Machining Metal Removal Control

Abstract

A process is disclosed for controlling the length of chips or shavings on materials that is inherent to produce long undesired chips when machined. Based on the work piece configuration and surface area to machine a determined outlay and process application for a continuous scribe or arrangements of different scribe pattern or patterns for the part and or surface is selected to provide optimal chip control during the machining operation. Engineered Interruptions are applied to the work object prior to the machining operation to maximize optimal chip control. Controlling the depth of scribe of the laser is accomplished and managed through the interface of hardware, software and electronics.

We claim: 
     
         1 . A method of machining a work piece, comprising:
 emitting an energy beam onto a to piece to form a first cut in a spiral orientation along the work piece and having a defined space between adjacent spinal sections of the first cut;   measuring a real-time cutting depth of the energy beam;   generating a feedback signal representing the real-time cuffing depth; and   making a second cut on the work piece with a cutting tool, the second out removing material from the work piece, the second cut being adjacent to where the first cut in the surface of the work piece was made by the energy beam, controlling the depth of the first cut made by the energy earn by adjusting, the position of the energy beam with respect to the work piece or adjusting the power supplied to the energy beam in response to the feedback signal, the depth of the first cut being from about 40% to about 60% of the depth of the second cut that remove material from the work piece, creating interruptions in the work piece with the first cut, the interruptions causing the material removed from the work piece by the cutting tool to break into pieces of a desired length, size of the defined space determining the desired length of the pieces.   
     
     
         2 . The method of  claim 1  in which adjusting the depth of the groove is accomplished by changing the speed at which the energy beam or the work piece moves. 
     
     
         3 . The method of  claim 1  in which measuring the cutting depth is accomplished by measuring the depth with a camera. 
     
     
         4 . The method of  claim 3  in which the energy beam is emitted in a pulsed manner. 
     
     
         5 . The method of  claim 4  in which measuring the cutting depth is accomplished between pulses the energy beam. 
     
     
         6 . The method of  claim 1  in which the first cut is disposed at an angle with respect to the direction at which the material is removed from the work piece. 
     
     
         7 . The method of  claim 6  in which chips are formed when the materiel removed from the work piece comes into contact with the first cut. 
     
     
         8 . The method of  claim 4  in which the pulsed energy beam creates a series of holes that form the first cut. 
     
     
         9 . The method of  claim 8  in which the hole have a diameter from about 0.002 of an inch to about 15 of an inch. 
     
     
         10 . The method of  claim 1  in which the first cut has a depth from about 25% to about 75% of the depth of the material removed adjacent to said groove. 
     
     
         11 . A method of machining a work piece comprising:
 emitting an energy beam onto a work piece to create a heat effected zone and harden an area on the work piece;   measuring real time the extent of the heat effected zone on the area of the work piece;   generating feedback signal representing the extent of the heat effected zone;   adjusting the energy beam in response to the feedback signal to control the extent of the heat effected zone;   removing a portion of material from the work piece adjacent the area; and   promoting the formation of chips when the material being removed from the work piece encounters the heat effected zone.