A methodology for laser tool setters calibration and its precise mathematical model

Abstract

On-machine tool setting is a pivotal approach in achieving intelligent manufacturing, and laser tool setters have become a crucial component of smart machine tools. Laser tool setters play a crucial role in precisely measuring the dimensions of cutting tools during the part machining process, focusing on tool length and diameter. As a measuring instrument, the positions of the laser axis of the laser tool setter need to be accurately calibrated before use. However, in actual calibration scenarios, traditional calibration methods face challenges due to installation errors in the tool setter and geometric errors in the measuring rod. To address this issue, this study proposes a novel calibration method. Initially, the calibration mechanism of the laser beam axis is established. Based on the accurate mathematical model of the laser beam and the measuring rod, and using the polygon clipping algorithm, the mathematical mechanism of the laser tool setter's work is established. Then, a novel method is introduced to calculate the compensation distance between the laser beam reference point and the rod bottom center point at each moment during calibration. Furthermore, by utilizing the kinematic chain of the tool setter calibration system, a new calibration method is developed to accurately calibrate the position of the laser beam axis in the machine tool coordinate system. Finally, the accuracy of the calibration method is verified through simulation experiments and calibration tests. This method improves the calibration accuracy of the tool setter, and the mathematical model of the laser tool setter can be extended to the measurement of tools, thereby improving the precision of tool measurements. This research significantly improves the efficient production performance of smart machine tools.