Boring machine side milling head accessory capable of being adjusted in multiple angles and method of boring machine side milling head accessory

Abstract

The invention relates to the technical field of boring machine machining auxiliary equipment, and discloses a multi-angle adjustable boring machine side milling head accessory and a method thereof.The multi-angle adjustable boring machine side milling head accessory comprises a connecting base, a middle body, a gear transmission assembly, a side milling head main shaft, a main shaft base, a bearing set, a lining and a cutterhead; the connecting base is fixedly connected with the boring machine spindle through the connecting flange, an annular positioning groove is formed in the end, away from the boring machine spindle, of the connecting base, the inner diameter of the annular positioning groove ranges from 80 mm to 100 mm, and the depth of the annular positioning groove ranges from 15 mm to 20 mm. The end, close to the connecting base, of the middle body is provided with a boss matched with the annular positioning groove, 8-12 positioning holes are evenly distributed in the periphery of the boss, the diameter of each positioning hole ranges from 8 mm to 12 mm, and two symmetrically-distributed pin holes are formed in the corresponding positions of the connecting base. Two pins with diameters matched with those of the positioning holes penetrate through the pin holes and the positioning holes to realize detachable positioning of the connecting seat and the middle body; milling in the horizontal left-right direction or the vertical up-down direction perpendicular to the boring machine main shaft is achieved, and the machining efficiency, the form and location tolerance precision and the surface roughness quality of the deep cavity type workpiece are improved.

Description

Technical Field

[0001] This invention relates to the field of boring machine machining auxiliary equipment, specifically to a boring machine side milling head accessory with multi-angle adjustment and its method. Background Technology

[0002] Manufacturing is the core pillar of the real economy, and "cost reduction and efficiency improvement" is a key demand for the sustainable development of manufacturing enterprises. In the field of machining, there are a large number of workpieces that require machining of internal square grooves and left and right side steps with a depth of more than 500mm. These workpieces require a surface roughness of Ra3.2 and must ensure the form and position tolerances of each machined surface.

[0003] In existing machining technologies, conventional gantry milling machines or boring machines are structurally limited and cannot reach deep into the cavities of workpieces to complete machining of designated areas. While wire EDM can handle some deep cavity machining scenarios, it has significant drawbacks: low machining efficiency, making it difficult to meet mass production needs, and poor surface roughness of the machined workpiece, failing to meet the Ra3.2 accuracy requirement. Furthermore, for workpieces requiring multi-face machining, existing technologies often require multiple clamping and positioning operations, further reducing machining efficiency and easily affecting the consistency of form and position tolerances across different surfaces due to clamping errors. Therefore, there is an urgent need for a boring machine machining accessory and design method that can adapt to deep cavity workpiece machining while balancing efficiency and accuracy. Summary of the Invention

[0004] The present invention aims to provide a multi-angle adjustable side milling head attachment for boring machines and its method, in order to solve the technical problems of existing gantry milling and boring machines being unable to process square grooves and internal steps in workpieces with a depth of more than 500mm, and the low efficiency and surface roughness of wire EDM processing (difficult to meet Ra3.2 requirements).

[0005] To solve the above problems, the present invention adopts the following technical solution: Option 1: A multi-angle adjustable side milling head attachment for a boring machine, comprising a connecting seat, an intermediate body, a gear transmission assembly, a side milling head spindle, a spindle seat, a bearing assembly, a bushing, and a cutter head; the connecting seat is fixedly connected to the boring machine spindle via a connecting flange, and the end of the connecting seat away from the boring machine spindle is provided with an annular positioning groove, the inner diameter of which is 80-100mm and the groove depth is 15-20mm; the intermediate body is provided with a boss that matches the annular positioning groove at the end near the connecting seat, and 8-12 positioning holes are evenly distributed around the outer circumference of the boss, the hole diameter being 8-12mm; the connecting seat is provided with two symmetrically distributed pin holes at corresponding positions, and the connecting seat and the intermediate body are detachably positioned by two pins with diameters matching the positioning holes passing through the pin holes and positioning holes; the gear transmission assembly includes mutually... Gear 1 and Gear 2 are meshing. Gear 1 is fixedly sleeved at the end of the boring machine spindle, and Gear 2 is fixedly sleeved at one end of the side milling head spindle. The modules of both gear 1 and gear 2 are 2-4, and the transmission ratio is 1:1. The diameter D of the gear shaft satisfies 1.8×m≤D≤2.5×m, where m is the gear module. The side milling head spindle is rotatably mounted in the spindle seat through a bearing assembly. The spindle seat is fixedly connected to the end of the intermediate body away from the connecting seat. The end of the side milling head spindle away from Gear 2 is detachably connected to the cutter head. The cutter head has a diameter of 60-100mm and 4-6 cutter head mounting slots are evenly distributed on the cutter head. By changing the pins in different positioning hole assembly positions, the angle adjustment of the side milling head spindle relative to the boring machine spindle in four fixed directions—horizontal left, horizontal right, vertical up, and vertical down—can be achieved.

[0006] Beneficial effects: By clearly defining the core transmission structure and angle adjustment function, multi-directional machining of deep-cavity workpieces is achieved, overcoming the limitations of conventional equipment. By specifying the key parameters of the connecting seat, intermediate body, and gears through specific dimensions, the specific methods and directions of angle adjustment are clarified, ensuring structural adaptability and assembly accuracy. This precisely covers the core structural design for deep-cavity machining, ensuring stable power transmission and accurate angle adjustment.

[0007] Furthermore, the bearing assembly includes bearing one, bearing two, and bearing three. Bearing one is installed in the bearing mounting hole inside the connecting seat, and bearing two and bearing three are respectively installed in the bearing mounting holes at both ends of the main shaft seat. Bearing one, bearing two, and bearing three are all deep groove ball bearings, model 6206-2RS. The bushing is sleeved on the outside of the gear shaft. The inner diameter of the bushing is 0.02-0.05mm larger than the diameter of the gear shaft, and the bushing length is 30-50mm.

[0008] Beneficial effects: Clearly defines the bearing model and bushing size matching parameters, improves the stability of gear transmission and side milling head spindle rotation, reduces radial runout, ensures machining accuracy, and extends the service life of accessories.

[0009] Furthermore, the connection length L between the connecting seat and the intermediate body is greater than or equal to L1 + d1 / 2, where L1 is the axial length of the intermediate body boss, which is 20-30mm; d1 is the pin diameter, the fitting clearance between the pin and the positioning hole and the pin hole is 0.005-0.01mm, and the angular positioning error does not exceed 0.02mm.

[0010] Beneficial effects: By defining specific length relationships and fitting clearances, the connection stability and angular positioning accuracy between the connector and the intermediate body are further improved, ensuring the consistency of form and position tolerances during multi-directional machining.

[0011] Furthermore, it also includes a dust cover, which is detachably installed on the end of the connector away from the intermediate body by bolts. The dust cover is made of 304 stainless steel with a thickness of 3-5mm. The inner side of the dust cover is provided with an annular sealing groove, and a rubber sealing ring is installed in the sealing groove.

[0012] Beneficial effects: The dust cover and sealing ring design effectively prevent machining debris and dust from entering the gear transmission area, protecting gears and bearings, reducing maintenance frequency, and ensuring long-term stable operation of accessories.

[0013] Furthermore, the cutter head is made of cemented carbide, and the cutting edge angle of the cutter head is 55°-60°. The cutter head and the side milling head spindle are positioned by an end face key and locked in place by bolts. The radial runout of the cutter head is no more than 0.01mm.

[0014] Beneficial effects: By clearly defining the tool tip material, cutting angle, and tool disc mounting method, the cutting force and surface quality are guaranteed, and the surface roughness can be stably achieved to Ra3.2 or higher, making it suitable for the high-precision machining requirements of deep cavity workpieces.

[0015] Option 2: A design method for a multi-angle adjustable boring machine side milling head attachment, comprising the following steps: S1: Design the connecting seat structure. The connecting seat is a cylindrical structure with an outer diameter of 120-150mm and a length of 80-100mm. One end is provided with a flange connection surface that is compatible with the connecting flange. The flange connection surface has 6-8 evenly distributed bolt holes with a bolt hole diameter of 12-16mm. The other end is provided with an annular positioning groove with an inner diameter of 80-100mm and a groove depth of 15-20mm. Two pin holes are symmetrically arranged on both sides of the annular positioning groove. The pin hole diameter is 0.005-0.01mm larger than the pin diameter. S2: Design an intermediate body structure with an overall length of 100-120mm. One end is equipped with a boss that matches the annular positioning groove of the connecting seat. The outer diameter of the boss is 0.01-0.02mm smaller than the inner diameter of the annular positioning groove. 8-12 positioning holes are evenly distributed around the outer circumference of the boss. The diameter of the positioning holes is 8-12mm, and the central angle between adjacent positioning holes is 30°-45°. The other end of the intermediate body is equipped with a connecting flange surface that matches the spindle seat. S3: Design the parameters of the gear transmission assembly. Gear 1 and Gear 2 are spur gears with a module of 2-4, a number of teeth of 20-30, a tooth addendum coefficient of 1, a clearance coefficient of 0.25, and a gear shaft diameter D that satisfies 1.8×m≤D≤2.5×m, where m is the gear module. The gear shaft length is 60-80mm. S4: Design the connection structure between the side milling head spindle and the cutter head. The side milling head spindle has a diameter of 30-40mm and a length of 150-200mm. One end is equipped with a keyway that matches the gear 2. The keyway width is 8-12mm and the depth is 4-6mm. The other end is equipped with an end face key that matches the cutter head. The cutter head has a diameter of 60-100mm and 4-6 cutter head mounting slots are evenly distributed. S5: Assembly and debugging. Install the bearing assembly and gear transmission components in the connecting seat and spindle seat in sequence. Use pins to position and assemble the connecting seat and intermediate body. Adjust the gear meshing clearance to 0.1-0.2mm. Check that the radial runout of the side milling head spindle is no more than 0.01mm and the angular positioning error is no more than 0.02mm. Ensure that the attachment can achieve stable milling in four directions: horizontal left, horizontal right, vertical up, and vertical down.

[0016] Beneficial effects: By designing in a step-by-step, detailed manner, the specific dimensions, structural parameters, and assembly requirements of each component are clearly defined, ensuring the feasibility and consistency of the accessory design, avoiding machining errors caused by ambiguous parameters, and ensuring that the accessories can stably achieve high-precision machining of deep cavities from multiple angles.

[0017] Furthermore, in step S1, an annular lubrication groove is provided on the inner side of the annular positioning groove of the connecting seat. The width of the lubrication groove is 5-8mm and the depth is 3-5mm. Two symmetrically distributed oil injection holes are provided in the lubrication groove. The diameter of the oil injection holes is 4-6mm, and a threaded plug is provided at the outer end of the oil injection holes.

[0018] Beneficial effects: The design of the lubrication groove and oil injection hole facilitates the lubrication of the mating surfaces of the connecting seat and the intermediate body, as well as the gear transmission area, reducing wear and improving the smoothness of angle adjustment and the service life of components.

[0019] Furthermore, in step S3, the surface roughness of gear one and gear two is Ra0.8-Ra1.6, the gear material is 40CrNiMoA, and the hardness reaches HRC28-32 after quenching and tempering treatment. The hardness of the tooth surface reaches HRC58-62 after carburizing and quenching treatment.

[0020] Beneficial effects: It clarifies the requirements for gear material, heat treatment process and surface roughness, improves gear strength, wear resistance and transmission accuracy, ensures the stability and reliability of power transmission, and adapts to long-term high-frequency processing needs.

[0021] Furthermore, in step S4, the width of the tool head mounting groove is 0.01-0.02mm larger than the thickness of the tool head, the groove depth is 15-20mm, the tool head is locked and fixed by an internal hex bolt, the bolt type is M6-M8, and the cutting edge radius of the tool head cutting edge is 0.1-0.2mm.

[0022] Beneficial effects: By matching the dimensions of the tool head mounting slot with the cutting edge parameters, the stability of the tool head installation and the sharpness of the cutting are ensured, cutting resistance is reduced, the surface quality of the machined surface is improved, and defects such as burrs and chipping are avoided.

[0023] Furthermore, in step S5, after assembly, a load test is performed. The test load is 5-10kN. After running continuously for 24 hours, the temperature of the gear meshing area does not exceed 60℃, the radial runout of the side milling head spindle does not exceed 0.005mm, and the angular positioning error does not change significantly.

[0024] Beneficial effects: By establishing clear load test parameters and acceptance criteria, the stability and durability of accessories in actual processing scenarios are ensured, the reliability of the design scheme is verified, and the decrease in accuracy or failure due to long-term operation is avoided.

[0025] The advantages of this invention are: 1. Breaking through processing limitations, it can realize the processing of square grooves and internal steps in workpieces with a depth of more than 500mm, solving the problem of deep cavity processing that existing equipment cannot reach.

[0026] 2. Enables multi-face machining with a single clamping, and completes milling of each face by adjusting the angle, greatly improving machining efficiency while avoiding geometric tolerance errors caused by multiple clamping.

[0027] 3. Excellent machining accuracy: pin positioning ensures precise angle adjustment, and gear transmission ensures stable power transmission, resulting in a surface roughness of Ra3.2, meeting high precision requirements.

[0028] 4. The structure is reasonably designed and easy to assemble. The inclusion of dust covers, bearings and other components enhances the durability and ease of maintenance of the accessories. Attached Figure Description

[0029] Figure 1 This is an assembly diagram of the boring machine side milling head accessory according to an embodiment of the present invention.

[0030] Figure 2 This is a schematic diagram of the dust cover structure according to an embodiment of the present invention.

[0031] Figure 3 This is a schematic diagram of the bearing housing structure according to an embodiment of the present invention.

[0032] Figure 4 This is a schematic diagram of a gear structure according to an embodiment of the present invention.

[0033] Figure 5 This is a schematic diagram of the bushing structure according to an embodiment of the present invention.

[0034] Figure 6 This is a schematic diagram of the intermediate structure in an embodiment of the present invention.

[0035] Figure 7 This is a schematic diagram of the gear shaft structure according to an embodiment of the present invention.

[0036] Figure 8 This is a schematic diagram of the connector structure according to an embodiment of the present invention.

[0037] Figure 9 This is a schematic diagram of the connecting flange structure according to an embodiment of the present invention.

[0038] Figure 10 This is a schematic diagram of the side milling head spindle structure according to an embodiment of the present invention.

[0039] Figure 11 This is a schematic diagram of the spindle seat structure according to an embodiment of the present invention.

[0040] Figure 12 This is a schematic diagram of the cutter head structure according to an embodiment of the present invention.

[0041] The reference numerals in the accompanying drawings are as follows: 1-dust cover, 2-bearing one, 3-bearing housing, 4-gear one, 5-bulb two, 6-intermediate body, 7-gear shaft, 8-bearing two, 9-connecting seat, 10-connecting flange, 11-boring machine spindle, 12-side milling head spindle, 13-spindle housing, 14-bearing three, 15-cutting head, 16-cutting head. Detailed Implementation

[0042] The following detailed description illustrates the specific implementation method: The present invention relates to a multi-angle adjustable side milling head accessory for boring machines, comprising a connecting seat, an intermediate body, a gear transmission assembly, a side milling head spindle, a spindle seat, a bearing assembly, a bushing, and a cutter head. The connecting seat is fixedly connected to the boring machine spindle via a connecting flange. An annular positioning groove is provided at the end of the connecting seat away from the boring machine spindle, with an inner diameter of 80-100 mm and a groove depth of 15-20 mm. A boss adapted to the annular positioning groove is provided at the end of the intermediate body near the connecting seat. Eight to twelve positioning holes are evenly distributed around the outer circumference of the boss, with a hole diameter of 8-12 mm. Two symmetrically distributed pin holes are provided at corresponding positions on the connecting seat. Detachable positioning of the connecting seat and the intermediate body is achieved by two pins with diameters matching the positioning holes passing through the pin holes and positioning holes. The gear transmission assembly includes a meshing gear one and a gear two. Gear 1 is fixedly mounted on the end of the boring machine spindle, and gear 2 is fixedly mounted on one end of the side milling head spindle. The modules of gear 1 and gear 2 are both 2-4, and the transmission ratio is 1:1. The diameter D of the gear shaft satisfies 1.8×m≤D≤2.5×m (m is the gear module). The side milling head spindle is rotatably mounted in the spindle seat through a bearing assembly. The spindle seat is fixedly connected to the end of the intermediate body away from the connecting seat. The end of the side milling head spindle away from gear 2 is detachably connected to the cutter head. The cutter head has a diameter of 60-100mm and 4-6 cutter head mounting slots are evenly distributed on the cutter head. By changing the pins in the assembly positions of different positioning holes, the angle of the side milling head spindle relative to the boring machine spindle in four fixed directions—horizontal left, horizontal right, vertical up, and vertical down—can be adjusted, thereby realizing multi-angle milling machining perpendicular to the boring machine spindle.

[0043] The bearing assembly includes bearing one, bearing two, and bearing three. Bearing one is installed in the bearing mounting hole inside the connecting seat. Bearing two and bearing three are respectively installed in the bearing mounting holes at both ends of the main shaft seat. Bearing one, bearing two, and bearing three are all deep groove ball bearings, model 6206-2RS. The bushing is sleeved on the outside of the gear shaft. The inner diameter of the bushing is 0.02-0.05mm larger than the diameter of the gear shaft, and the bushing length is 30-50mm.

[0044] The connection length between the connecting seat and the intermediate body is L≥L1+d1 / 2 (where L1 is the axial length of the intermediate body boss, which is 20-30mm; d1 is the pin diameter), the fitting clearance between the pin and the positioning hole and the pin hole is 0.005-0.01mm, and the angular positioning error does not exceed 0.02mm.

[0045] In addition, the multi-angle adjustable boring machine side milling head accessory also includes a dust cover. The dust cover is detachably installed on the end of the connecting seat away from the intermediate body by bolts. The dust cover is made of 304 stainless steel with a thickness of 3-5mm. The inner side of the dust cover is provided with an annular sealing groove, and a rubber sealing ring is installed in the sealing groove.

[0046] The cutter head is made of cemented carbide, and the cutting edge angle of the cutter head is 55°-60°. The cutter head and the side milling head spindle are positioned by an end face key and locked in place by bolts. The radial runout of the cutter head is no more than 0.01mm.

[0047] The following methods and steps were used when designing the multi-angle adjustable boring machine side milling head attachment: S1: Design the connecting seat structure. The connecting seat is a cylindrical structure with an outer diameter of 120-150mm and a length of 80-100mm. One end is provided with a flange connection surface that is compatible with the connecting flange. The flange connection surface has 6-8 evenly distributed bolt holes with a bolt hole diameter of 12-16mm. The other end is provided with an annular positioning groove with an inner diameter of 80-100mm and a groove depth of 15-20mm. Two pin holes are symmetrically arranged on both sides of the annular positioning groove. The pin hole diameter is 0.005-0.01mm larger than the pin diameter. S2: Design an intermediate body structure with an overall length of 100-120mm. One end is equipped with a boss that matches the annular positioning groove of the connecting seat. The outer diameter of the boss is 0.01-0.02mm smaller than the inner diameter of the annular positioning groove. 8-12 positioning holes are evenly distributed around the outer circumference of the boss. The diameter of the positioning holes is 8-12mm, and the central angle between adjacent positioning holes is 30°-45°. The other end of the intermediate body is equipped with a connecting flange surface that matches the spindle seat. In step S1, an annular lubrication groove is provided inside the annular positioning groove of the connecting seat. The lubrication groove is 5-8mm wide and 3-5mm deep. Two symmetrically distributed oil injection holes are provided in the lubrication groove, with a diameter of 4-6mm. Threaded plugs are provided at the outer ends of the oil injection holes. The design of the lubrication groove and oil injection holes facilitates lubrication of the mating surfaces of the connecting seat and the intermediate body, as well as the gear transmission area, reducing wear and improving the smoothness of angle adjustment and the service life of the components.

[0048] S3: Design the parameters of the gear transmission assembly. Gear 1 and Gear 2 are spur gears with a module of 2-4, a number of teeth of 20-30, a tooth addendum coefficient of 1, a clearance coefficient of 0.25, and a gear shaft diameter D that satisfies 1.8×m≤D≤2.5×m (m is the gear module). The gear shaft length is 60-80mm. In step S3, the surface roughness of gear one and gear two is Ra0.8-Ra1.6. The gear material is 40CrNiMoA, which achieves a hardness of HRC28-32 after quenching and tempering, and a hardness of HRC58-62 after carburizing and quenching. Clearly defining the gear material, heat treatment process, and surface roughness requirements improves the gear's strength, wear resistance, and transmission accuracy, ensuring the stability and reliability of power transmission and adapting to long-term, high-frequency processing needs.

[0049] S4: Design the connection structure between the side milling head spindle and the cutter head. The side milling head spindle has a diameter of 30-40mm and a length of 150-200mm. One end is equipped with a keyway that matches the gear 2. The keyway width is 8-12mm and the depth is 4-6mm. The other end is equipped with an end face key that matches the cutter head. The cutter head has a diameter of 60-100mm and 4-6 cutter head mounting slots are evenly distributed. In step S4, the width of the tool head mounting groove is 0.01-0.02 mm larger than the thickness of the tool head, and the groove depth is 15-20 mm. The tool head is secured with an internal hex bolt of type M6-M8. The radius of curvature of the cutting edge of the tool head is 0.1-0.2 mm. Through the dimensional fit of the tool head mounting groove and the design of the cutting edge parameters, the stability of the tool head installation and the sharpness of the cutting are ensured, cutting resistance is reduced, the surface quality of the machined surface is improved, and defects such as burrs and chipping are avoided.

[0050] S5: Assembly and debugging. Install the bearing assembly and gear transmission components in the connecting seat and spindle seat in sequence. Use pins to position and assemble the connecting seat and intermediate body. Adjust the gear meshing clearance to 0.1-0.2mm. Check that the radial runout of the side milling head spindle is no more than 0.01mm and the angular positioning error is no more than 0.02mm. Ensure that the attachment can achieve stable milling in four directions: horizontal left, horizontal right, vertical up, and vertical down.

[0051] In step S5, after assembly, a load test is performed with a load of 5-10 kN. After 24 hours of continuous operation, the temperature in the gear meshing area should not exceed 60℃, the radial runout of the side milling head spindle should not exceed 0.005 mm, and the angular positioning error should not change significantly. By establishing clear load test parameters and acceptance criteria, the stability and durability of the accessories in actual machining scenarios are ensured, the reliability of the design scheme is verified, and accuracy degradation or malfunctions due to long-term operation are avoided.

[0052] The non-obviousness of this invention is reflected in three core dimensions: the particularity of the technical problem, the innovation of the technical means, and the unexpectedness of the technical effect. These three aspects are interconnected and progressive, and cannot be easily conceived or implemented by those skilled in the art based on existing technology, as detailed below: I. The Special Nature of the Technical Problem: Unconventional and Difficult to Solve The technical problem to be solved by this invention is not a common problem in conventional processing scenarios in this field, but rather a high-precision processing requirement for the internal square groove and left and right side steps of workpieces with a depth of more than 500mm, which must meet the surface roughness requirement of Ra3.2 and strict geometric tolerance requirements.

[0053] In the field of machining, conventional machining needs are mostly concentrated on shallow cavities, outer surfaces, or simple hole machining. Machining of deep cavities (over 500mm) with multiple steps inside is a niche demand in special scenarios. These workpieces are often used in special fields such as high-end equipment and heavy machinery. They are difficult to machine and have high technical requirements, and are not routine problems faced by those skilled in the art.

[0054] In the existing technology, conventional equipment such as gantry milling machines and boring machines are limited by their structure and cannot penetrate deep into the cavity. Wire cutting can barely cope with the problem, but its efficiency is extremely low and its accuracy is insufficient. Dedicated customized equipment is expensive and has poor versatility. As a result, this technical problem has long been in a state of "no effective solution". Its particularity and difficulty in solving further highlight the non-obviousness of the present invention - if special research and development is not carried out for this special scenario, it is difficult for those skilled in the art to actively focus on and start solving this problem.

[0055] II. Innovativeness of Technical Means: Unconventional Combination and Unique Logic To address the aforementioned specific technical problems, the combined technical approach of "gear conversion of power direction + angle adjustment of connecting seat and intermediate body + precise pin positioning" adopted in this invention is not a conventional technical choice in this field, nor can it be inspired by existing technologies.

[0056] Firstly, while gear transmission is a common technology in the mechanical field, its application in the power direction conversion of a boring machine's side milling head to achieve a power transmission path of "boring machine spindle rotation power → gear one → gear shaft → gear two → side milling head spindle" is specifically adapted for power transmission within deep cavities, rather than conventional direct drive or belt drive. This application scenario and transmission logic are unique. Existing technologies only disclose the size range of the gear shaft keyway and do not involve the application design of power direction conversion; another existing technology only mentions single-dimensional machining and is unrelated to the power transmission structure. Existing technologies do not provide any technical inspiration for using gear transmission for power conversion in deep cavity side milling.

[0057] Secondly, the angle adjustment structure between the connecting seat and the intermediate body, combined with pin positioning, achieves precise adjustment from 0-90° (positioning error not exceeding 0.02mm), an innovative design for multi-directional machining needs. Conventional boring machine accessories are mostly fixed structures without angle adjustment functionality. For those skilled in the art to achieve multi-directional machining, the conventional approach is to adjust the workpiece clamping angle or replace different accessories, rather than designing an adjustable structure within the accessory itself. This approach of "accessory angle adjustment replacing workpiece adjustment" breaks with traditional machining logic. Furthermore, the coordinated design of pin positioning and angle adjustment ensures both ease of adjustment (each adjustment takes no more than 3 minutes) and improved positioning accuracy, going beyond a simple structural overlay.

[0058] Finally, the unique combination logic of the above-mentioned technical means organically integrates the three core functions of power conversion, angle adjustment, and precise positioning, forming a complete technical chain of "power adaptation - adjustable direction - controllable precision," rather than an isolated accumulation of technologies. When faced with deep cavity machining problems, those skilled in the art often limit themselves to single-dimensional thinking such as "optimizing cutting tools" and "improving equipment stroke," and find it difficult to conceive of cross-dimensional combined technical solutions. The innovation of this combined approach further confirms the non-obviousness of this invention.

[0059] III. Unexpected Technological Results: Far Exceeding Expectations and Achieving Breakthroughs in Multiple Dimensions The technical effect of this invention is not a single-dimensional improvement, but a multi-dimensional breakthrough in processing range, efficiency, precision, and versatility, far exceeding the conventional expectations of those skilled in the art.

[0060] In terms of processing range, this invention successfully breaks through the limitation of conventional equipment in processing cavities deeper than 500mm, and can accurately process internal square grooves and steps. This effect cannot be achieved by conventional technical means. If those skilled in the art use existing technology, even with optimized parameters, it is difficult to achieve this processing depth, let alone guarantee the processing quality.

[0061] In terms of processing efficiency, multi-faceted processing can be completed in a single clamping, reducing processing time from 8 hours for wire EDM to 1.5 hours, an efficiency improvement of approximately 533%. This improvement far exceeds the expectations of conventional technology improvements. In conventional technologies, multi-faceted processing often requires multiple clamping operations, with efficiency improvements typically ranging from 10% to 50%. The efficiency breakthrough of this invention is significantly unexpected.

[0062] In terms of machining accuracy, the surface roughness reaches Ra2.8 (better than the preset Ra3.2), the form and position tolerances are controlled within 0.02mm, and the radial runout of the gear shaft is no more than 0.01mm. This level of accuracy is extremely rare in deep cavity machining scenarios. Those skilled in the art generally believe that deep cavity machining is difficult to guarantee high precision due to space constraints. However, this invention achieves a balance between "deep cavity machining" and "high precision" through the synergistic effect of technical means, exceeding conventional understanding.

[0063] In addition, the present invention has additional benefits such as strong versatility, convenient operation and controllable cost. It can be adapted to conventional boring machines without the need for customized special equipment, which solves the pain points of poor versatility and high cost of special equipment. This additional benefit further highlights the unexpectedness of the technical effect.

[0064] The specific implementation process of the example is as follows: I. Overall Structure and Component Parameters of the Annex (in conjunction with the appendix) Figure 1 -Appendix Figure 12 ) As attached Figure 1As shown, the multi-angle adjustable boring machine side milling head accessory of this embodiment includes a dust cover 1, bearing 1 2, bearing seat 3, gear 1 4, bushing 2 5, intermediate body 6, gear shaft 7, bearing 2 8, connecting seat 9, connecting flange 10, boring machine spindle 11, side milling head spindle 12, spindle seat 13, bearing 3 14, cutter head 15, and cutter head 16. The specific structure and parameters of each component are as follows: (a) Connector 9 (attached) Figure 8 ) The connecting seat 9 is a cylindrical structure with an outer diameter of 135mm and a length of 90mm. One end is provided with a flange connection surface that is compatible with the connecting flange 10. The flange connection surface has 7 bolt holes evenly distributed, with a bolt hole diameter of 14mm, which are used to fix the connecting flange 10 with bolts, thereby realizing the assembly with the boring machine spindle 11.

[0065] The end of the connecting seat 9 away from the boring machine spindle 11 is provided with an annular positioning groove. The annular positioning groove has an inner diameter of 90mm and a groove depth of 18mm. The inner side of the annular positioning groove is provided with an annular lubrication groove with a width of 6mm and a depth of 4mm. Two 5mm diameter oil injection holes are symmetrically arranged in the lubrication groove. Threaded plugs are installed at the outer ends of the oil injection holes to facilitate subsequent replenishment of grease.

[0066] Two pin holes are symmetrically provided on both sides of the annular positioning groove. The diameter of the pin hole is 0.008mm larger than the diameter of the pin, which is used to cooperate with the positioning hole of the intermediate body 6 to achieve precise positioning.

[0067] (II) Intermediate 6 (attached) Figure 6 ) The intermediate body 6 has an overall length of 110mm. One end is provided with a boss that matches the annular positioning groove of the connecting seat 9. The outer diameter of the boss is 0.015mm smaller than the inner diameter of the annular positioning groove to ensure coaxiality and fitting accuracy after assembly.

[0068] Ten positioning holes are evenly distributed around the outer circumference of the boss. The positioning hole diameter is 10mm, and the central angle between adjacent positioning holes is 36°. By selecting different positioning holes to cooperate with the pin holes of the connecting seat 9, the angle can be precisely switched. The other end of the intermediate body 6 is provided with a connecting flange surface that is adapted to the spindle seat 13, and the two are fixedly connected by bolts.

[0069] (III) Gear transmission assembly (attached) Figure 4 Appendix Figure 7 ) The gear transmission assembly includes meshing gear 4 and gear 2 (not shown separately, assembled at the end of the side milling head spindle 12), both of which are spur gears with a module of 3, number of teeth of 25, addendum coefficient of 1, clearance coefficient of 0.25, and transmission ratio of 1:1.

[0070] The gear shaft 7 has a diameter D = 2.2 × m = 6.6 mm (m is the gear module 3) and a length of 70 mm. A bushing 2 5 is fitted on the outer side of the gear shaft 7 (attached). Figure 5 The inner diameter of bushing 25 is 0.03mm larger than the diameter of gear shaft 7, and its length is 40mm. It serves as a guide and protector.

[0071] The surface roughness of gear 1 and gear 2 is Ra1.2. The material is 40CrNiMoA, and the hardness reaches HRC30 after quenching and tempering. The hardness reaches HRC60 after carburizing and quenching treatment, ensuring the strength and wear resistance of the gears.

[0072] (iv) Side milling head spindle 12 and cutter head 15 (attached) Figure 10 Appendix Figure 12 ) The side milling head spindle 12 has a diameter of 35mm and a length of 180mm. One end is provided with a keyway that matches the gear 2. The keyway is 10mm wide and 5mm deep. It is fixedly connected to the gear 2 by a flat key. The other end is provided with an end face key that matches the cutter head 15 to ensure the positioning accuracy of the cutter head 15.

[0073] The cutter head 15 has a diameter of 80mm and five evenly distributed cutter head mounting slots. The width of the cutter head mounting slot is 0.015mm larger than the thickness of the cutter head 16, and the slot depth is 18mm. The cutter head 16 is made of cemented carbide, with a cutting edge angle of 58° and a cutting edge radius of 0.15mm. It is locked and fixed to the cutter head 15 by M7 socket head cap screws.

[0074] (v) Bearing assembly and dust cover 1 (attached) Figure 2 Appendix Figure 3 ) The bearing assembly includes bearing 1 (2), bearing 2 (8), and bearing 3 (14), all of which are 6206-2RS deep groove ball bearings. Bearing 1 (2) is mounted in bearing housing 3 (attached). Figure 3 Bearing 2 (8) and bearing 3 (14) are respectively installed in the bearing mounting holes inside the spindle seat 13 (attached). Figure 12 The bearing mounting holes at both ends ensure the smooth rotation of the side milling head spindle 12 and the gear shaft 7.

[0075] Dust cover 1 (with) Figure 2 The material is 304 stainless steel with a thickness of 4mm. It can be detachably installed on the end of the connecting seat 9 away from the intermediate body 6 by bolts. The dust cover 1 has an annular sealing groove on the inside, and a rubber sealing ring is installed in the sealing groove to effectively prevent processing debris and dust from entering the internal transmission area.

[0076] II. Assembly Process (in conjunction with Appendix) Figure 1 (Assembly relationship) First, press the bearing 2 into the bearing housing 3, and then fix the bearing housing 3 to the corresponding mounting position of the connecting seat 9 with bolts to ensure that the outer ring of the bearing 2 fits tightly with the mounting hole.

[0077] The gear 4 is heat-shrinkly fixed to the end of the boring machine spindle 11, and the connecting seat 9 is fixedly connected to the boring machine spindle 11 through the connecting flange 10 to ensure that the axis of the gear 4 is coaxial with the boring machine spindle 11.

[0078] Bushing 2 5 is fitted onto the outside of gear shaft 7, and then gear shaft 7 is inserted into the inner ring of bearing 1 2, so that the gear at the end of gear shaft 7 meshes with gear 1 4, and the gear meshing clearance is adjusted to 0.15mm.

[0079] Press bearing 2 (8) and bearing 3 (14) into the bearing mounting holes at both ends of the spindle seat 13. Insert the side milling head spindle 12 into the inner rings of bearing 2 (8) and bearing 3 (14). Fix gear 2 to the end of the side milling head spindle 12 near the gear shaft 7 to ensure precise meshing between gear 2 and the gear at the end of the gear shaft 7.

[0080] The main spindle seat 13 and the connecting flange of the intermediate body 6 are fixedly connected by bolts. Then, the boss of the intermediate body 6 is embedded into the annular positioning groove of the connecting seat 9. The corresponding positioning hole is selected, and two pins are inserted through the pin hole of the connecting seat 9 and the positioning hole of the intermediate body 6 to achieve positioning and fixation of the two. At this time, the connection length between the connecting seat 9 and the intermediate body 6 is L=L1+d1 / 2 (L1 is the axial length of the intermediate body boss, 25mm, d1 is the pin diameter, 10mm, L=25+5=30mm). The fitting clearance between the pin and the positioning hole and the pin hole is 0.008mm.

[0081] Install the cutter head 16 into the mounting slot of the cutter head 15 and tighten it with hex bolts. Then, position the cutter head 15 with the end face key and tighten it with bolts to fix it to the end of the side milling head spindle 12. Finally, install the dust cover 1 on the end of the connecting seat 9 to complete the overall assembly.

[0082] III. Angle Adjustment and Working Process (a) Angle adjustment method In this embodiment, angle adjustment is achieved by the cooperation of a pin with different positioning holes, as detailed below: When the pin is inserted into the No. 1 and No. 6 positioning holes, the side milling head spindle 12 is in the horizontal left direction and perpendicular to the boring machine spindle 11; When inserting into the 3rd and 8th positioning holes, the side milling head spindle 12 is vertically upward and perpendicular to the boring machine spindle 11; When inserting the 5th and 10th positioning holes, the side milling head spindle 12 is in a horizontal right-hand direction, perpendicular to the boring machine spindle 11; When inserting the 7th and 2nd positioning holes, the side milling head spindle 12 is vertically downward and perpendicular to the boring machine spindle 11.

[0083] Each time the angle is adjusted, simply remove the pin, rotate the intermediate body 6 to the target angle, and reinsert the pin. The adjustment time is no more than 3 minutes, and the angle positioning error is no more than 0.02mm, meeting the requirements of high-precision machining.

[0084] (II) Work Process The workpiece to be machined (a square groove with a depth of 550mm and internal left and right side steps) is clamped on the boring machine table. The angle of the side milling head spindle 12 is adjusted according to the requirements of the machining surface. For example, when machining the left side step, the horizontal left direction is selected.

[0085] When the boring machine is started, the boring machine spindle 11 drives gear 4 to rotate. Gear 4 drives gear shaft 7 to rotate through meshing. Gear shaft 7 then drives gear 2 to rotate, which in turn drives the side milling head spindle 12, the cutter head 15, and the cutter head 16 to rotate synchronously, thereby realizing the transmission of cutting power.

[0086] The feed mechanism of the boring machine is controlled so that the side milling head attachment goes deep into the workpiece cavity along with the boring machine spindle 11. The cutter head 16 performs milling on the target machining surface. During the machining process, the lubricating grease in the lubrication groove reduces the wear of the parts, and the dust cover 1 prevents debris from entering.

[0087] Once one machining surface is completed, there is no need to disassemble the workpiece. Simply adjust the angle of the side milling head to sequentially complete the milling of other machining surfaces, achieving multi-face machining with a single clamping.

[0088] IV. Test Results of the Example After assembly, a load test was conducted. The test load was 8kN. After running continuously for 24 hours, the temperature of the gear meshing area was 55℃, which did not exceed 60℃. The radial runout of the side milling head spindle 12 was 0.007mm, and the change did not exceed 0.005mm. The angular positioning error did not change significantly and remained within 0.02mm.

[0089] In actual processing tests, the square groove and internal steps of a workpiece with a depth of 550mm were successfully processed. The surface roughness test result was Ra2.8, which is better than the preset requirement of Ra3.2. The parallelism tolerance of each processed surface was controlled within 0.018mm, and the form and position tolerances were excellent. The processing efficiency was improved by 533% compared with wire EDM, which fully verified the practicality and superiority of the invention.

[0090] The above descriptions are merely embodiments of the present invention, and common knowledge such as specific technical solutions and / or characteristics are not described in detail here. It should be noted that those skilled in the art can make various modifications and improvements without departing from the technical solutions of the present invention, and these should also be considered within the scope of protection of the present invention. These modifications and improvements will not affect the effectiveness of the implementation of the present invention or the practicality of the patent. The scope of protection claimed in this application should be determined by the content of its claims, and the specific embodiments described in the specification can be used to interpret the content of the claims.

Claims

1. A side milling head attachment for a boring machine that is adjustable at multiple angles, characterized in that, The assembly includes a connecting seat, an intermediate body, a gear transmission assembly, a side milling head spindle, a spindle seat, a bearing assembly, bushings, and a cutter head. The connecting seat is fixedly connected to the boring machine spindle via a connecting flange. The end of the connecting seat away from the boring machine spindle has an annular positioning groove with an inner diameter of 80-100 mm and a depth of 15-20 mm. The intermediate body has a boss at the end near the connecting seat that matches the annular positioning groove. 8-12 positioning holes are evenly distributed around the outer circumference of the boss, with a hole diameter of 8-12 mm. The connecting seat has two symmetrically distributed pin holes at corresponding positions. Two pins with diameters matching the positioning holes pass through the pin holes and positioning holes to achieve detachable positioning of the connecting seat and the intermediate body. The gear transmission assembly includes two meshing gears, Gear 1 and Gear 2. Gear 1 is fixedly sleeved at the end of the boring machine spindle, and gear 2 is fixedly sleeved at one end of the side milling head spindle. The modules of gear 1 and gear 2 are both 2-4, and the transmission ratio is 1:

1. The diameter D of the gear shaft satisfies 1.8×m≤D≤2.5×m, where m is the gear module. The side milling head spindle is rotatably mounted in the spindle seat through a bearing assembly. The spindle seat is fixedly connected to the end of the intermediate body away from the connecting seat. The end of the side milling head spindle away from gear 2 is detachably connected to the cutter head. The cutter head has a diameter of 60-100mm and 4-6 cutter head mounting slots are evenly distributed on the cutter head. By changing the pins in the assembly positions of different positioning holes, the angle adjustment of the side milling head spindle relative to the boring machine spindle in four fixed directions—horizontal left, horizontal right, vertical upward, and vertical downward—can be achieved.

2. The multi-angle adjustable boring machine side milling head accessory according to claim 1, characterized in that, The bearing assembly includes bearing one, bearing two, and bearing three. Bearing one is installed in the bearing mounting hole inside the connecting seat. Bearing two and bearing three are respectively installed in the bearing mounting holes at both ends of the main shaft seat. Bearing one, bearing two, and bearing three are all deep groove ball bearings, model 6206-2RS. The bushing is sleeved on the outside of the gear shaft. The inner diameter of the bushing is 0.02-0.05mm larger than the diameter of the gear shaft, and the bushing length is 30-50mm.

3. The multi-angle adjustable boring machine side milling head accessory according to claim 1, characterized in that, The connection length between the connecting seat and the intermediate body is L≥L1+d1 / 2, where L1 is the axial length of the intermediate body boss, which is 20-30mm; d1 is the pin diameter, the fitting clearance between the pin and the positioning hole and the pin hole is 0.005-0.01mm, and the angular positioning error does not exceed 0.02mm.

4. The multi-angle adjustable boring machine side milling head accessory according to claim 1, characterized in that, It also includes a dust cover, which is detachably installed on the end of the connector away from the middle body by bolts. The dust cover is made of 304 stainless steel with a thickness of 3-5mm. The inside of the dust cover is provided with an annular sealing groove, and a rubber sealing ring is installed in the sealing groove.

5. The multi-angle adjustable boring machine side milling head accessory according to claim 1, characterized in that, The cutter head is made of cemented carbide, and the cutting edge angle of the cutter head is 55°-60°. The cutter head and the side milling head spindle are positioned by an end face key and locked in place by bolts. The radial runout of the cutter head is no more than 0.01mm.

6. A design method for a multi-angle adjustable boring machine side milling head attachment, characterized in that, Includes the following steps: S1: Design the connecting seat structure. The connecting seat is a cylindrical structure with an outer diameter of 120-150mm and a length of 80-100mm. One end is provided with a flange connection surface that is compatible with the connecting flange. The flange connection surface has 6-8 evenly distributed bolt holes with a bolt hole diameter of 12-16mm. The other end is provided with an annular positioning groove with an inner diameter of 80-100mm and a groove depth of 15-20mm. Two pin holes are symmetrically arranged on both sides of the annular positioning groove. The pin hole diameter is 0.005-0.01mm larger than the pin diameter. S2: Design an intermediate body structure with an overall length of 100-120mm. One end is equipped with a boss that matches the annular positioning groove of the connecting seat. The outer diameter of the boss is 0.01-0.02mm smaller than the inner diameter of the annular positioning groove. 8-12 positioning holes are evenly distributed around the outer circumference of the boss. The diameter of the positioning holes is 8-12mm, and the central angle between adjacent positioning holes is 30°-45°. The other end of the intermediate body is equipped with a connecting flange surface that matches the spindle seat. S3: Design the parameters of the gear transmission assembly. Gear 1 and Gear 2 are spur gears with a module of 2-4, a number of teeth of 20-30, a tooth addendum coefficient of 1, a clearance coefficient of 0.25, and a gear shaft diameter D that satisfies 1.8×m≤D≤2.5×m, where m is the gear module. The gear shaft length is 60-80mm. S4: Design the connection structure between the side milling head spindle and the cutter head. The side milling head spindle has a diameter of 30-40mm and a length of 150-200mm. One end is equipped with a keyway that matches the gear 2. The keyway width is 8-12mm and the depth is 4-6mm. The other end is equipped with an end face key that matches the cutter head. The cutter head has a diameter of 60-100mm and 4-6 cutter head mounting slots are evenly distributed. S5: Assembly and debugging. Install the bearing assembly and gear transmission components in the connecting seat and spindle seat in sequence. Use pins to position and assemble the connecting seat and intermediate body. Adjust the gear meshing clearance to 0.1-0.2mm. Check that the radial runout of the side milling head spindle is no more than 0.01mm and the angular positioning error is no more than 0.02mm. Ensure that the attachment can achieve stable milling in four directions: horizontal left, horizontal right, vertical up, and vertical down.

7. The design method for a multi-angle adjustable boring machine side milling head accessory according to claim 6, characterized in that, In step S1, the inner side of the annular positioning groove of the connecting seat is provided with an annular lubrication groove. The lubrication groove is 5-8mm wide and 3-5mm deep. There are two symmetrically distributed oil injection holes in the lubrication groove. The diameter of the oil injection holes is 4-6mm. The outer end of the oil injection hole is provided with a threaded plug.

8. The design method for a multi-angle adjustable boring machine side milling head accessory according to claim 6, characterized in that, In step S3, the surface roughness of gear one and gear two is Ra0.8-Ra1.6, the gear material is 40CrNiMoA, and the hardness reaches HRC28-32 after quenching and tempering treatment. The hardness of the tooth surface reaches HRC58-62 after carburizing and quenching treatment.

9. The design method for a multi-angle adjustable boring machine side milling head accessory according to claim 6, characterized in that, In step S4, the width of the tool head mounting groove is 0.01-0.02mm greater than the thickness of the tool head, and the groove depth is 15-20mm. The tool head is locked and fixed by an internal hex bolt of type M6-M8. The radius of the cutting edge of the tool head is 0.1-0.2mm.

10. The design method for a multi-angle adjustable boring machine side milling head attachment according to claim 6, characterized in that, In step S5, after assembly, a load test is performed. The test load is 5-10kN. After running continuously for 24 hours, the temperature of the gear meshing area does not exceed 60℃, the radial runout of the side milling head spindle does not exceed 0.005mm, and the angular positioning error does not change significantly.

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