An approach for recognizing surface defects in products with a complex helical shape

Pivkin, Petr M.; Yazev, Anton M.; Grechishnikov, Vladimir A.; Ershov, Artem A.; Minin, Ilya V.; Zelensky, Alexander A.; Alenina, Elena E.; Jiang, Xiaohui; Nadykto, Alexey B.

doi:10.1117/12.2690093

Cited by 4 publications

(1 citation statement)

References 92 publications

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“…As has already been described in earlier works [94], in this regard, to solve the problem of image processing, recognizing area in focal plate and recreating the front helical surface of the instrument, methods of image processing and the creation of fundamentally focal zones were used in the work to identify the nodal points of the profile.…”

Section: Methodsmentioning

confidence: 99%

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

Pivkin,

Yazev,

Ershov

et al. 2024

Optics, Photonics, and Digital Technologies for Imaging Applications VIII

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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.

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Section: Methodsmentioning

confidence: 99%

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

Pivkin,

Yazev,

Ershov

et al. 2024

Optics, Photonics, and Digital Technologies for Imaging Applications VIII

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A computer vision system for measuring the geometric parameters of helical surfaces obtained by multicoordinate grinding on CNC machines

Pivkin,

Yazev,

Grechishnikov

et al. 2024

Optical Metrology and Inspection for Industrial Applications XI

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Helical surfaces are important elements of solid end mills. Their production is carried out using multi-coordinate grinding. Shape errors and reduction in the quality of the screw surface appear due to abrasion, high pressure, and wear of the grinding wheel. Therefore, it is extremely important to measure geometric accuracy, to perform linear and angular measurements, and to study the properties of rake helical surfaces. The paper proposes improvements to monitoring of helical surfaces via the use of a new computer vision system for assessing microtexture on helical surfaces after multiaxis grinding on CNC machines. A computer vision system was developed to evaluate defects on helical surfaces after multi-coordinate grinding on CNC machines, and a comprehensive analysis of existing indicators for recognizing the defect was carried out in a guaranteed range of probability of finding a solution of 99.7% for the distribution density of grinds. To verify the developed method, the accuracy of surfaces obtained by using the one was compared with the measurements carried out using specialized equipment for the control of the accuracy of helical surfaces. A new system for monitoring the accuracy and defects of cutting edges, helical front and rear surfaces allows establishing the main geometric parameters of the cutting edges and cutting wedge such as flute angle and rake angle at the apex using key indicators of the difference in color intensity in the focal zone of the image. When developing this approach, it was found that areas with smaller curvature of the rake surface are more susceptible to the accumulation of helical flute pitch errors after grinding. Experimental studies of the system operation were conducted to provide empirical evidence on helical surfaces after multiaxis grinding on CNC machines, demonstrating excellent convergence and defect recognition accuracy. The accuracy of determining the results of the inclination angles of the microtexture surface after grinding at the control point is 2-2.5 degrees, which allows you to form a comprehensive solution for scanning the surface, which will allow you to apply a simple method of control using a camera in reflected light.

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New technological solutions for the manufacturing and sharpening of three-flute drills

Pivkin,

Ershov

2024

Advanced Laser Processing and Manufacturing VIII

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In high-precision mechanical engineering, the need for small-sized products has been steadily increasing over the past decades and, thus, small-sized cutting tools are used for their production. Laser processing has become one of the most convenient and effective technologies. A new approach to manufacturing micro-cutting three-prong drills is based on the laser ablation technology, which allows to remove material from the workpiece surface regardless of its and has a small zone affected by heating. Laser ablation does not cause workpiece deformation or wear, which ensures high precision of shaping. The work presents a special technology of continuous impact on a section of the front and rear surfaces when forming a sharpening in the form of a set of B-splines. The splines are arranged in such a way that, as a result of removing material from the end of the drill, the cutting wedge forms an angle close to constant with a minimum duration of laser exposure, ensuring in this way the edge. Thus, the algorithm allows forming the working part of a three-tooth drill depending on the diameter, offset of the cutting edge, angle of inclination of the helical flute, front and rake angles of the blade. The new technology allows, for the first time, to form a point and back surface with constant angles on microcutting three-tooth drills with a minimum duration of laser exposure, in particular, when restoring restoration or cyst pointing of the cutting part of the drill. Unlike the known model of the tool is not discredited by the edge sections and the formation of the standard form of the flank surface, but creates geometry along the freely formed cutting edge. The goal of minimizing the number of necessary physical tests while expanding the capabilities of the modeling results is achieved. The mathematical model of the process of forming the main rear surface of the drill will ensure the constancy of the normal clearence angle along the cutting edge of an freely shape.

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An approach for recognizing surface defects in products with a complex helical shape

Cited by 4 publications

References 92 publications

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

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

A computer vision system for measuring the geometric parameters of helical surfaces obtained by multicoordinate grinding on CNC machines

New technological solutions for the manufacturing and sharpening of three-flute drills

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