rotational axis of the work, and the cutting control unit controls the first moving unit and the second moving unit to translate the cutting tool along the first and second axes, thereby cutting the rotating work while the cutting tool is oriented toward the rotational axis of the work while the longitudinal axis of the cutting tool and the rotational axis of the work are maintained in the crossed state.

3. The cutting apparatus according to claim 1, wherein the cutting tool is mounted to a tool post that is positioned in the plane perpendicular to the rotational axis of the work, wherein the angle changing unit includes a composite saddle including a lower saddle for adjusting a height of the tool post and including an upper saddle provided over the lower saddle for changing the cutting angle of the cutting tool mounted to the tool post, the upper saddle includes a single-axis moving unit for translating the cutting tool along a direction of the set cutting angle, the angle setting unit controls an angle of the upper saddle so that the cutting angle of the cutting tool mounted to the tool post becomes equal to the angle of the angular position at which the work has largest dynamic rigidity as detected by the angle detecting unit, and controls the lower saddle so that the longitudinal axis of the cutting tool crosses the rotational axis of the work, and the cutting control unit controls the single-axis moving unit to cut the rotating work while the cutting tool is oriented toward the rotational axis of the work.

4. The cutting apparatus according to claim 1, wherein the cutting tool is mounted to a tool-main-spindle that is positioned in a plane perpendicular to the rotational axis of the work, the tool-main spindle including a tool rotating unit, wherein the angle changing unit includes a first moving unit for causing movement of the cutting tool along a first axis provided in the plane perpendicular to the rotational axis of the work, a second moving unit for causing movement of the cutting tool along a second axis different from the first axis and which second axis is provided in the plane perpendicular to the rotational axis of the work, and a tool-main-spindle pivoting portion provided in the tool-main-spindle for enabling the cutting angle to be changed, the angle setting unit controls the cutting angle of the cutting tool mounted to the tool-main-spindle so that the cutting angle of the cutting tool mounted to the tool-main-spindle becomes equal to the angle of the angular position at which that work has largest dynamic rigidity as detected by the angle detecting unit, and controls the first moving unit and the second moving unit so that the longitudinal axis of the cutting tool crosses the rotational axis of the work, and the cutting control unit controls the first moving unit and the second moving unit to translate the cutting tool along the first and second axes, and rotates the cutting tool while the longitudinal axis of the cutting tool and the rotational axis of the work are maintained in the crossed state, thereby cutting the work with the cutting tool oriented toward the rotational axis of the work.

5. The cutting apparatus according to claim 1, wherein the cutting tool is mounted to a tool post that is positioned in the plane perpendicular to the rotational axis of the work, and the tool post includes a tool rotating unit, wherein the angle changing unit includes a composite saddle including a lower saddle for adjusting a height of the tool post and including an upper saddle provided over the lower saddle for changing the cutting angle of the cutting tool mounted to the tool post, the upper saddle includes a single-axis moving unit for translating the cutting tool along a direction of the set cutting angle, the angle setting unit controls an angle of the upper saddle so that the cutting angle of the cutting tool mounted to the tool post is set to the angle of the angular position at which the work has largest dynamic rigidity as detected by the angle detecting unit, and controls the lower saddle so that the longitudinal axis of the cutting tool crosses the rotational axis of the work, and the cutting control unit controls the single-axis moving unit and rotates the cutting tool while the tool longitudinal axis and the work rotational axis are maintained in the crossed state, thereby cutting the work while the cutting tool is oriented toward the rotational axis of the work.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a plan view illustration showing a first embodiment of a cutting apparatus according to the present invention;

(2) FIG. 2 is a front view illustration of FIG. 1;

(3) FIG. 3 is a block diagram of a control device of the cutting apparatus of FIG. 1;

(4) FIG. 4 is a front view illustration showing a second embodiment of the cutting apparatus according to the present invention;

(5) FIG. 5 is a block diagram of a control device of the cutting apparatus of FIG. 4;

(6) FIG. 6 is a plan view illustration showing a third embodiment of the cutting apparatus according to the present invention;

(7) FIG. 7 is a front view illustration of FIG. 6;

(8) FIG. 8 is a block diagram of a control device of the cutting apparatus of FIG. 6;

(9) FIG. 9 is a front view illustration showing a fourth embodiment of the cutting apparatus according to the present invention;

(10) FIG. 10 is a block diagram of a control device of the cutting apparatus of FIG. 9;

(11) FIG. 11 is a schematic diagram of a conventional cutting apparatus; and

(12) FIG. 12 is a measurement diagram of the dynamic compliance of a work which shows that the dynamic rigidity of the work is anisotropic.

DETAILED DESCRIPTION OF THE INVENTION

(13) Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings.

(14) (First Embodiment)

(15) FIGS. 1 to 3 are illustrations showing a first embodiment of a cutting apparatus according to the present invention. FIG. 1 is a plan view from a Y-axis direction, and FIG. 2 is a front view from an axis direction of a work. In FIGS. 1 and 2, reference numeral 1 indicates a spindle stock of the cutting apparatus, reference numeral 2 indicates a main spindle rotatably supported by the spindle stock 1, reference numeral 3 indicates a chuck provided at the tip of the main spindle 2 and including a pawl 4 for holding the work 5, reference numeral 6 indicates a cutting tool, reference numeral 7 indicates a tool-main-spindle to which the cutting tool 6 is attached, reference numeral 8 indicates a Y-axis moving mechanism portion for translating the tool-main-spindle 7 in the Y-axis direction, reference numeral 9 indicates a saddle mounted on a base (not shown) of the cutting apparatus for enabling the tool-main-spindle 7 to be moved in an X-axis direction, and reference numeral 10 indicates an X-axis moving mechanism portion for translating the saddle 9 in the X-axis direction.

(16) The Y-axis moving mechanism portion 8 and the X-axis moving mechanism portion 10 are formed by ball screw mechanisms. The Y-axis moving mechanism portion 8 is driven by a Y-axis motor 8a mounted on the saddle 9, and the X-axis moving mechanism portion 10 is driven by an X-axis motor 10a mounted on the base.

(17) It should be noted that reference numeral M1 indicates a work axis which is the rotation center of the work, reference numeral M2 indicates a tool-main-spindle axis, and reference numeral M3 indicates a tool axis. A plane perpendicular to the work axis M1 is an XY plane. The tool-main-spindle 7 holds the cutting tool 6 at an end thereof in a rotationally indexable manner so that the tool-main-spindle axis M2 and the tool axis M3 cross each other. The tool-main-spindle 7 includes a tool-main-spindle pivoting portion L1 for enabling the cutting angle of the cutting tool to be changed.

(18) FIG. 3 shows a control device for controlling this cutting apparatus. As shown in FIG. 3, the control device includes a numerical control device 40 for controlling various motors, an angle detection device 41 for calculating an angle with large dynamic rigidity, a main-spindle angle detector 42 for detecting a rotation angle of the main spindle 2, an X-axis detector 43 for detecting an X-axis displacement amount resulting from driving with the X-axis motor 10a, a Y-axis detector 44 for detecting a Y-axis displacement amount resulting from driving with the Y-axis motor 8a, and a tool-angle detector 45 for detecting an angle of the cutting tool 6.

(19) It should be noted that reference numeral 2a indicates a main-spindle motor for rotating the main spindle 2, and reference numeral 7a indicates a tool-main-spindle motor for driving the tool-main-spindle pivoting portion L1.

(20) The numerical control device 40 includes a program storage section 47 for storing a work processing program, a program analysis section 48 for analyzing the processing program, and a drive control section 49 for controlling various motors. The angle detection device 41 includes an impulse hammer 51, a dynamic-compliance calculation section 52, and a computing section 53 for calculating the angle with the largest dynamic rigidity based on dynamic compliance.

(21) More specifically, in the angle detection device 41, vibration generated by the impulse hammer 51 is processed (e.g., Fourier analysis) into a dynamic compliance value in the dynamic-compliance calculation section 52. The computing section 53 simultaneously receives the dynamic compliance value and the main-spindle angle, and obtains a main-spindle angle, i.e., a work angle (e), of the smallest dynamic compliance (the largest dynamic rigidity). This process may be performed either by comparing the dynamic compliance values sequentially supplied during measurement by the impulse hammer with the previous value and leaving the smaller value and angle, or by storing the values for one rotation of the main spindle (work) and selecting the smallest angle.

(22) Then, the angle with the largest dynamic rigidity obtained by the computing section 53 is applied to the drive control section 49. The drive control section 49 combines the received angle with a control command generated by analyzing a normal processing program, thereby producing a motor driving signal to control each motor.

(23) The cutting apparatus structured as described above performs cutting as follows. First, an angle (e) with the largest dynamic rigidity is obtained by the above procedure. In the case where the measurement result shows that the direction in which the work 5 has large dynamic rigidity is at an angle of from the X-axis direction (the state shown in FIG. 2), the numerical control device 40 controls the tool-main-spindle pivoting portion L1 of the tool-main-spindle 7 so that a cutting angle toward the axis M1 of the work 5, that is, toward the rotation center, becomes .

(24) The numerical control device 40 then operates the X-axis motor 10a and the Y-axis motor 8a so as to maintain the state in which the tool axis M3 of the cutting tool 6 crosses the work axis M1 at this angle. Thus, a cutting control (lathe turning control) is performed so that the cutting tool 6 cuts the work 5 toward the work axis MI.

(25) Outer-diameter cutting of the work 5 is performed by maintaining the cutting angle 8 of the cutting tool 6 at a fixed value while rotating the work 5 together with the main spindle 2, and translating the cutting tool 6 while maintaining the state in which the tool axis M3 crosses the work axis MI. In other words, outer-diameter cutting is performed by cutting the work 5 with the cutting tool 6 toward the work axis MI.

(26) The cutting tool 6 is translated by moving the tool-main-spindle 7 through cooperative operation of the X-axis motor 10a and the Y-axis motor 8a. The outer peripheral surface of the work 5 is cut in this manner. The cutting tool 6 is then fed along the work axis M1, whereby the outer-diameter cutting is performed.

(27) It should be noted that a similar operation is performed when the outer periphery of the work 5 is grooved. Like outer-diameter cutting, cutting is performed by indexing an angle of the cutting tool 6, and feeding the tool-main-spindle 7 along the tool axis M3 in a moving operation achieved by synthesis of the X-axis and the Y-axis.

(28) Because the cutting angle toward the rotation center of the work is thus set to a direction in which the work has large dynamic rigidity, the generation of chatter vibration can be suppressed and accurate processing can be implemented. Further, since a device such as a steady rest is not required, high versatility can be obtained without affecting the processing region.

(29) Moreover, the cutting angle can be easily set to an angle with large dynamic rigidity by pivoting the tool-main-spindle pivoting portion. By translating the cutting tool using the X-axis moving mechanism portion and the Y-axis moving mechanism portion, cutting of the rotating work can be performed while the work axis and the tool axis are maintained in the crossed state. As a result, accurate lathe turning can be implemented.

(30) (Second Embodiment)

(31) FIG. 4 shows a second embodiment of the cutting apparatus according to the present invention. FIG. 4 is a front view from the axis direction of the work 5. In FIG. 4, reference numeral 15 indicates a lower saddle which translates in the Y-axis direction, reference numeral 16 indicates a Y-axis moving mechanism portion for translating the lower saddle 15 in the Y-axis direction, reference numeral 18 indicates an upper saddle positioned above the lower saddle 15 for providing a cutting angle to a cutting tool 19, reference numeral 17 indicates a jack for adjusting a tilt angle of the upper saddle 18, reference numeral 20 indicates a tool post to which the cutting tool 19 is mounted, and reference numeral 21 indicates an XS-axis moving mechanism portion for translating the tool post 20.

(32) The upper saddle 18 has one end thereof on the work 5 side rotatably connected to the lower saddle 15, and another end supported by the retractable jack 17. The tool post 20 is mounted to the upper saddle 18 through the XS-axis moving mechanism portion 21 provided on the upper saddle 18. The tool post 20 is mounted so as to be translatable in the maximum tilting direction of the upper saddle 18.

(33) The Y-axis moving mechanism portion 16 and the XS-axis moving mechanism portion 21 are formed by ball screw mechanisms. The Y-axis moving mechanism portion 16 is driven by a Y-axis motor 16a mounted on a base (not shown), and the XS-axis moving mechanism portion 21 is driven by an XS-axis motor 21a mounted on the upper saddle 18. Thus, the tool post 20 moves vertically by a composite saddle formed from the lower saddle 15 and the upper saddle 18, and the cutting angle of the tool post 20 can be changed. The tool post 20 can be set to any cutting angle by controlling the Y-axis motor 16a and a jack drive motor (not shown) provided for the jack 17. Reference numeral M4 indicates a tool axis.

(34) FIG. 5 shows a control device for controlling this cutting apparatus. The control device of FIG. 5 is different from that of FIG. 3 with regard to the structures of the motors and the detectors controlled by the drive control section 49. The control device of FIG. 5 includes the XS-axis motor 21a, an XS-axis detector 55 for detecting a displacement amount resulting from driving with the XS-axis motor 21a, a jack drive motor 17a for driving the jack 17, and a jack-angle detector 57 for detecting an angle which is changed by driving with the jack drive motor 17a. It should be noted that components similar to those of FIG. 3 are denoted by the same reference numerals and characters as used in FIG. 3, and descriptions thereof will be omitted.

(35) The cutting apparatus structured as described above performs cutting as follows. First, an angle () with the largest dynamic rigidity is obtained by a procedure similar to that of the first embodiment. This angle is an angle viewed from the X-axis direction, and FIG. 4 shows a state in which the cutting angle has been set to the obtained angle .

(36) Based on the angle information thus obtained, the numerical control device 40 controls the jack drive motor 17a to set the cutting angle toward the rotation center of the work 5 to .

(37) Next, the numerical control device 40 adjusts the height of the tool post 20 using the Y-axis motor 16a of the Y-axis moving mechanism portion 16 so that the work axis M1 and the tool axis M4 cross each other. Then, the numerical control device 40 controls the XS-axis motor 21a of the XS-axis moving mechanism portion 21 to translate the tool post 20 and the cutting tool 19, thereby cutting the work 5 toward the rotation center of the work 5. Cutting is thus performed in this manner.

(38) Because the cutting angle toward the rotation center of the work is thus set to a direction in which the work has large dynamic rigidity, the generation of chatter vibration can be suppressed and accurate processing can be implemented. Further, since a device such as a steady rest is not required, high versatility can be obtained without affecting the processing region.

(39) Moreover, the cutting angle can be easily set to an angle with large dynamic rigidity by changing the tilt angle of the tool post. The lower saddle and the upper saddle cross the axis of the cutting tool with the axis of the work, and cutting of the rotating work can be performed while the work axis and the tool axis are maintained in the cross state. As a result, accurate lathe turning can be implemented.

(40) It should be noted that, in the first and second embodiments, the cutting tools 6, 19 are moved with respect to the work 5. Cutting is performed through relative movement of the work 5 and the cutting tools 6, 19, however, and the work 5 may be moved with respect to the cutting tools 6, 19.

(41) (Third Embodiment)

(42) FIGS. 6 and 7 are illustrations showing a third embodiment of the cutting apparatus according to the present invention. FIG. 6 is a front view from the Y-axis direction, and FIG. 7 is a front view from an axis-M direction of the work 5. The cutting apparatus of the third embodiment has a similar tool drive mechanism to that of the first embodiment, but is different from the first embodiment in that a cutting tool 25 itself rotates to perform rotary cutting.

(43) In FIGS. 6 and 7, reference numeral 24 indicates a tool-main-spindle having a built-in tool rotation motor (not shown), reference numeral 25 indicates a rotating tool (cutting tool) for performing rotary cutting, and reference numeral 26 indicates a main-spindle support for moving the tool-main-spindle 24 using a saddle 9. Components similar to those of FIG. 1 are denoted by the same reference numerals and characters as used in FIG. 1. The main-spindle support 26 is provided with a tool-main-spindle pivoting portion L2 for enabling the cutting angle of the cutting tool 25 to be changed.

(44) FIG. 8 shows a control device for controlling this cutting apparatus. The control device of FIG. 8 is different from that of FIG. 3 in that the control device of FIG. 8 additionally controls a tool rotation motor 25a for rotating the tool 25, and that the cutting angle of the cutting tool 25 is changed by a main-spindle-support motor 26a for driving the tool-main-spindle pivoting portion L2. It should be noted that components similar to those of FIG. 3 are denoted by the same reference numerals and characters as used in FIG. 3, and descriptions thereof will be omitted.

(45) The cutting apparatus structured as described above performs cutting as follows. First, an angle () with the largest dynamic rigidity is obtained by the procedure described in the first embodiment. This angle is an angle viewed from the X-axis direction, and FIG. 7 shows a state in which the cutting angle has been set to the obtained angle .

(46) Based on the angle information thus obtained, the numerical control device 40 pivots the tool-main-spindle pivoting portion L2 of the main-spindle support 26 to set the cutting angle toward the rotation center of the work 5 to 8. The numerical control device 40 then controls the X-axis motor 10a and the Y-axis motor 8a so that the tool axis M3 of the cutting tool 25 crosses the work axis M1 at this angle, and the cutting tool 25 cuts the work 5 toward the work axis M1.

(47) In this case, cutting of the work 5 is performed without rotating the work 5. Cutting of the work 5 is performed by rotating the cutting tool 25 using the tool rotation motor 25a while the cutting angle of the cutting tool 25 is maintained at a fixed value and the tool axis M3 and the work axis M1 are maintained in the crossed state. In other words, rotary cutting of the work is performed by cutting the work 5 toward the work axis M1 with the rotating tool 25.

(48) It should be noted that a similar operation is performed when the outer periphery of the work is grooved or a plane surface of the work is processed by feeding a tool such as an end mill in the axis direction of the work. In this case, cutting is performed by indexing an angle of the cutting tool 25, by cutting the work by feeding the tool along the tool axis M3 in a moving operation achieved by synthesis of the X-axis and the Y-axis, and further by causing movement along a Z-axis (the work axis direction) that is not shown.

(49) Because the cutting angle toward the rotation center of the work is thus set to a direction in which the work has large dynamic rigidity, the generation of chatter vibration can be suppressed and accurate processing can be implemented. In addition, since a device such as a steady rest is not required, high versatility can be obtained without affecting the processing region.

(50) Moreover, the cutting angle can be easily set to an angle with large dynamic rigidity by pivoting the tool-main-spindle pivoting portion of the main-spindle support, and cutting with the rotating tool can be performed by translating the cutting tool using the X-axis moving mechanism portion and the Y-axis moving mechanism portion while the work axis and the tool axis are maintained in the crossed state. As a result, accurate rotary cutting can be implemented.

(51) (Fourth Embodiment)

(52) FIG. 9 shows a fourth embodiment of the cutting apparatus according to the present invention. FIG. 9 is a front view from the axis direction of the work 5. The cutting apparatus of the fourth embodiment has a similar tool drive mechanism to that of the second embodiment, but is different from the second embodiment in that a cutting tool 29 itself rotates to perform rotary cutting.

(53) In FIG. 9, reference numeral 29 indicates a rotating tool (cutting tool) for performing rotary cutting, and reference numeral 30 indicates a tool post having a built-in motor (tool rotation motor). Components similar to those of FIG. 4 are denoted by the same reference numerals and characters as used in FIG. 4, and descriptions thereof will be omitted.

(54) FIG. 10 shows a control device for controlling this cutting apparatus. The control device of FIG. 10 is different from that of FIG. 5 in that the control device of FIG. 10 additionally controls a tool rotation motor 29a for rotating the cutting tool 29. Components similar to those of FIG. 5 are denoted by the same reference numerals and characters as used in FIG. 5, and descriptions thereof will be omitted.

(55) The cutting apparatus structured as described above performs cutting as follows. First, an angle () with the largest dynamic rigidity is obtained by the procedure described in the first embodiment. This angle is an angle viewed from the X-axis direction, and FIG. 9 shows a state in which the cutting angle has been set to the obtained angle . The numerical control device 40 controls the jack drive motor of the jack 17 to set the cutting angle toward the rotation center of the work 5 to .

(56) Next, the numerical control device 40 adjusts the height of the tool post 30 using the Y-axis motor 16a of the Y-axis moving mechanism portion 16 so that the work axis M1 and the tool axis M4 cross each other. Then, the numerical control device 40 controls the XS-axis motor 21a of the XS-axis moving mechanism portion 21 to translate the tool post 30 and the cutting tool 29, thereby cutting the work 5 toward the axis M1 of the work 5 with the rotating cutting tool 5. Cutting (rotary cutting) is thus performed in this manner.

(57) It should be noted that, like the third embodiment, a similar operation is performed when the outer periphery of the work is grooved or a plane surface of the work is processed by feeding a tool such as an end mill in the axis direction of the work. In this case, cutting is performed by indexing an angle of the cutting tool 29, cutting the work by feeding the tool along the tool axis M4 in a moving operation along the XS-axis, and through further movement along the Z-axis (the work axis direction) that is not shown.

(58) Because the cutting angle toward the rotation center of the work is thus set to a direction in which the work has large dynamic rigidity, the generation of chatter vibration can be suppressed and accurate processing can be implemented. Further, since a device such as a steady rest is not required, high versatility can be obtained without affecting the processing region.

(59) Moreover, the cutting angle can be easily set to an angle with large dynamic rigidity by changing the tilt angle of the tool post. The lower saddle and the upper saddle cross the axis of the cutting tool with the axis of the work, and the work can be cut with the rotating tool while maintaining the cutting angle. As a result, the generation of chatter vibration is suppressed and accurate rotary cutting can be implemented.

(60) It should be noted that in each of the above embodiments, the control device includes the angle detection device 41, and obtains the direction with largest dynamic rigidity by calculating dynamic compliance through a control of the control device itself. However, the angle detection device 41 may be provided as a separate element from the control device, that is, as a separate element from the cutting apparatus, and the angle detection device 41 may be mounted when it is necessary to obtain dynamic compliance and the like.