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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 productivity. During metal cutting, various physical phenomena occur, such as cutting forces, heat generation, tool wear, and surface quality. These factors are closely related to the chip formation process. Many practical issues like built-up edge (BUE), vibration, chipping, and chip breaking are all influenced by the deformation that occurs during cutting. Therefore, understanding the metal cutting deformation process is essential for optimizing machining performance.
There are several methods used to study this process, including side grid observation, high-speed photography, rapid drop-off techniques, and scanning electron microscopy. However, these approaches often require extensive time, lack real-time feedback, and may alter the cutting conditions. In contrast, using an industrial television system offers a more convenient and immediate way to observe the deformation process. By mounting a camera on a microscope head and displaying the image on a TV screen, it becomes possible to record the cutting process at any speed, then replay it slowly or frame by frame for detailed analysis. This method provides a clear, visual representation of the cutting deformation, making it an effective tool for research.
The industrial television camera works based on the lens imaging principle. Light from the object passes through the lens and is focused onto a photoelectric converter, where it is converted into electrical signals. These signals are then transformed into video signals and displayed on the TV screen. The basic lens formula is 1/l + 1/l' = 1/f, where l is the object distance, l' is the image distance, and f is the focal length. When the object is placed between the focal point and twice the focal length, an inverted, magnified real image is formed beyond twice the focal length.
To improve visibility, small black-and-white squares (0.126 × 0.126 mm) can be etched onto the workpiece. As the cutting progresses, the deformation of these squares becomes visible, allowing researchers to track the cutting behavior accurately.
The industrial television camera setup includes a camera mounted on the lateral carriage of a vertical milling machine. The workpiece is secured on the longitudinal table, and the tool is attached to the spindle. To minimize vibrations, the tool is fixed while the workpiece moves slowly. A piece of glass is placed to block chips from interfering with the view, ensuring a clearer observation of the cutting zone.
To achieve the desired magnification, an additional lens is added to the system. The TV screen has a diagonal of 440 mm with a 3:2 aspect ratio. The screen is divided into six equal parts, with two sections dedicated to the workpiece, two to the cutting area, and two to the chip region. The camera’s photoelectric converter has a diameter of 14 mm, and the effective image must match the 3:2 aspect ratio. Based on the calculations, the required magnification is approximately 10 times. Using the lens formula, the focal length is determined to be 16.5 mm.
To ensure proper illumination, a half-mirror is used to direct light from a slide projector toward the cutting zone. The lens is positioned 182 mm away from the photoelectric converter. Due to the long distance, an aluminum cylinder is used to support the lens and allow for adjustments.
In conclusion, after the design and implementation, the industrial television camera system provides a stable and effective means of observing metal cutting deformation. It operates reliably within a working speed range of 14 to 900 mm/min, offering valuable insights into the mechanics of metal cutting. This system has significantly contributed to the understanding of cutting processes and the advancement of machining technology.