RU2146577C1 - Method for multistart cutting of profiled grooves - Google Patents

Abstract

FIELD: metal cutting, possibly precision cutting of separate profiled grooves or set of grooves, mainly, one-profile grooves, for example, at forming relief in functional layers of metallographic blocks (cliche) used at making different types of paper currency and in other ranges of technology needing formation of predetermined-depth patterns with submicron resolution in functional layers of articles. SUBSTANCE: at cutting grooves cutter P1 with two cutting edges and with profile corresponding to contour of groove K4 is used. Before each pass for forming first lateral surface of groove one edge of cutter is arranged in zone of generatrix of first lateral surface of groove. Before each pass for forming second lateral surface of groove another cutting edge of cutter is arranged in zone of generatrix of second lateral surface of groove. In fist variant of invention groove is formed at successively working parallel cutting zones whose profile width in any cross section corresponds to width of groove profile in the same section. Height of zones corresponds to depth of cutting in any pass of cutter in that zone. In each zone after first two passes for forming portions of lateral surfaces of groove in that zone, additional passes for removing allowance in center of that zone are performed. According to other variants, at working groove each cutting edge of cutter is arranged in zone of generatrices spaced by distance Z from (corresponding to said cutting edge) generatrix of lateral surface of maximum profile of groove (nominal profile of groove) in first pass for forming said lateral surface. In next passes for forming the same lateral surface of groove, edge of cutter is arranged in such a way that it is spaced by distance X (towards axis of groove) from generatrix of portion of lateral surface of actual profile of groove formed in previous pass. Values of distances Z and X satisfy to predetermined conditions. EFFECT: possibility of mechanically creating in functional layer structures (for example, printing and blanks members) with set (by height or depth respectively) geometry parameters with submicron resolution and high accuracy, enlarged functional possibilities due to decreasing or whole elimination of negative influence upon cutting tool of asymmetric reactive loads acting from side of material of blank in process of forming portions of groove profile. 18 cl, 44 dwg

Description

 The invention relates to the field of metal cutting and can be used for precision cutting of individual profile grooves or families of grooves (mainly single-profile), for example, when forming relief in the functional layers of metallographic forms (clichés) used in the production of various types of securities (requiring high degree of protection against counterfeiting), also in other areas of technology where it is necessary to obtain a picture of a given depth with submicron resolution in the functional layers of the products.

 Since all the shortcomings of the following methods of multi-pass cutting of profile grooves known from the prior art are most clearly manifested in precision processes for forming groove profiles with submicron accuracy (resolution) of their geometric parameters, for example, in the processes of manufacturing metallographic forms for letterpress printing, it is advisable to reveal the main features of these processes related to the restrictions imposed on them with respect to the accuracy parameters generated by these percent esses of profile structures.

In particular, metallographic (model) forms for letterpress printing, used to obtain printed products that require a high degree of protection against counterfeiting, have grooves on the working surface with a section of a trapezoidal profile. The shape of the grooves along the length can be rectilinear, circular, sinusoidal, etc. In addition, the grooves can intersect at angles of up to 15 ^o .

The requirements for the accuracy of the groove elements and their shape are characterized by the following deviations from the nominal parameters:
- deviation from a given shape - ± 3 microns;
- deviation from a given width - ± 4 microns;
- deviation from the set depth - ± 5 microns;
- the deviation of the profile elements (side surfaces, bottom, ribs) from flatness and straightness - ± 4 microns.

 A very important requirement, from the point of view of processing accuracy, is the need to ensure the sharpness and straightness of the ribs formed by the lateral surfaces (sides) of the groove and the working (upper) plane of the metallographic shape. As well as the requirement to avoid distortion of the shape of the profile (section) of the groove at the intersection of the grooves.

 In production practice, various methods are used to obtain grooves by machining (cutting), the cross-sectional profile of which is formed by flat surfaces. In this case, tools are used, the working profile of which coincides with the profile of the formed groove or is slightly different (downward in the corresponding geometric parameters) with respect to the latter.

 As a rule, forming a profile of grooves during turning and planing operations (for example, when forming threads, grooves of pulleys, grooves and grooves of large length on flat parts) is obtained by the multi-pass method, since the strength of the tool is insufficient for working in one pass. A similar restriction on the scheme of the processing process is also imposed when forming profile grooves that form a given relief on the working surface of metallographic forms.

 Depending on the requirements for the machined surfaces, various schemes for selecting material from the area limited by the groove profile, which are described in the present application when describing the prior art, can be used.

 However, the following methods and techniques for forming profile grooves do not allow solving the problem of obtaining profile grooves forming a given relief structure on the working surface of metallographic forms (for example, for letterpress printing) due to the high requirements for the accuracy of the corresponding profile elements of these grooves (since the increase the accuracy of manufacturing relief structures of metallographic forms is directly dependent on the increase in the degree of protection of securities printed with their help) and relatively low rigidity of the tool in relation to the magnitude of the perceived lateral loads.

 In order to ensure the straightness of the ribs formed by the intersection of the side surfaces (sides) of the groove and the upper working plane of the metallographic shape, it is necessary to eliminate or at least minimize the asymmetry of the side loads on the cutter.

 In order to provide the necessary requirements for the accuracy of forming the width of the grooves and the relative position of the grooves, it is necessary to have technical means that allow the cutter to be repeatedly moved across the groove without creating additional lateral loads on the cutter from the sections of the side surfaces of the groove profile that were finally formed in the previous passes. The discreteness of these movements should be significantly less than the minimum discreteness of movements provided by the numerical control system of the machine. Therefore, these movements must be carried out by an autonomous drive (with respect to the numerical program control system of the machine), which (i.e., an autonomous drive) upon completion of the groove profile formation returns the cutter to the initial position provided by the numerical program control system of the machine.

 A known method of obtaining a pattern (microrelief formation) on the surface of the functional layer using x-ray radiation in films of X-ray resistors. The common name for this method is X-ray lithography (W. Moro, Microlithography, vol. 1, M., Mir, 1990, p. 12, p. 466).

Creating a pattern (microrelief formation) by lithographic method in any functional layer, for example, in functional layers of integrated circuits, according to the known technology, is carried out in the following sequence of operations:
- create a functional layer on the substrate;
- apply a resistive layer over the functional layer;
- dry the applied resistive layer;
- expose the resistive layer through the template;
- showing a latent image obtained in the resistive layer as a result of exposure;
- subdue the resulting resistive mask;
- process the functional layer through a resistive mask (etch, dope, etc.).

 In the case of X-ray lithography, X-ray radiation is used for exposure. As X-ray resistors, in practice organic polymers based on polymethyl methacrylate are used, which are applied to substrates and developed in a liquid manner.

 Vacuum X-ray resistors are known that are applied and developed in a dry manner, but are not used in industry because of their low sensitivity.

 The method of X-ray lithography is the most productive in comparison with all other lithographic methods, which allow obtaining submicron resolution of formed microrelief structures in resistive layers.

 However, this known method of x-ray lithography, firstly, requires expensive equipment for its industrial implementation, and secondly, it cannot be provided with the necessary mechanical strength of structures (relief elements) formed by etching directly on the functional layer to a depth of more than 0, 5 microns.

 This is explained by the fact that when the corresponding sections of the functional layer are etched to a greater depth, the side surfaces of the formed structures of the functional layer are etched and, as a result, not only the possibility of maintaining the necessary submicron resolution of the formed structures is excluded, but also the mechanical weakening of these structures in the zone of their bases.

 Therefore, this known method of X-ray lithography cannot be used, for example, in the technology of manufacturing printed (metallographic) forms for letterpress printing (in which the height of the structures formed in the functional layer - printing elements reaches 50 μm or more) due to the low mechanical strength of these structures (printing elements).

 A known method of multi-pass cutting profile grooves (in particular - threads), according to which use a cutter with two side cutting edges, the angles of which are less than the corresponding angles of inclination of the forming side surfaces of the profile of the formed thread. The cutter is informed of radial axial movement so that the family of successive positions of the tips of the cutter has an envelope forming the trough of the thread. In this case, the treatment starts at the bottom of the thread cavity, and with each subsequent pass, the cutter is removed from the bottom (SU, 642081, class B 23 B 1/00, 1979).

 The disadvantages of this prior art method of multi-pass threading include the following.

 Firstly, the above-described known cutting pattern can be implemented only for finishing a pre-formed (draft) thread profile with technologically predetermined size and shape of the finishing allowance profile.

 This is unacceptable, for example, for the industrial implementation of super-precision machining of submicron structures of the formed relief (for example, in the manufacture of metallographic forms for letterpress printing), because preliminary roughing will introduce an additional error and, thereby, reduce the accuracy of manufacturing the formed thread profile as a whole.

 Secondly, the known cutting pattern provides for a single-sided contact of the cutter with the material of the workpiece during each pass, i.e., contact from the side of only the cutting edge that is currently forming the profile of the thread depression. And this causes elastic deformation (one-sided bending) of the cutter during the cutting process due to the asymmetry of the reactive forces applied to it from the material of the workpiece being processed.

 Therefore, during processing under the influence of the asymmetric reactive forces mentioned above, the cutter will deviate from the theoretically specified trajectory of its movement in the direction of the axis of symmetry of the formed profile. It also reduces the accuracy of the manufacture of the formed profile.

 Thirdly, when implementing this known method of multi-pass cutting, the tip of the cutter in some passes (due to the inevitable error of its positioning) can be set with an offset relative to the generatrix of the nominal (i.e. technologically defined) groove profile in the zone of positive deviation of the tolerance field.

 Based on this, we can conclude that in this case there will be an increase in the width of the chips removed in this passage. This is explained by the fact that the cutting edge of the tool captures part of the allowance, which technologically should have been removed in subsequent passes.

 This random nature of the change in the width of the chips at different passages makes an additional negative contribution to the total error of the machining of the formed profile and, therefore, reduces the accuracy of its manufacture as a whole.

 It should also be noted here that, given the random (probabilistic) nature of the above-described phenomenon, the possibility of correcting the error caused by this phenomenon is excluded, even when implementing this method known on the prior art on numerically controlled machines (i.e., by appropriately adjusting the program control based on information obtained in trial or previous passes).

 A known method of multi-pass cutting of profile grooves (in particular, threads) on numerically controlled machines, according to which a cutter is used with two lateral cutting edges and one vertex formed by the intersection of said cutting edges. The inclination angles of the side cutting edges are made close (taking into account the manufacturing error) or equal (if neglecting the manufacturing error) to the corresponding inclination angles of the forming side surfaces of the profile of the formed thread.

 According to this processing method known from the prior art, the supply of the cutter is carried out at an angle to the axis of the thread. The first pass is carried out at the position of the tip of the cutter on the axis of symmetry of the thread profile. In subsequent passes, one of the lateral cutting edges is positioned sequentially (alternately) with an offset (by the amount of feed) towards the first side surface of the thread profile formed by this cutting edge, and the other cutting edge is offset (by the same amount of feed) towards the formed this cutting edge of the second side surface of the thread profile. At the same time, there is a mandatory gap between the non-working (partially) in this passage the cutting edge of the tool and the corresponding side surface of the profile formed in the previous passage (SU, 549267, class B 23 B 1/00, 1977).

 The disadvantages of this prior art method of multi-pass cutting of profile grooves (threads) on numerically controlled machines include the following.

 Firstly, this known cutting pattern (in contrast to the previously discussed) provides for each pass a two-way contact of the cutter with the material of the workpiece, i.e. contact from both cutting edges. However, this only partially (with the exception of the first pass) provides compensation for the elastic deformation (one-sided bending) of the cutter during the cutting process, again due to the asymmetry of the reactive forces applied to it from the material of the workpiece and a significant difference in the values of these reactive forces.

 Therefore, during processing under the influence of the asymmetric reactive forces mentioned above, the cutter will deviate from the theoretically specified trajectory of its movement in the direction of the axis of symmetry of the formed profile. And this, as mentioned earlier, significantly affects the decrease in the accuracy of manufacturing the formed profile.

 Secondly, when implementing this known method of multi-pass threading, the width of the chip from the side of the cutting edge of the tool, which forms a profile of the corresponding side surface of the thread at this pass, progressively increases (relative to the width of the chip in the first pass). In this case, the width of the chips from the side of the opposite cutting edge practically does not change.

 That is, with each subsequent pass, starting from the second, the asymmetry of the reactive forces acting on the cutter from the side of the workpiece material progressively grows and has a maximum value in the last two passes, which directly form the final profile of the side surfaces of the thread.

 This natural progressive nature of the change (increase) in the width of the chip from the side of the corresponding cutting edge of the tool in all passes (relative to the first pass) makes an additional negative contribution to the total error of the machining of the formed profile and, therefore, reduces the accuracy of its manufacture as a whole.

 It should also be noted here that, taking into account the regular (i.e. theoretically predicted for each specific case) nature of the above phenomenon, the possibility of correcting the error caused by this phenomenon during the implementation of this method known from the prior art on machines with numerical control (i.e. e. by appropriate adjustment of the management program, for example, based on information obtained in the trial or previous passes). However, this complicates the processing process as a whole. In addition, it should be noted that the AIDS system (machine - tool - tool - part) of modern numerically controlled machines in itself has such a positioning error value that is commensurate with the tolerance for manufacturing submicron structures formed mechanically (for example, on the surface a functional layer of metallographic forms for letterpress) relief. And this narrows the functionality of the considered well-known technical solutions.

 A known method of multi-pass cutting of profile grooves (in particular, threads) on numerically controlled machines, according to which a cutter is used with two lateral cutting edges and one vertex formed by the intersection of said cutting edges. The inclination angles of the side cutting edges are made close (taking into account the manufacturing error) or equal (if neglecting the manufacturing error) to the corresponding inclination angles of the forming side surfaces of the profile of the formed thread.

 According to this method of processing known from the prior art, the first draft passage is carried out with the position of the tip of the cutter on the generatrix of one of the sides of the thread profile. The supply of the cutter in subsequent rough passes (carried out with the same depth of cut relative to the first pass) is carried out along the axis of the thread until an auxiliary multi-start thread is obtained with a step equal to the step of the formed single-thread finish. Moreover, the step of the formed fine single-start thread is equal to the product of the number of starts of the formed (with rough passes) multi-start thread and the value of the axial step of the last run (SU, 782962, class B 23 B 1/00, 1980).

 The disadvantages of this prior art method of multi-pass cutting of profile grooves (threads) on numerically controlled machines include the following.

 It should be noted that this known cutting pattern (in contrast to the previously considered ones) theoretically provides for each pass (at least when processing part of the formed profile of a single-thread) a symmetrical two-way contact of the cutter with the material of the workpiece, i.e. symmetrical loading pattern of both cutting edges. This provides compensation for the elastic deformation (unilateral bending) of the cutter during the cutting process, due to the symmetry of the reactive forces applied to it from the material of the workpiece and the equality of the values of these reactive forces.

 Therefore, during processing under the influence of the above-mentioned symmetrical reactive forces, the cutter will not deviate from the theoretically specified trajectory of its movement in one direction or another.

 However, this (positively affecting the processing accuracy) quality with the processing method under consideration inevitably entails such a phenomenon that negatively affects the cutter durability, such as a progressive increase in the cross-sectional area of the material being removed (at different levels of the formed thread profile) (i.e., the chip cross-sectional area ) And this significantly affects the decrease in the accuracy of manufacturing the formed thread profile and imposes additional requirements on the strength characteristics of the cutting tool and the rigidity of the AIDS system of the machine, which limits the functionality of the industrial application of the known multi-pass processing method under consideration.

 In addition, in the practical implementation of this known method of multi-pass processing, the tip of the cutter in some passes (due to the inevitable error of its positioning) can be set with an offset relative to the generatrix of the nominal (i.e., technologically defined) groove profile in the zone of positive or negative tolerance deviation .

 Based on this, it can be concluded that in the passages of the second level and all subsequent passages, an increase in the width of the removed chips will occur.

 This is explained by the fact that the cutting edge of the tool captures a part of the material already processed by passes of the previous surface level, including in the area of the previously formed side surface of a single-thread. This random nature of the change in the width of the chips in the respective passages makes an additional negative contribution to the total error of the machining of the formed profile of a single thread and, therefore, reduces the accuracy of its manufacture as a whole.

 Here (as in the case of implementing the processing method according to SU, N 642081), it should be noted that, given the random (probabilistic) nature of the above phenomenon, the possibility of correcting the error caused by this phenomenon is excluded, even when implementing this method known from the prior art on numerical machines program management (i.e., by appropriately adjusting the management program based on information obtained, for example, in test or previous passes). And this limits the functionality of industrial applications of the known prior art multi-pass processing.

 The closest in technical essence and the achieved result with respect to the claimed invention is a method of multi-pass cutting of profile grooves (in particular, threads), according to which a cutter with two side cutting edges is used, the tilt angles of which are less than the corresponding tilt angles of the forming side threads of the formed thread profile. Before each passage forming the first side surface of the thread profile (grooves), one of the side cutting edges of the cutter is placed in the region of the corresponding forming first side surface of the thread profile (grooves), before each passage forming the second side surface of the thread profile (grooves), another the lateral cutting edge of the cutter is located in the region of the corresponding generatrix of the second side surface of the thread profile (grooves). Moreover, the mentioned arrangement of the lateral cutting edges of the cutter is provided by means of kinematic connection of the cutter with the executive body of the lateral feed means (SU, 612753, class B 23 B 1/00, 1978).

 The disadvantages of this prior art method of multi-pass cutting of profile grooves (threads) on numerically controlled machines include the following.

 It should be noted here that this known cutting pattern provides for each pass (at least when processing part of the formed thread profile) a bilateral, but not symmetrical, contact of the cutter with the material of the workpiece, i.e. asymmetric loading pattern of both cutting edges. This provides elastic deformation (one-sided bending) of the cutter during the cutting process, due to the asymmetry of the reactive forces applied to it from the material of the workpiece and the difference in the values of these reactive forces.

 Therefore, during processing under the influence of the asymmetric reactive forces mentioned above, the cutter will deviate from the theoretically specified trajectory of its movement in one direction or another, depending on the geometry of the cutting tool. And this negatively affects the accuracy of the processing provided in the process of industrial implementation of this known method.

 In addition, in the practical implementation of this known method of multi-pass processing, the tip of the cutter in some passes (due to the inevitable error of its positioning) can be set with an offset relative to the generatrix of the nominal (i.e., technologically defined) groove profile in the zone of positive deviation of the tolerance field.

 Based on this, it can be concluded that in all passages, starting from the second, the possibility of increasing the width of the removed chip from the side of the cutting edge, which at this pass directly forms a section of the final profile of the side surface of the thread, is not excluded.

 This is explained by the fact that the cutting edge of the tool captures part of the material already processed in previous passes of the sections of the side surface of the thread profile.

 This random nature of the change in the width of the chips in the respective passages makes an additional negative contribution to the total error of the machining of the formed thread profile and, therefore, reduces the accuracy of its manufacture as a whole.

 Here (as in the case of implementing the processing method according to SU, N 642081), it should be noted that, given the random (probabilistic) nature of the above phenomenon, the possibility of correcting the error caused by this phenomenon is excluded, even when implementing this method known from the prior art on numerical machines program management (i.e., by appropriately adjusting the management program based on information obtained, for example, in test or previous passes). And this limits the functionality of industrial applications of the known prior art multi-pass processing.

 Thus, all the above-described disadvantages of the multi-pass methods for cutting profile grooves known to the applicant from the prior art have a certain negative impact on the accuracy of the manufacture of the finishing profile formed by these methods (in particular, the thread profile), which narrows the functionality of the known methods. Namely, it virtually eliminates the possibility of their industrial application in the manufacture of relief structures on the surface of the workpiece with submicron resolution (submicron accuracy) of these structures, for example, in the manufacture of metallographic forms (clichés) for letterpress printing used for the manufacture of banknotes and other securities.

 The basis of the claimed invention was the task of creating such variants of a multi-pass cutting method (mainly precision) of profile grooves (mainly in the manufacture of printing plates for letterpress printing), in which, along with the possibility of creating structures formed in the functional layer mechanically (for example, printing and white space elements) with specified (in height or depth, respectively) geometric parameters, the possibility of obtaining the above structures with by submicron resolution and high accuracy, as well as expanding the functionality by reducing or completely eliminating the negative effect of asymmetric reactive loads on the cutting tool from the material of the workpiece processed during the sequential formation of groove profile sections.

The task according to the first variant of the method is solved by the fact that in this variant of the multi-pass cutting of profile grooves, according to which a cutter with two lateral cutting edges is used, before each passage forming the first side surface of the groove profile, one of the side cutting edges of the cutter is located in the zone the corresponding generatrix of the first side surface of the groove profile, before each passage forming the second side surface of the groove profile, the other side cutting the edge of the cutter is positioned in the region of the second lateral surface of the groove profile profile corresponding to it; according to the invention, a cutter is used for machining with the inclination angles of the side cutting edges close to or equal to the corresponding inclination angles of the forming side surfaces of the profile of the formed groove, forming at least part of the complete groove profile carried out by sequential processing of at least two parallel to one another cutting zones, the profile width F of which in any section ns corresponds to the width B _k profile formed by a groove in this same section, the height H _t of each cutting area corresponding to the depth t of cut in any of the tool passes, forming a section of the profile grooves in the cutting zone, wherein in at least a first cutting zone after the first two at least one additional cutter pass, through which the allowance formed in the central part of this cutting zones as a result of the implementation of the aforementioned first two passes of the cutter.

 The cutter passes in each cutting zone are carried out with the same cutting depth t.

 For processing, a cutter is used, mainly with a profile shape corresponding to the profile shape of the formed groove.

To implement the processing, a cutter with a width L _{h of the} profile is used, at a distance h from its peak, not exceeding the maximum permissible minimum width B _{kmin of} the groove profile at a depth of H _x , which is equal to:
H _x = H _max - h
where H _max - the maximum depth of the profile of the formed grooves.

To perform grooving of the trapezoidal profile, a cutter with two vertices is used, which is formed by the intersection of the side cutting edges of the cutter with its transverse cutting edge, and at least part of the complete groove profile is formed by sequential processing of at least two cutting zones parallel to one another until formation groove profile to a depth H _x , at the level of which the maximum permissible maximum width B _{kmax of the} profile of the formed groove is not less than twice the width L _min profile of the cutter at its vertices.

To implement the processing, use a cutter with a width L _{min of the} profile at its vertices, which satisfies the following relation:
L _min ≤ B _kmin / 2,5
where B _kmin is the maximum permissible minimum width of the profile of the formed groove in the maximum upper section of this profile located at the outlet of the groove.

где B_kmax - предельно допустимая (технологически) максимальная ширина профиля канавки на заданной глубине H_x канавки;
B_kmin - предельно допустимая (технологически) минимальная ширина профиля канавки на той же заданной глубине H_x канавки;

абсолютная величина погрешности T позиционирования исполнительного органа средства поперечной подачи;
N - количество проходов резца, необходимых для формирования полного профиля одной из боковых поверхностей формируемой канавки на максимальную глубину H_max профиля этой канавки;
а в качестве средства поперечной подачи используют средство перемещения с величиной дискретности D шага перемещения и абсолютной величиной погрешности T позиционирования исполнительного органа, каждая из которых, соответственно, одновременно удовлетворяет следующим условиям:

Все проходы резца в процессе обработки профиля формируемой канавки на заданную глубину H_x осуществляют с одинаковой глубиной резания.The task according to the second variant of the method is solved by the fact that in this embodiment of the method of multi-pass cutting of profile grooves, according to which a cutter with two side cutting edges is used, before each passage forming the first side surface of the groove profile, one of the side cutting edges of the cutter is located in the zone the corresponding generatrix of the first side surface of the nominal groove profile, before each passage forming the second side surface of the groove profile, another the lateral cutting edge of the cutter is located in the region of the corresponding forming second second surface of the nominal groove profile, while the said arrangement of the lateral cutting edges of the cutter is provided by kinematic connection of the cutter with the actuator of the transverse feed means, according to the invention, a cutter with the angles of inclination of the lateral cutting edges is used for processing close to or equal to the corresponding angles of inclination of the generatrix lateral surfaces of the nominal profile of the formed groove, in the process of processing at least part of the profile of the formed grooves, each side cutting edge of the cutter is located in the zone of the said generators at a distance Z in the direction of the axis of the groove relative to the corresponding forming cutting edge of the forming side surface of the maximum permissible maximum profile of the groove, at the first pass forming this side surface of the groove, and in subsequent passages forming the same lateral surface of the groove - at a distance X in the direction of the axis of the groove relative to the forming section of the lateral surface the surface of the real groove profile obtained in the previous pass, while the values of the distances Z and X satisfy the following conditions:

where B _kmax is the maximum permissible (technologically) maximum width of the groove profile at a given depth H _{x of the} groove;
B _kmin - the maximum allowable (technologically) minimum width of the groove profile at the same predetermined depth H _{x of the} groove;

the absolute value of the error T of positioning the executive body of the transverse feed means;
N is the number of cutter passes necessary to form a complete profile of one of the side surfaces of the formed groove to the maximum depth H _{max of the} profile of this groove;
and as a means of transverse feed use a means of movement with the discreteness value D of the step of movement and the absolute value of the error T of positioning of the actuator, each of which, respectively, simultaneously satisfies the following conditions:

All cutter passes in the process of processing the profile of the formed groove to a given depth H _x carry out with the same cutting depth.

 To implement the processing, a cutter with a profile shape corresponding to the profile shape of the formed groove is used.

For processing, a cutter with a profile width L _h at a distance h from its top, not exceeding the maximum permissible minimum width B _{kmin of} the groove profile at a depth of H _x = H _max - h, where H _max is the maximum profile depth of the formed groove, is used.

To form grooves, mainly of a trapezoidal profile, a cutter with two vertices is used, which are formed by the intersection of the side cutting edges of the cutter with its transverse cutting edge, and the formation of at least part of the complete groove profile by arranging the side cutting edges of the cutter at distances Z and X relative to the corresponding generatrices until the profile of the groove is formed to a depth H _x , at the level of which the maximum permissible maximum width B _{kmax of the} profile of the formed groove is not less than doubled width L _min profile of the cutter at its vertices.

For processing, a cutter is used with a profile width L _min at its vertices that satisfies the following ratio L _min ≤ B _kmin / 2.5, where B _kmin is the maximum allowable minimum profile width of the formed groove in the maximum upper section of this profile located at the groove exit.

где B_knom - номинальная ширина профиля канавки на заданной глубине H_x канавки;
B_kmin - предельно допустимая (технологически) максимальная ширина профиля канавки на той же заданной глубине H_x канавки;

абсолютная величина погрешности T позиционирования исполнительного органа средства поперечной подачи;
N - количество проходов резца, необходимых для формирования полного профиля одной из боковых поверхностей формируемой канавки на максимальную глубину H_max профиля этой канавки;
а в качестве средства поперечной подачи используют средство перемещения с величиной дискретности D шага перемещения и абсолютной величиной погрешности T позиционирования исполнительного органа, каждая из которых, соответственно, одновременно удовлетворяет следующим условиям:

Все проходы резца в процессе обработки профиля формируемой канавки на заданную глубину H_x осуществляют с одинаковой глубиной резания.The task according to the third variant of the method is solved by the fact that in this variant of the multi-pass cutting of profile grooves, according to which a cutter with two lateral cutting edges is used, before each passage forming the first side surface of the groove profile, one of the side cutting edges of the cutter is located in the zone to the corresponding generatrix of the first side surface of the nominal groove profile, before each passage forming the second side surface of the groove profile, to a friend the lateral cutting edge of the cutter is located in the region of the corresponding forming second second surface of the nominal groove profile, while the said arrangement of the lateral cutting edges of the cutter is provided by kinematic connection of the cutter with the actuator of the lateral feed means, characterized in that a cutter with lateral angles is used for processing cutting edges close to or equal to the corresponding angles of inclination of the forming side surfaces of the nominal profile of the formed groove, in In the process of processing at least part of the profile of the formed groove, each side cutting edge of the cutter is placed in the zone of the said generators at a distance Z relative to the corresponding forming cutting edge of the forming side surface of the nominal groove profile in the first pass forming this side surface of the groove, and in subsequent passes forming this the lateral surface of the groove is at a distance X, in the direction of the axis of the groove, relative to the generatrix of the side surface of the real groove profile obtained w in the previous pass, while the values of the distances Z and X satisfy the following conditions:
Z ≤ (B _knom - B _kmin ) / 2N;

where B _knom is the nominal width of the groove profile at a given depth H _{x of the} groove;
B _kmin - the maximum allowable (technologically) maximum width of the groove profile at the same given depth H _{x of the} groove;

the absolute value of the error T of positioning the executive body of the transverse feed means;
N is the number of cutter passes necessary to form a complete profile of one of the side surfaces of the formed groove to the maximum depth H _{max of the} profile of this groove;
and as a means of transverse feed use a means of movement with the discreteness value D of the step of movement and the absolute value of the error T of positioning of the actuator, each of which, respectively, simultaneously satisfies the following conditions:

All cutter passes in the process of processing the profile of the formed groove to a given depth H _x carry out with the same cutting depth.

 To implement the processing, a cutter with a profile shape corresponding to the profile shape of the formed groove is used.

For processing, a cutter with a profile width L _h at a distance h from its top not exceeding the maximum allowable minimum width B _{kmin of} the groove profile at a depth of H _x = H _max -h, where H _max is the maximum profile depth of the formed groove, is used.

For grooving, mainly of a trapezoidal profile, a cutter with two vertices is used, which is formed by the intersection of the side cutting edges of the cutter with its transverse cutting edge, and the formation of at least part of the complete groove profile by arranging the side cutting edges of the cutter at distances Z and X relative to the corresponding generators are carried out until the profile of the groove is formed to a depth H _x , at the level of which the maximum permissible maximum width B _{kmax of the} profile formed grooves not less than twice the width L _{min of the} profile of the cutter at its vertices.

It is most effective for processing to use a cutter with a width L _{min of the} profile at its vertices that satisfies the following relation L _min ≤ B _kmin / 2,5, where B _kmin is the maximum allowable minimum profile width of the formed groove in the maximum upper section of this profile located at the exit grooves.

 Descriptions of embodiments of the multi-pass method of cutting profile grooves are illustrated by the following drawings.

 In FIG. 1 shows one of the possible forms of the groove (trapezoidal profile) formed in accordance with the variants of the claimed invention, indicating the designations used in the application characterizing the geometric and technological parameters of this groove.

 In FIG. 2 and FIG. 3 shows the shapes of the profiles of the working parts of cutting tools (indicating the designations used in the application characterizing the geometric parameters and elements of these cutting tools), by means of which a groove indicated in FIG. 1 profile form (within the technologically specified tolerance field).

 In FIG. Figure 4 shows the cutting zones parallel to one another (indicating the designations of the geometric parameters of these zones used in the application), as a result of sequential processing of which the groove profile is formed according to the first (from the declared) method variant, i.e. the method described in claims 1 to 6 of the claims.

 In FIG. 5, 6 show the sequence of passes of the cutting tool, through which the groove profile is formed according to the first (of the claimed) method variant, i.e. the method described in paragraphs. 1-6 of the claims (in Figs. 7,8,11,15, two consecutive passes are shown, and subsequent passages, in each of these figures, are conventionally indicated by the profile of the cutting tool shown by the dashed line).

 In FIG. 17 to 22 show the sequence of passes of the cutting tool, through which the groove profile is formed according to the second or third (of the declared) variants of the method, i.e. the methods described in paragraphs. 7 to 12 or in claims 13 to 18 of the claims (i.e., according to cases of specific implementation of these options, by means of which the profile of the formed groove actually obtained as a result of processing is located partially in the zone of the upper deviation of the tolerance field and partially in the zone of the lower deviation of the tolerance field )

 In FIG. 23 to 28 show the sequence of passes of the cutting tool, by means of which the groove profile can be formed according to only the second (of the declared) method variant, i.e. the method described in paragraphs. 7 to 12 of the claims (i.e., according to the case of a specific embodiment of this embodiment, by means of which the profile of the formed groove actually obtained as a result of processing is located exclusively in the zone of the upper deviation of the tolerance field).

 In FIG. 29 to 34 show the sequence of passes of the cutting tool by which the groove profile can be formed according to only the third (of the declared) method variant, i.e. the method described in claims 13 to 18 of the claims (i.e., according to the case of a specific embodiment of this embodiment, by means of which the profile of the formed groove actually obtained as a result of processing is located exclusively in the zone of lower deviation of the tolerance field).

 In FIG. 35 to 44, a sequence of passes of a cutting tool is shown, by means of which a groove profile can be formed by combining the first and second, or the first and third (of the declared) variants of the method, i.e. the method described in claims 1 to 6 and claims 7 to 12 or in claims 1 to 6 and claims 13 to 18 of the claims, respectively (in Fig. 38 two successive passes are shown, and the subsequent pass is conditionally indicated by the profile of the cutting tool shown by the dashed line). According to this processing scheme, an example of a specific implementation of the claimed method was carried out.

 Variants of multi-pass cutting profile grooves according to the invention are as follows.

 With regard to the implementation of the first variant of the method of multi-pass cutting profile grooves described in claims 1 to 6 of the claims.

According to this variant of the multi-pass profile grooving method, a cutter 1 with at least two lateral cutting edges 2 and 3 is used. The inclination angles of the lateral cutting edges 2 and 3 are made close (if the manufacturing error is taken into account) or equal (without taking into account the manufacturing error) to the corresponding tilt angles forming the side surfaces of the profile of the formed groove 4. Before each passage of the cutter 1 forming the first side surface of the profile of the groove 4, one of the side cutting edges 2 of the cutter 1 is placed in one corresponding to it forming the first side surface of the profile of the groove 4. Before each passage forming the second side surface of the profile of the groove 4, the other side cutting edge 3 of the cutter 1 is located in the area corresponding to it forming the second side surface of the profile of the groove 4. In this case, the formation of the full profile of the groove 4 or parts of its full profile are carried out by sequential processing of at least two cutting zones 5, 6 and 7 parallel to one another. The width F of the profile of these cutting zones 5, 6 and 7 in any section (perpendicular to the axis of symmetry 8 of the profile of the groove 4) corresponds to the width B _{k of the} profile of the formed groove 4 in the same section. The height H _{t of} each cutting zone 5, 6 and 7 corresponds to the cutting depth t in any of the passages of the cutter 1, forming a section of the groove profile 4 in this cutting zone 5, or 6 or 7 of the cutting. A special case is also not excluded when the cutting depth t is the same in all cutting zones 5, 6 and 7.

 At the same time, in at least the first cutting zone 5 after the first two passes of the cutter 1 (Fig. 5, 6), by means of which the corresponding sections of the side surfaces of the profile of the groove 4 are directly formed in this zone 5, at least one additional pass of the cutter 1 is carried out (Fig. 7, 8), by means of which the allowance 9 formed in the central part of this cutting zone 5 is removed as a result of the aforementioned first two passes of the cutter 1.

 It is obvious that in the case of the formation of an allowance 9 in the subsequent zones 6 and 7 of the cutting, it is necessary to carry out its removal by a similar method.

To illustrate the above (first) embodiment of the patented method of multi-junction cutting of profile grooves, as well as all subsequent options, the following notations are also introduced in graphic materials:
position 10 — the real profile (or part of it) of the formed groove 4 obtained as a result of processing;
position 11 is the nominal (technologically specified) profile of the formed groove 4, that is, the profile with the nominal (technologically specified) width B _knom at a given depth H _{x of the} groove 4;
position 12 is the maximum permissible (technologically) maximum profile of the formed groove 4, i.e. a profile with a maximum permissible (technologically) maximum width B _kmax at a given depth H _{x of} groove 4;
position 13 - the maximum allowable (technologically) minimum profile of the formed groove 4, i.e. profile with the maximum allowable (technologically) minimum width B _kmin at a given depth H _x grooves 4.

 The horizontal arrows above the figures of the drawings conventionally show the direction of the transverse feed S of the cutter 4 for the subsequent passage, while the sequence of passes in all the figures corresponds to the sequence of numbering of the figures of the drawings.

 In addition, in order to simplify the description of the patented method according to the first embodiment (claims 1 to 6 of the claims), an assumption is made that the real profile 10 of the formed groove 4 coincides with the nominal profile 11 of this groove.

The above set of operations, combined with a certain sequence of their execution by means of cutter 1 with a given geometry, can significantly reduce the likelihood of the occurrence of cutter 1 during the corresponding passes (through which the corresponding sections of the side surfaces of the groove 4 profile are formed in zones 5, 6 and 7 cutting), asymmetric lateral loads (within the height H _{t of the} currently processed zone 5, or 6, or 7 cutting) on the cutter 1, causing x its bend, as illustrated clearly in FIG. 5, 6, 9, 10, 13 and 14 graphic materials. The absence of asymmetric lateral loads on the cutter 1 during the cutting process eliminates the unregulated deviation of the cutter 1 from a given trajectory of its movement, which increases the accuracy of processing the elements of the formed groove 4 as a whole.

 The implementation of all the passes of the cutter 1 in each cutting zone 5, 6 and 7 with the same cutting depth t allows to simplify the control system of the mechanism for moving the cutter 1.

 Using for processing a cutter 1 with a profile shape corresponding to the profile shape of the formed groove 4 allows (for example, when forming a groove 4 of the trapezoidal profile) to reduce the number of additional passes that remove the allowance 9 formed in the Central part of the corresponding zone 5, 6, or 7 cutting .

The implementation of the cutting tool 1 with a width L _{h of the} profile, at a distance h from its top, not exceeding the maximum permissible minimum width B _{kmin of the} profile of the groove 4 at a depth of H _x (which is: H _x = H _max -h, where H _max is the maximum depth the profile of the formed groove 4), allows you to use the same cutter 1 for machining the groove 4 to its maximum depth H _max .

When processing by means of a cutter 1 with two vertices, which are formed by the intersection of the side cutting edges 2 and 3 of the cutter 1 with its transverse cutting edge 14, the formation of at least part of the complete profile 10 of the groove 4 (by sequential processing of at least two zones parallel to one another 5, 6, 7 cutting) is carried out until the formation of the profile 10 of the groove 4 to a depth H _x , at the level of which the maximum permissible maximum width B _{kmax of the} profile 12 of the formed groove 4 is at least twice the width L _{min of the} profile of the cutter 1 pr and its peaks. This restriction was introduced on the basis that, at a depth H _x , at which the corresponding geometric parameters of the grooves 4 and the cutter 1 do not satisfy the above condition, the effect of the complete symmetry of the lateral reactive loads on the cutter 1 (and therefore their complete mutual compensation) is not guaranteed, although partial compensation of counter-directed reactive loads (acting on the lateral edges 2 and 3 of cutter 1) will still be provided.

In some cases, it becomes necessary to process the lateral surfaces of the real profile 10 of the groove 4 with submicron accuracy by about half the depth of this groove 4. In this case, a trapezoidal profile cutter 1 with a profile width L _min at its vertices satisfying the following relation is used: L _min ≤ B _kmin / 2,5, where B _kmin is the maximum permissible minimum width of the profile of the formed groove 4 in the maximum upper section of this profile located at the outlet of the groove 4.

 With regard to the implementation of the second variant of the method of multi-pass cutting profile grooves described in claims 7-12 of the claims.

 According to this variant of the multi-pass profile grooving method, a cutter 1 with at least two lateral cutting edges 2 and 3 is used. The inclination angles of the lateral cutting edges 2 and 3 are made close (if the manufacturing error is taken into account) or equal (without taking into account the manufacturing error) to the corresponding tilt angles forming lateral surfaces of the real profile 10 of the formed groove 4. Before each passage of the cutter 1 forming the first side surface of the real profile 10 of the groove 4, one of the side cutting edges 2 cutters 1 are located in the area of the corresponding generatrix of the first side surface of the maximum permissible maximum profile 12 of the groove 4. Before each passage forming the second side surface of the real profile 10 of the groove 4, the other side cutting edge 3 of the cutter 1 is placed in the area of the corresponding second generatrix of the side surface maximum permissible maximum profile 12 of the groove 4. The mentioned arrangement of the lateral cutting edges 2 and 3 of the cutter 1 is provided by kinematic connection of the cutter 1 with the executive body redstva infeed (FIGS DRAWINGS cross feed means and its actuator with the appropriate drive connection with the cutter 1 are not shown).

где B_kmax - предельно допустимая (технологически) максимальная ширина профиля канавки на заданной глубине H_x канавки;
B_kmin - предельно допустимая (технологически) минимальная ширина профиля канавки на той же заданной глубине H_x канавки;

абсолютная величина погрешности T позиционирования исполнительного органа средства поперечной подачи;
N - количество проходов резца, необходимых для формирования полного профиля одной из боковых поверхностей формируемой канавки на максимальную глубину H_max профиля этой канавки.Moreover, during processing of at least part of the real profile 10 of the formed groove 4, each side cutting edge 2 and 3 of the cutter 1 is located in the zone of the above-mentioned generators at a distance of 2 in the direction of the axis 8 of the groove relative to the corresponding forming cutting edge 2 or 3 of the forming side surface permissible maximum profile 12 of the groove 4 during the first pass forming this side surface of the real profile 10 of the groove 4. And in subsequent passes forming the same side surface of the real profile 10 of the channel ki 4 - at a distance X in the direction of axis 8 of the groove 4 with respect to the generatrix of the side surface 10 of the real profile of the groove 4, obtained in the previous pass. In this case, the distances Z and X must satisfy the following conditions:

where B _kmax is the maximum permissible (technologically) maximum width of the groove profile at a given depth H _{x of the} groove;
B _kmin - the maximum allowable (technologically) minimum width of the groove profile at the same predetermined depth H _{x of the} groove;

the absolute value of the error T of positioning the executive body of the transverse feed means;
N is the number of cutter passes necessary to form a complete profile of one of the side surfaces of the formed groove to the maximum depth H _{max of the} profile of this groove.

В случае, когда для осуществления обработки используют резец 1 с двумя вершинами (которые образованы пересечением боковых режущих кромок 2 и 3 резца 1 с его поперечной режущей кромкой 14), формирование по меньшей мере части полного реального профиля 10 канавки 4 посредством расположения боковых режущих кромок 2 и 3 резца 1 на расстояниях Z и X относительно соответствующих образующих осуществляют до момента формирования реального профиля 10 канавки 4 на глубину H_x, на уровне которой предельно допустимая максимальная ширина B_kmax профиля 12 формируемой канавки 4 не меньше удвоенной ширины L_min профиля резца 1 при его вершинах. Это ограничение введено на основании того, что при глубине H_x, на которой соответствующие геометрические параметры канавки 4 и резца 1 не удовлетворяют вышеприведенному условию, эффект взаимной компенсации боковых реактивных нагрузок на резец 1 прогрессивно снижается (особенно в случае осуществления обработки с одинаковой глубиной резания во всех проходах), хотя частичная компенсация встречно направленных реактивных нагрузок (действующих на боковые кромки 2 и 3 резца 1) обеспечиваться все-таки будет.In addition, to implement this variant of the method, as a means of transverse feed, it is necessary to use a means of movement with a step resolution D of step
displacement and the absolute value of the error T of positioning of the executive body, each of which, respectively, must simultaneously satisfy the combination of the following conditions:

In the case when a cutter 1 with two vertices (which are formed by the intersection of the side cutting edges 2 and 3 of the cutter 1 with its transverse cutting edge 14) is used for processing, the formation of at least part of the complete real profile 10 of the groove 4 by positioning the side cutting edges 2 and 3 cutters 1 at distances Z and X relative to the corresponding generators are carried out until the formation of a real profile 10 of groove 4 to a depth of H _x , at the level of which the maximum permissible maximum width B _{kmax of} profile 12 is formed oh groove 4 is not less than twice the width L _min profile of the cutter 1 at its vertices. This restriction was introduced on the basis that, at a depth H _x , at which the corresponding geometrical parameters of grooves 4 and cutter 1 do not satisfy the above condition, the effect of mutual compensation of lateral reactive loads on cutter 1 is progressively reduced (especially in the case of processing with the same cutting depth in all passes), although partial compensation of counter-directed reactive loads (acting on the lateral edges 2 and 3 of cutter 1) will still be provided.

 Particular cases of implementation (see paragraphs 8, 9, 10, 12 of the claims) of this (second) variant of the method are not disclosed in detail when describing it, since the technical effect realized through these particular cases completely coincides with the technical effect disclosed for identical special cases of implementation according to the first (previously considered) version of the method.

 Thus, according to the second variant of the method described above, it is possible to process the profile grooves in cases where the deviation of the real profile 10 of the formed groove 4 is technologically allowed exclusively in the region of the upper limit deviation of the tolerance field (Fig. 23 - 28) or both in the region of the upper and in the region of the lower limit deviation of the tolerance field (Fig. 17 - 22).

 With regard to the implementation of the third variant of the method of multi-pass cutting profile grooves, described in paragraphs. 13-18 claims.

 According to this variant of the multi-pass profile grooving method, a cutter 1 with at least two lateral cutting edges 2 and 3 is used. The inclination angles of the lateral cutting edges 2 and 3 are made close (if the manufacturing error is taken into account) or equal (without taking into account the manufacturing error) to the corresponding tilt angles forming lateral surfaces of the real profile 10 of the formed groove 4. Before each passage of the cutter 1 forming the first side surface of the real profile 10 of the groove 4, one of the side cutting edges 2 cutters 1 are located in the zone of the first side surface of the nominal profile 11 of the groove 4 corresponding to them forming the generatrix 4. Before each passage forming the second side surface of the real profile 10 of the groove 4, the other side cutting edge 3 of the cutter 1 is placed in the zone of the second side surface of the nominal profile forming it 11 grooves 4. The aforementioned arrangement of the side cutting edges 2 and 3 of the cutter 1 is provided by kinematic connection of the cutter 1 with the executive body of the lateral feed means (in the figures their material infeed means and its actuator with the appropriate drive connection with the cutter 1 are not shown).

где B_knom - предельно допустимая (технологически) максимальная ширина профиля канавки на заданной глубине H_x канавки;
B_kmin - предельно допустимая (технологически) минимальная ширина профиля канавки на той же заданной глубине H_x канавки;

абсолютная величина погрешности T позиционирования исполнительного органа средства поперечной подачи;
N - количество проходов резца, необходимых для формирования полного профиля одной из боковых поверхностей формируемой канавки на максимальную глубину H_max профиля этой канавки.Moreover, during processing of at least part of the real profile 10 of the formed groove 4, each side cutting edge 2 and 3 of the cutter 1 is placed in the zone of the above generators at a distance Z relative to the corresponding cutting edge 2 or 3 forming the side surface of the nominal profile 11 of the groove 4 when the first pass forming this lateral surface of the real profile 10 of the groove 4. And with subsequent passes forming the same lateral surface of the real profile 10 of the groove 4 - at a distance X in the direction of the axis 8 of the groove 4 from relative to the forming portion of the side surface of the real profile 10 of the groove 4 obtained in the previous passage. In this case, the distances Z and X must satisfy the following conditions:
Z ≤ (B _knom - B _kmin / 2N;

where B _knom is the maximum allowable (technologically) maximum width of the groove profile at a given depth H _{x of the} groove;
B _kmin - the maximum allowable (technologically) minimum width of the groove profile at the same predetermined depth H _{x of the} groove;

the absolute value of the error T of positioning the executive body of the transverse feed means;
N is the number of cutter passes necessary to form a complete profile of one of the side surfaces of the formed groove to the maximum depth H _{max of the} profile of this groove.

Частные случаи реализации (см. пп. 14, 15, 16, 17, 18 формулы изобретения) данного (третьего) варианта способа подробно не раскрываются при его описании, поскольку технический эффект, реализуемый посредством этих частных случаев, полностью совпадает с техническим эффектом, раскрытым для идентичных частных случаев реализации согласно первому и второму (ранее рассмотренных) вариантам способа.In addition, for the implementation of this variant of the method, it is necessary to use a moving means with a step increment D of the moving step and an absolute value of the positioning error T of the actuator, each of which accordingly must simultaneously satisfy the combination of the following conditions:

Particular cases of implementation (see paragraphs 14, 15, 16, 17, 18 of the claims) of this (third) variant of the method are not disclosed in detail when describing it, since the technical effect realized through these particular cases completely coincides with the technical effect disclosed for identical particular cases of implementation according to the first and second (previously considered) variants of the method.

 Thus, according to the above-described third variant of the method, it is possible to process the profile grooves in cases where the deviation of the real profile 10 of the formed groove 4 is technologically allowed exclusively in the region of the lower limit deviation of the tolerance field (Fig. 29 - 34) or both in the region of the upper and in the region of the lower limit deviation of the tolerance field (Fig. 17 - 22).

 A more detailed description of the operations of multi-pass cutting of profile grooves in the functional layer of the workpiece, as well as the control of geometric parameters of submicron elements of the topology of the pattern obtained on the surface of the functional layer through a certain relative position of the formed grooves, are widely known from published sources of information.

 In order to ensure the formation of profile annular grooves, it is necessary to use the above-described schemes for moving the tool with its relative rotation relative to the workpiece around the circumference. It is advisable to use a cutter, which should have lateral angles that allow one cutter to process a certain range of diameters, which makes the processing process more unified.

 In order to ensure the formation of curved grooves, it is necessary to use the above-described schemes for moving the tool to a depth and the rotation of the tool associated with longitudinal movement. Moreover, the rotation of the tool should ensure that the front face of the tool is normal to the midline of the groove.

 In order to ensure that the desired profile of the grooves is obtained at their intersections at an acute angle, the following technique is used.

 First, grooves of that family are formed in which the depth of the grooves has a maximum value. Then, these grooves with maximum depth are filled with a composition (for example, ice) that is easily removed using known means, the hardness of which is close to the hardness of the workpiece material (for example, metallographic material). After that, another family of grooves is processed according to one of the described schemes or by the totality of the corresponding operations of two of the described schemes. Then remove the filler.

 When using the variant of the claimed method according to claim 1, in conjunction with the corresponding operations of the methods according to claim 7 or claim 13 of the claims, as well as using the last two of the above options yourself, you can get different (predetermined) in shape (relief) side surfaces of the profile of the formed grooves. This provides the claimed variants of the method of multi-pass formation of profile grooves with a significant advantage compared to known methods, for example, in the manufacture of metallographic forms for letterpress printing, in which the relief of the side surfaces of structures (printing, space elements) of the formed pattern has a significant effect on the retention of ink on the profile working surfaces of the finished metallographic form. In addition, the formation of a certain relief on the lateral surfaces of the grooves (i.e., structures formed in the functional layer of the metallographic shape of the pattern) can increase the degree of protection of printed products, since the likelihood of reproducing an identical relief with the same accuracy by any other means (for example, by manual engraving) is practically excluded.

 It should be noted that in order to obtain higher accuracy parameters of the grooves, it is necessary to use a special machine with an attachment unit for the cutter, characterized by increased rigidity, and special attachment units for magnetostrictive feed units, since The accuracy parameters of the grooves depend both on the characteristics of the magnetostrictive feed units themselves and on the dynamic characteristics of the machine used.

 A significant increase in the accuracy of manufacturing profile grooves is also possible due to the use for the manufacture of metallographic forms of special blanks from materials made by powder metallurgy using a special patented technology.

Thus, when using the claimed variants of the multi-pass method for cutting profile grooves, the following types of grooves and their profiles can be obtained:
- straight grooves of constant depth;
- straight grooves with variable depth;
- families (groups) of straight grooves;
- intersecting families of straight grooves;
- circular grooves of constant depth;
- circular grooves with variable depth;
- a family of circular grooves of different diameters (radius up to 0.5 mm);
- intersecting families of circular grooves of the same size;
- intersecting families of circular grooves of different sizes;
- sinusoidal grooves;
- sinusoidal groove family;
- intersecting families of sinusoidal grooves;
- sections of the curves of the second order with a change in the angle of the tangent at any point in the section of not more than ± 15 degrees;
- families of sections of curves of the second order;
- intersecting families of second-order curves.

 An example of a specific implementation.

The practical implementation of the method of multi-pass cutting of profile grooves was carried out on a pilot plant (mounted in a thermoconstant room based on equipment and components known from the prior art) by the totality of operations reflected in paragraph 1 and paragraph 13 of the claims, as an example of the formation of a family of ten rectilinear trapezoidal grooves with the following technologically defined geometric parameters:
- the width of the grooves in the upper section is 50 μm;
- the depth of the grooves is 50 μm;
- the length of the grooves is 110 mm;
- cutting depth - 10 microns;
- deviation from a given shape - ± 3 microns;
- deviation from a given width - ± 4 microns;
- deviation from the set depth - ± 5 microns;
- the deviation of the profile elements (side surfaces / walls /, bottom, ribs) grooves from flatness and straightness - ± 4 microns.

For grooving, a cutter was used with an angle of inclination of the cutting edges equal to 15 ^o , and a workpiece with dimensions of 110 x 45 x 5 mm from heat-treated aluminum alloy brand D16.

The pilot installation included the following nodes:
- dividing machine MS-40, the minimum step (resolution) of movement - 5 microns;
- magnetostrictive nodes for moving (feeding) the MN-1 cutter with a minimum step (resolution) of movement: with manual control - 0.004 μm, with computer control - 0.00001 μm;
- Micron-2 displacement meters with displacement ranges of ± 20 μm, ± 200 μm, ± 2000 μm, resolution 0.01 μm, 0.1 μm, 1 μm, respectively, and a measurement error of less than 0.5%.

 Straight grooves were formed by repeatedly moving the workpiece relative to the tool by moving the support (in which the workpiece was fixed) along the guides of the dividing machine. In this case, the critical parameter was the rigidity of the attachment block of the cutting tool, which determines the magnitude of uncontrolled deviations of the cutter, which are random in nature. The adjusting movement of the cutter to the width and depth of the groove was carried out by magnetostrictive feed units manually. The magnetostrictive feeding units MN-1 during the practical implementation of the above patented method of multi-pass cutting of profile grooves made it possible to provide installation movements of the cutting tool along the depth and width of the groove with a discreteness value D of the travel step equal to 0.1 μm and an absolute value of the positioning error T not more than 0.005 microns, which was limited by the resolution of the used displacement meters.

Measurements of geometric parameters formed in the functional layer of a sample of relief structures (in particular, profile grooves) showed that the actual deviations of these geometric parameters do not exceed the technologically regulated tolerance field for the manufacture of letterpress printing plates used in the manufacture of banknotes and other valuable papers requiring submicron resolution of the print pattern. Namely, the ranges of the corresponding size deviations were in the following limits:
- deviation from the given shape - ± 1 μm;
- deviation from a given width - ± 1 μm;
- deviation from the set depth - ± 1.5 microns;
- the deviation of the profile elements (side surfaces / walls /, bottom, ribs) of the grooves from flatness and straightness ± 1 μm.

 Thus, variants of the multi-pass method of cutting profile grooves can be used for precision cutting of individual profile grooves or families of grooves (mainly single-profile), for example, when mechanically forming a relief in the functional layers of metallographic forms (clichés) for high printing with submicron resolution of the formed structures (printed and white space elements) used in the production of banknotes and other securities (requiring a high degree of protection against counterfeiting), also in other technical fields, where necessary to obtain a predetermined pattern depth with submicron resolution structures in the functional layers of the articles.

Claims (16)

1. A method of multi-pass cutting of profile grooves, according to which a cutter with two lateral cutting edges is used, before each pass forming the first side surface of the groove profile, one of the side cutting edges of the cutter is located in the region of the corresponding first generatrix side surface of the groove profile, before each pass forming the second side surface of the groove profile, the other side cutting edge of the cutter is located in the area corresponding to it forming the second side surface of the profile ka skills, characterized in that for the implementation of the processing using a cutter with angles of inclination of the side cutting edges close to or equal to the corresponding angles of inclination of the forming side surfaces of the profile of the formed groove, the formation of at least part of the complete profile of the groove is carried out by sequential processing of at least two parallel to one another cutting zones, the profile width of which in any section corresponds to the profile width of the groove being formed in the same section, the height of each cutting zone, respectively There is a depth of cut in any of the cutter passages forming a section of the groove profile in this cutting zone, at least one of the at least first cutting zone after the first two cuts of the cutter directly forming the corresponding sections of the side surfaces of the groove profile in this zone additional cutter pass through which
remove the allowance formed in the central part of this cutting zone as a result of the implementation of the aforementioned first two passes of the cutter.  2. The method according to claim 1, characterized in that the cutter passes in each cutting zone is carried out with the same cutting depth.  3. The method according to claim 1 or 2, characterized in that for the processing using a cutter with a profile shape corresponding to the profile shape of the formed groove. 4. The method according to claim 1 or 2, characterized in that for the processing using a cutter with a profile width at a distance h from its top, not exceeding the maximum allowable minimum width B _{k min of} the groove profile at a depth of H _x = H _max - h, where H _max - the maximum depth of the profile of the formed grooves. 5. The method according to claim 1 or 2, characterized in that for processing use a cutter with two vertices, which are formed by the intersection of the side cutting edges with its transverse cutting edge, and the formation of at least part of the complete groove profile by sequential processing of at least two parallel cutting zones to one another is carried out until the formation of a groove profile on H _x depth at which the maximum allowable maximum width B _{k max} profile groove formed at least twice the width L _min profile cutter at its vertices. 6. The method according to claim 5, characterized in that for the processing using a cutter with a width L _min profile at its vertices, satisfying the following ratio:
L _min ≤ B _{k min} / 2,5,
where B _{k min} is the maximum permissible minimum width of the profile of the formed groove in the maximum upper section of this profile located at the outlet of the groove. 7. The method of multi-pass cutting of profile grooves, according to which a cutter with two lateral cutting edges is used, before each passage forming the first side surface of the groove profile, one of the side cutting edges of the cutter is located in the region of the corresponding forming first side surface of the nominal groove profile, in front of each the passage forming the second side surface of the groove profile, the other cutting edge of the cutter is located in the area corresponding to it forming the second side surface of the nom of the groove profile, the aforementioned arrangement of the lateral cutting edges of the cutter is provided by kinematic connection of the cutter with the actuator of the transverse feed means, characterized in that for the implementation of the processing, a cutter is used with angles of inclination of the side cutting edges close to or equal to the corresponding angles of inclination of the forming side surfaces of the nominal the profile of the formed groove, during processing of at least part of the profile of the formed groove, each side cutting edge of the cutter is positioned they are located in the zone of said generators at a distance Z in the direction of the groove axis relative to the generatrix of the lateral surface of the maximum permissible maximum groove profile corresponding to this cutting edge at the first pass forming this side surface of the groove, and at subsequent passes forming the same lateral surface of the groove, at a distance X in the direction of the groove axis relative to the generatrix of the side surface portion of the actual groove profile obtained in the previous pass, while the distances Z and X are satisfactory ryayut the following conditions:

where B _{k max} is the technologically maximum allowable maximum width of the groove profile at a given depth H _{x of the} groove;
B _{k min} is the technologically maximum permissible minimum width of the groove profile at the same predetermined depth H _{x of the} groove;

the absolute value of the error T of positioning the executive body of the transverse feed means;
N is the number of cutter passes required to form a complete profile of one of the side surfaces of the formed groove to the maximum depth H _{max of the} profile of this groove,
and as a means of transverse feed, a moving means is used with the discreteness value D of the moving step and the absolute value of the positioning error T of the actuator, each of which respectively simultaneously satisfies the following conditions:

8. The method according to p. 7, characterized in that all the cutter passes during the processing of the profile of the formed groove to a given depth H _{x are} carried out with the same cutting depth.  9. The method according to claim 7 or 8, characterized in that for the implementation of the processing using a cutter with a profile shape corresponding to the profile shape of the formed grooves. 10. The method according to claim 7 or 8, characterized in that for the processing using a cutter with a profile width at a distance h from its top, not exceeding the maximum permissible minimum width B _{k min of} the groove profile at a depth of H _x = H _max - h, where H _max - the maximum depth of the profile of the formed grooves. 11. The method according to claim 7 or 8, characterized in that for the processing using a cutter with two vertices, which are formed by the intersection of the side cutting edges of the cutter with its transverse cutting edge, and the formation of at least part of the complete groove profile by positioning the side cutting edges the cutter at distances Z and X relative to the corresponding generators is carried out until the profile of the groove is formed to a depth H _x , at the level of which the maximum permissible maximum width B _{k max of the} profile of the formed groove n e less than twice the width L _min profile of the cutter at its vertices. 12. The method according to claim 11, characterized in that for the processing using a cutter with a width L _min profile at its vertices, satisfying the following ratio:
L _min ≤ B _{k min} / 2,5,
where B _{k min} is the maximum permissible minimum width of the profile of the formed groove in the maximum upper section of this profile located at the outlet of the groove. 13. A method of multi-pass cutting of profile grooves, according to which a cutter with two lateral cutting edges is used, before each passage forming the first side surface of the groove profile, one of the side cutting edges of the cutter is located in the region of the corresponding generatrix of the first side surface of the nominal groove profile, in front of each the passage forming the second side surface of the groove profile, the other side cutting edge of the cutter is located in the area corresponding to it forming the second side surface the nominal groove profile, the aforementioned arrangement of the lateral cutting edges of the cutter is provided by kinematic connection of the cutter with the executive body of the lateral feed means, characterized in that for the processing using a cutter with angles of inclination of the side cutting edges close to or equal to the corresponding angles of inclination of the forming side surfaces nominal profile of the formed groove, during processing of at least part of the profile of the formed groove, each side cutting edge of the cutter placed in the zone of the said generators at a distance Z relative to the generatrix of the lateral surface of the nominal groove profile corresponding to this cutting edge at the first pass forming this lateral surface of the groove, and at subsequent passes forming the same lateral surface of the groove, at a distance X towards the axis of the groove relative to forming a portion of the side surface of the actual groove profile obtained in the previous pass, while the distances Z and X satisfy the following conditions:
Z ≤ (B _{k nom} - B _{k min} ) / 2N;

where B _{k nom} is the nominal width of the groove profile at a given depth H _x grooves;
B _{k min} - technologically maximum allowable maximum width of the groove profile at the same given depth H _{x of the} groove;

the absolute value of the error T of positioning the executive body of the transverse feed means;
N is the number of cutter passes required to form a complete profile of one of the side surfaces of the formed groove to the maximum depth H _{max of the} profile of this groove,
and as a means of transverse feed, a moving means is used with the discreteness value D of the moving step and the absolute value of the positioning error T of the actuator, each of which respectively simultaneously satisfies the following conditions:

14. The method according to item 13, wherein all the cutter passes during processing of the profile of the formed groove to a given depth H _{x is} carried out with the same cutting depth.  15. The method according to item 13 or 14, characterized in that for the processing using a cutter with a profile shape corresponding to the profile shape of the formed groove. 16. The method according to item 13 or 14, characterized in that for the processing using a cutter with a profile width at a distance h from its top, not exceeding the maximum permissible minimum width B _{k min of} the groove profile at a depth of H _x = H _max - h, where H _max - the maximum depth of the profile of the formed grooves. 17. The method according to item 13 or 14, characterized in that for processing use a cutter with two vertices, which are formed by the intersection of the side cutting edges of the cutter with its transverse cutting edge, and the formation of at least part of the complete groove profile by positioning the side cutting edges the cutter at distances Z and X relative to the corresponding generators is carried out until the profile of the groove is formed to a depth of H _x , at the level of which the maximum permissible maximum width B _{k max of the} profile of the formed groove not less than twice the width L _min profile of the cutter at its vertices. 18. The method according to 17, characterized in that for the processing using a cutter with a width L _min profile at its vertices, satisfying the following ratio:
L _min ≤ B _{k min} / 2,5,
where B _{k min} is the maximum permissible minimum width of the profile of the formed groove in the maximum upper section of this profile located at the outlet of the groove.

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