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Industrial TV Camera System Design for Observing Metal Cutting Deformation
The study of the metal cutting deformation process plays a crucial role in advancing cutting technology, ensuring high-quality machining, reducing production costs, and improving overall productivity. Metal cutting involves various physical phenomena such as cutting forces, heat generation, tool wear, and surface finish quality, all of which are closely related to chip formation. Many practical issues like built-up edge (BUE), vibration, chipping, and chip breaking are also linked to the deformation process during cutting. Therefore, understanding this process is essential for optimizing machining performance.
There are several methods used to study metal cutting deformation, including side grid observation, high-speed photography, rapid drop-off techniques, and scanning electron microscopy. However, these methods often require long observation periods, lack real-time feedback, and may alter the cutting conditions, making them less practical for certain applications. An alternative approach is using an industrial television system. By mounting a camera on a microscope head and displaying the process on a TV screen, it becomes possible to record the cutting deformation at any speed and then review it in slow motion or frame-by-frame, allowing for more detailed analysis. This method is both intuitive and time-efficient, offering a clearer way to observe and understand the cutting process.
The principle behind an industrial television camera relies on the lens imaging system. Light from the object passes through the lens and is focused onto a photoelectric converter, converting the image into an electrical signal. This signal is then transmitted as a video signal to the TV screen, enabling real-time viewing. The lens has a specific focal length, and when an object is placed between the focal point and twice the focal length, an inverted, magnified real image is formed on the other side of the lens. Using the lens formula: 1/l + 1/l’ = 1/f, where l is the object distance, l’ is the image distance, and f is the focal length, we can calculate the required positioning of the lens and the workpiece to capture the deformation process clearly.
To enhance the visibility of the deformation, small black and white squares (0.126 × 0.126 mm) are etched onto the side of the workpiece. These squares help visualize the distortion caused by the cutting action, providing a clear reference for analyzing how the material deforms under stress.
The industrial television camera device is designed to be simple and user-friendly, allowing clear observation of the cutting deformation. It is mounted on the lateral carriage of a vertical milling machine using screws, and the position can be adjusted to suit the workpiece. The workpiece is secured on the longitudinal table with a fixture, while the cutting tool is installed on the spindle. To minimize vibrations, the tool remains fixed, and the workpiece moves slowly along the longitudinal axis. During the cutting process, chips may form on both sides, potentially obstructing the view. A piece of glass is placed to block the chips, keeping the cutting area visible and clear.
To achieve the necessary magnification, an additional lens is added to the original camera setup. The TV screen has a diagonal length of 440 mm with a 3:2 aspect ratio. For clarity, the screen width is divided into six equal sections, with two sections dedicated to the workpiece, two to the cutting zone, and two to the chips. The camera’s photoelectric converter has a circular target with a diameter of 14 mm, and the effective image projected must match the 3:2 aspect ratio. Based on calculations, the magnification is approximately 10 times. Using the lens formula and magnification ratio, the focal length is determined to be 16.5 mm, ensuring a compact and functional design.
Due to the short object distance, the light reaching the cutting zone may be insufficient. To address this, a half-mirror is used to direct light from the main optical axis toward the cutting area. The lens is positioned 182 mm away from the camera’s photoelectric converter, requiring an aluminum housing that allows for adjustment and stability.
In conclusion, after the design and implementation of the industrial television camera system, it can be successfully used to observe the metal cutting deformation process. The system operates stably within a working speed range of 14 to 900 mm/min, producing clear images that aid in the study of cutting mechanics. This system has proven invaluable in enhancing our understanding of metal cutting processes and accelerating technological advancements in machining.