Foamed ceramic composite machine tool bed integrated with cooling channels

Abstract

The utility model provides a kind of foamed ceramic composite machine bed of integrated cooling runner, including foamed ceramic pedestal, reinforcing rib, workbench, the inside of foamed ceramic pedestal is equipped with the hole structure of net-like distribution, hole structure includes rib hole and runner hole, rib hole is used to fill reinforcing rib, runner hole constitutes cooling medium passage;Runner hole inner wall is equipped with sealing layer, runner hole is equipped with medium inlet and medium outlet on foamed ceramic pedestal side wall;Reinforcing rib is filled in the inner wall of rib hole, and is integrated with foamed ceramic pedestal solidification, form built-in reinforcing framework;Workbench is fixedly arranged on the upper surface of foamed ceramic pedestal, and workbench is integrally connected with reinforcing rib at the orifice of rib hole.This foamed ceramic composite machine bed of integrated cooling runner has active temperature control capability, and has the advantages of lightweight, strong vibration absorption and damping capacity, high structural strength, good dimensional stability.

Description

Technical Field

[0001] This utility model relates to the field of machine tool technology, specifically to a foamed ceramic composite machine tool bed with integrated cooling channels. Background Technology

[0002] The machine tool bed is the fundamental supporting component of a machine tool, and its performance directly affects machining accuracy and stability. There are three main types of common machine tool beds: First, cast iron beds, which have high compressive strength but are heavy, difficult to transport and install, and have poor damping performance, making them prone to vibration during high-speed machining. Second, natural granite beds, which have good vibration absorption and a low coefficient of thermal expansion, but have natural defects, are difficult and costly to manufacture, and large beds require splicing, resulting in poor overall integrity. Third, mineral casting beds, made of aggregate and resin binder, offer improved damping performance, but the resin curing shrinkage is large, resulting in insufficient dimensional stability. Furthermore, the mismatch in the coefficients of thermal expansion between the resin and aggregate can easily lead to micro-cracks over long-term use.

[0003] Furthermore, existing machine tool beds generally lack active thermal management capabilities. During prolonged high-speed machining, frictional heat and cutting heat generated by moving parts are gradually conducted to the machine bed, causing localized temperature rises and thermal deformation, which in turn affects machining accuracy. Although some high-end machine tools use external cooling systems, these systems are complex, occupy a large space, and their cooling effect is not uniform enough. Utility Model Content

[0004] To address the problems of existing machine tool beds, such as the difficulty in simultaneously achieving lightweight, high damping, and high strength, as well as the lack of active thermal management capabilities, this utility model provides a foamed ceramic composite machine tool bed with integrated cooling channels. It has active temperature control capabilities and also features lightweight design, strong vibration absorption and damping capabilities, high structural strength, and good dimensional stability.

[0005] To achieve the above objectives, this utility model provides the following technical solution: a foamed ceramic composite machine tool bed with integrated cooling channels, comprising: a foamed ceramic base, wherein the interior of the foamed ceramic base is provided with a mesh-like channel structure, the channel structure including rib holes and flow channel holes, the rib holes being used to fill reinforcing ribs, and the flow channel holes forming cooling medium channels; the inner wall of the flow channel holes is provided with a sealing layer, and the flow channel holes are provided with a medium inlet and a medium outlet on the side wall of the foamed ceramic base; reinforcing ribs, the reinforcing ribs being filled in the inner wall of the rib holes and solidified integrally with the foamed ceramic base to form an internal reinforcing skeleton; and a worktable, the worktable being fixed to the upper surface of the foamed ceramic base, and the worktable being connected integrally with the reinforcing ribs at the openings of the rib holes.

[0006] Furthermore, the channel structure includes multiple transverse slots spaced at intervals along the horizontal direction and multiple longitudinal slots spaced at intervals along the vertical direction. The transverse slots and longitudinal slots intersect and communicate with each other to form a three-dimensional mesh channel. Among them, the transverse slots located in the first layer below the workbench surface are flow channel holes, and the remaining transverse slots and all longitudinal slots are rib holes.

[0007] Furthermore, the diameter of the flow channel hole is 80-100mm, and the diameter of the rib hole is 100-120mm.

[0008] Furthermore, at the intersection of the reinforcing rib and the flow channel hole, a through hole is radially provided for the cooling medium to pass through.

[0009] Furthermore, the sealing layer is an epoxy resin coating, uniformly coated on the inner wall of the flow channel hole, with a thickness of 0.5-1.5mm, used to prevent the cooling medium from seeping into the interior of the foamed ceramic base.

[0010] Furthermore, metal pipe joints are pre-embedded at the medium inlet and medium outlet, and the metal pipe joints are integrated with the sealing layer of the inner wall of the flow channel hole.

[0011] Furthermore, the reinforcing ribs completely fill the rib holes, and the material of the reinforcing ribs penetrates into the micropores on the surface of the inner wall of the rib holes of the foamed ceramic base, forming a mechanically interlocking structure.

[0012] Furthermore, the workbench surface and the reinforcing rib form a T-shaped anchoring structure at the opening of the rib hole.

[0013] The bed of this foamed ceramic composite machine tool has the following beneficial effects:

[0014] 1. Strong active temperature control capability: The foamed ceramic base has pre-set flow channel holes, which can be circulated with coolant or constant temperature medium. This can actively remove the heat generated by the machine tool during operation, control the temperature of the bed to be uniform, fundamentally reduce thermal deformation, and ensure long-term machining accuracy.

[0015] 2. Lightweight: The density of the foamed ceramic base is only 0.5-0.7g / cm³, which greatly reduces the weight of the whole machine compared with the traditional cast iron bed, significantly reducing the difficulty of handling, installation and carrying upstairs. At the same time, it reduces the driving energy consumption of the moving parts of the machine tool and improves the response speed.

[0016] 3. Strong vibration absorption and damping capacity: The foamed ceramic base itself has porous vibration absorption characteristics, and the internal reinforcing ribs also have high damping performance. The worktable surface and the reinforcing ribs are made of the same material and have the same coefficient of thermal expansion, which can quickly absorb and consume the vibration energy generated during processing, making the machine tool run more smoothly and the processed parts have a higher surface finish and better dimensional accuracy.

[0017] 4. High structural strength: The flow channel holes and rib holes have clearly defined functions. The reinforcing ribs within the rib holes form a complete three-dimensional reinforced skeleton network. The worktable and the reinforcing ribs form a T-shaped anchoring structure at the hole openings, allowing the force to be directly transmitted from the worktable to the internal skeleton. The reinforcing rib material penetrates into the micropores of the base to form a mechanical interlock, ensuring a firm bond between the layers and preventing separation, greatly enhancing the bed's resistance to compression, bending, and torsion.

[0018] 5. Good dimensional stability: The active cooling channel can eliminate the main source of thermal deformation; the worktable and reinforcing ribs are made of the same material with the same coefficient of thermal expansion, so there will be no internal stress or deformation due to the difference in expansion when the temperature changes; the foamed ceramic base itself has a low coefficient of thermal expansion, ensuring that the entire bed can maintain dimensional stability under different temperature environments and working conditions. Attached Figure Description

[0019] Figure 1 This is a three-dimensional structural diagram of the foamed ceramic composite machine tool bed (without reinforcing ribs) with integrated cooling channels in this utility model.

[0020] Figure 2 This is a three-dimensional structural diagram of the foamed ceramic base (without reinforcing ribs) in this utility model.

[0021] Figure 3 This is a cross-sectional view of the foamed ceramic base (without reinforcing ribs) in this utility model.

[0022] Figure 4 This is a cross-sectional view of the foamed ceramic base (with reinforcing ribs) in this utility model.

[0023] Figure reference numerals: 1. Foamed ceramic base; 2. Hole structure; 21. Rib hole; 22. Flow channel hole; 3. Reinforcing rib; 31. Through hole; 4. Worktable surface; 5. Sealing layer; 6. Medium inlet; 7. Medium outlet; 8. Metal pipe joint. Detailed Implementation

[0024] The technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0025] Please see the appendix Figure 1-4 The present invention provides a foamed ceramic composite machine tool bed with integrated cooling channels, comprising:

[0026] A foamed ceramic base 1 has a mesh-like channel structure 2 inside. The channel structure 2 includes rib holes 21 and flow channel holes 22. The rib holes 21 are used to fill reinforcing ribs 3, and the flow channel holes 22 form cooling medium channels. The inner wall of the flow channel holes 22 is provided with a sealing layer 5. The flow channel holes 22 have a medium inlet 6 and a medium outlet 7 on the side wall of the foamed ceramic base 1.

[0027] Reinforcing rib 3 (see attached) Figure 3 and 4 The reinforcing ribs 3 fill the inner wall of the rib holes 21 and are solidified with the foamed ceramic base 1 to form an internal reinforcing skeleton;

[0028] The worktable 4 is fixed on the upper surface of the foamed ceramic base 1, and the worktable 4 and the reinforcing rib 3 are connected as one unit at the opening of the rib hole 21.

[0029] This utility model discloses a foamed ceramic composite machine tool bed with integrated cooling channels. The channel structure 2 is functionally partitioned, dividing the channels into two types: rib holes 21 and flow channel holes 22. Rib holes 21 are filled with reinforcing ribs 3 to form a reinforced skeleton, ensuring structural strength. Flow channel holes 22, however, are not filled with reinforcing ribs 3 but serve as cooling medium channels. A sealing layer 5 is provided on the inner wall to prevent cooling medium from seeping into the foamed ceramic base 1. Coolant or a constant-temperature medium can be introduced through the medium inlet 6 and medium outlet 7, achieving active temperature control of the machine bed, fundamentally reducing thermal deformation and further ensuring machining accuracy. The rib holes 21 and flow channel holes 22 have clearly defined functions, ensuring that structural strength and cooling function do not interfere with each other.

[0030] In this utility model, reference is made to the appendix. Figure 3 and 4 The channel structure 2 includes multiple horizontally spaced slots at equal intervals along the horizontal direction and multiple vertically spaced slots at equal intervals along the vertical direction. The horizontal and vertical slots intersect and connect with each other, forming a three-dimensional mesh channel. Among them, the horizontal slots in the first layer below the worktable 4 are flow channel holes 22, and the remaining horizontal slots and all the vertical slots are rib holes 21. Arranging the flow channel holes 22 in the first layer below the worktable 4 can most directly remove the heat conducted down from the worktable 4, resulting in the highest cooling efficiency. At the same time, only one layer of horizontal slots is used as a flow channel, while the remaining channels are still filled with reinforcing ribs 3, ensuring the integrity and strength of the skeleton network.

[0031] In this utility model, reference is made to the appendix. Figure 4The reinforcing rib 3 has a radially formed through hole 31 at its intersection with the flow channel hole 22, allowing the cooling medium to pass through. Since the transverse and longitudinal slots in the foamed ceramic base 1 form an intersecting and interconnected structure during sintering, when the longitudinal slots serve as rib holes 21 to fill the reinforcing rib 3, and the intersecting transverse slots (the transverse slots in the first layer below the worktable 4) serve as flow channel holes 22, it is necessary to ensure the flow channel holes 22 are unobstructed at the intersection. Therefore, before pouring the mineral composite material of the reinforcing rib 3 into the rib holes 21, a removable core is placed at the intersection of the rib holes 21 and the flow channel hole 22; after the mineral composite material of the reinforcing rib 3 is poured and cured, the core is removed, forming a radial through hole 31 at the intersection, ensuring the flow channel hole 22 remains unobstructed at the intersection. The core can be a wax mold, a soluble core, or a detachable metal mandrel, and its removal method can be heating and melting, water dissolution, or mechanical extraction, depending on the core type.

[0032] In this invention, the diameter of the flow channel hole 22 is 80-100mm, and the diameter of the rib hole 21 is 100-120mm. The diameter of the flow channel hole 22 facilitates the smooth flow of the cooling medium and improves the heat exchange efficiency; the diameter of the rib hole 21 ensures the structural strength after filling.

[0033] In this invention, the sealing layer 5 is an epoxy resin coating, uniformly coated on the inner wall of the flow channel hole 22, with a thickness of 0.5-1.5 mm (see attached diagram). Figure 3 and 4 The thickness ratio has been enlarged to better illustrate the state of the epoxy resin coating (this does not represent the actual thickness of the epoxy resin coating within the flow channel pores). This coating is used to prevent cooling medium from seeping into the foamed ceramic substrate 1. The foamed ceramic substrate 1 itself has a microporous structure; if cooling medium seeps in, it will not only reduce cooling efficiency but may also cause material damage due to liquid expansion and contraction. The epoxy resin coating effectively seals the micropores on the inner wall of the flow channel, forming a dense, impermeable layer. Furthermore, the epoxy resin bonds well to the foamed ceramic substrate 1, making it resistant to peeling off over long-term use.

[0034] In this utility model, reference is made to the appendix. Figure 2-4 Metal pipe joints 8 are pre-embedded at the medium inlet 6 and the medium outlet 7. The metal pipe joints 8 are integrally connected to the sealing layer 5 on the inner wall of the flow channel hole 22. The pre-embedded metal pipe joints 8 can be easily connected to the external cooling system and are integrally connected to the sealing layer 5 to ensure that there is no leakage at the interface.

[0035] In this utility model, reference is made to the appendix. Figure 4The reinforcing ribs 3 completely fill the rib holes 21, and the material of the reinforcing ribs 3 penetrates into the micropores on the inner surface of the rib holes 21 of the foamed ceramic base 1, forming a mechanical interlocking structure. The reinforcing ribs 3 completely fill the rib holes 21 without leaving gaps, ensuring a continuous and complete internal framework. Simultaneously, the material of the reinforcing ribs 3 penetrates into the micropores on the surface of the rib walls of the foamed ceramic base 1, and after curing, forms countless tiny resin nails that firmly lock the reinforcing ribs 3 and the foamed ceramic base 1 together. This mechanical interlocking structure prevents the two materials from separating, resulting in excellent overall integrity of the bed frame and preventing the reinforcing ribs 3 from loosening or falling off even after long-term use.

[0036] In this invention, the foamed ceramic base 1 is a one-piece sintered structure with a density of 0.5-0.7 g / cm³. The one-piece sintering of the foamed ceramic base 1 ensures good integrity and eliminates seams, unlike natural granite which requires multiple pieces and creates weak points. The density control between 0.5-0.7 g / cm³ makes the entire machine bed very lightweight, reducing the effort required for transportation and installation, and also lowering energy consumption during machine tool movement.

[0037] In this invention, the thickness of the worktable surface 4 is 100-150mm. This thickness ensures that the worktable surface 4 has sufficient strength and rigidity to directly support heavy workpieces without deformation, while also providing sufficient machining allowance to facilitate subsequent precision grinding to achieve high flatness requirements. Simultaneously, this thickness also facilitates the full connection between the worktable surface 4 and the reinforcing ribs 3 at the openings of the rib holes 21, forming a robust overall structure.

[0038] In this invention, the worktable surface 4 and the reinforcing rib 3 form a T-shaped anchoring structure at the opening of the rib hole 21. The reinforcing rib 3 is a vertical column that fills the rib hole 21 from bottom to top, and the worktable surface 4 is a single flat plate covering it. The two meet at the opening, forming a T-shaped connection. This structure allows the pressure on the worktable surface 4 to be directly transmitted to the internal reinforcing rib 3 through the T-shaped anchoring point. At the same time, the worktable surface 4 is firmly nailed to the base, preventing warping or peeling, resulting in a very strong and reliable connection.

[0039] It should be noted that the appendix Figure 1-4 This illustration only shows a foamed ceramic base 1 with two layers of transverse pores. Depending on actual needs, more layers of transverse pores can be added to form a more complex pore structure. These variations all fall within the protection scope of this utility model.

[0040] In this invention, the reinforcing rib 3 is composed of 98±0.5% mineral composite material and 2±0.5% basalt wire. The mineral composite material constitutes the majority, ensuring the density and bonding strength after filling; while the small amount of basalt wire acts like short reinforcing bars in concrete, effectively holding the surrounding material together, preventing cracking, and providing a toughening effect. The mineral composite material comprises the following components by weight: 65±2 parts basalt, 20±2 parts basalt powder, 1.5-2 parts fiber mixture, 7±1 parts modified epoxy resin, 3±0.5 parts curing agent, 5±1 parts functional filler, 0.07±0.01 parts polydimethylsiloxane defoamer, antimony additive (added at 0.25%±0.02% of the total weight of modified epoxy resin and curing agent in the mineral composite material), and bismuth additive (added at 0.25%±0.02% of the total weight of modified epoxy resin and curing agent in the mineral composite material). The mineral composite material uses specially modified epoxy resin and adds two special trace additives, antimony and bismuth. The main purpose of this is to make the reinforcing rib 3 less prone to thermal expansion and contraction when the weather changes, and to ensure that its dimensions are very stable. With the reinforcing rib 3 having stable dimensions, it can firmly hold the foamed ceramic base 1, and the entire bed will not deform due to temperature changes, thus ensuring the machining accuracy of the machine tool during long-term use.

[0041] The fiber mixture is composed of metal fibers and mineral fibers. Preferably, the mass ratio of metal fibers to mineral fibers is (40-60%):(40-60%). Metal fibers have high strength and good toughness, while mineral fibers bond firmly to resin and are corrosion-resistant. The combination of the two can leverage their respective advantages, giving the reinforcing rib 3 both rigidity and toughness, making it less prone to fatigue cracks under long-term vibration.

[0042] The modified epoxy resin is prepared in the following steps:

[0043] Step 1: Preheat E-51 epoxy resin, polypropylene glycol diglycidyl ether, and octyl glycidyl ether to 40-50℃ to reduce viscosity and facilitate mixing. Polypropylene glycol diglycidyl ether acts as a flexible modifier, introducing flexible segments to reduce the brittleness of the cured resin, improve impact resistance, and reduce internal stress. Octyl glycidyl ether acts as an active diluent to reduce viscosity, facilitating mixing and casting with high filler content. Step 2: Add 690g of preheated E-51 epoxy resin, 247g of polypropylene glycol diglycidyl ether, and 124g of octyl glycidyl ether to the reactor in sequence. Start stirring at 100-150 rpm for 5-8 minutes to ensure thorough mixing of the three main materials. Step 3: While maintaining stirring, add BHT antioxidant 1... Add 3g of KH-560 coupling agent and 1g of polydimethylsiloxane defoamer, and continue stirring for 3-5 minutes to ensure complete dissolution and dispersion of the additives. KH-560 coupling agent forms chemical bonds between the modified epoxy resin and inorganic fillers (aggregates, powders), improving interfacial bonding strength and enhancing the mechanical properties of the composite material. BHT antioxidant inhibits the thermal oxidative aging of the modified epoxy resin during curing and use, extending the service life of the component. Polydimethylsiloxane defoamer can reduce pore defects and improve density and surface quality. Step 4: Add 0.2g of triethylamine catalyst, continue stirring for 2-3 minutes, mix evenly, and allow to stand for degassing under vacuum conditions (vacuum degree ≤ -0.095MPa) for 10-15 minutes to obtain the modified epoxy resin, which is then sealed and stored for later use.

[0044] The curing agent is composed of 30-70% polyetheramine and 30-70% alicyclic amine. Polyetheramine increases flexibility, while alicyclic amine increases rigidity. When flexibility is required, a curing agent of 70% polyetheramine and 30% alicyclic amine is preferred; when rigidity is required, a curing agent of 30% polyetheramine and 70% alicyclic amine is preferred.

[0045] The functional filler includes at least one of alumina powder and silica powder. Alumina powder and silica powder, as functional fillers, can further improve the wear resistance, heat resistance, and interfacial bonding strength of the mineral composite, and reduce curing internal stress.

[0046] The antimony additive is antimony trioxide, and the bismuth additive is an organic bismuth compound.

[0047] The foamed ceramic base 1 can be made of conventional foamed ceramic materials in the art, such as clay, feldspar, quartz, etc., with the addition of foaming agents such as silicon carbide or calcium carbonate. The raw materials are melted, foamed, and solidified by high-temperature sintering to form a porous ceramic body with micron-level closed pores inside. This process is prior art and will not be described in detail here.

[0048] The worktable surface 4 is made of the same material as the reinforcing rib 3, both being a mixture of mineral composite material and basalt wire, and the worktable surface 4 and the reinforcing rib 3 are connected as one piece at the opening of the rib hole 21. The worktable surface 4 can be directly used as a workpiece mounting reference surface or a guide rail mounting surface, without the need for an additional metal table surface. The worktable surface 4 and the reinforcing rib 3 have the same coefficient of thermal expansion, so they are not easily affected by thermal expansion and contraction, resulting in very stable dimensions. It also has high damping characteristics, which can further absorb processing vibrations and improve processing accuracy. In addition, the wear resistance of the worktable surface 4 is superior to that of the foamed ceramic base 1, extending the overall service life of the machine bed.

[0049] It should be noted that the arrangement of the flow channel holes 22 is not limited to the horizontal strip holes in the first layer below the worktable. Depending on the actual cooling requirements, more layers of horizontal strip holes can be set as flow channel holes 22, or some of the vertical strip holes can also be set as flow channel holes 22 to form a more complex cooling network. These variations are all within the protection scope of this utility model.

[0050] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A foamed ceramic composite machine tool bed with integrated cooling channels, characterized in that: include: A foamed ceramic base has a mesh-like channel structure inside. The channel structure includes rib holes and flow channels. The rib holes are used to fill reinforcing ribs, and the flow channels form cooling medium channels. The inner wall of the flow channels is provided with a sealing layer, and the flow channels have a medium inlet and a medium outlet on the side wall of the foamed ceramic base. The reinforcing ribs are filled into the inner wall of the rib holes and are solidified together with the foamed ceramic base to form an internal reinforcing skeleton. The work surface is fixed to the upper surface of the foamed ceramic base, and the work surface and the reinforcing rib are connected as one unit at the opening of the rib hole.

2. The foamed ceramic composite machine tool bed with integrated cooling channels according to claim 1, characterized in that: The channel structure includes multiple transverse slots spaced at intervals along the horizontal direction and multiple longitudinal slots spaced at intervals along the vertical direction. The transverse slots and longitudinal slots intersect and connect with each other to form a three-dimensional mesh channel. Among them, the transverse slots located in the first layer below the workbench are flow channel holes, and the remaining transverse slots and all longitudinal slots are rib holes.

3. The foamed ceramic composite machine tool bed with integrated cooling channels according to claim 2, characterized in that: The diameter of the flow channel hole is 80-100mm, and the diameter of the rib hole is 100-120mm.

4. The foamed ceramic composite machine tool bed with integrated cooling channels according to claim 3, characterized in that: At the intersection of the reinforcing rib and the flow channel hole, a through hole is provided radially for the cooling medium to pass through.

5. The foamed ceramic composite machine tool bed with integrated cooling channels according to claim 1, characterized in that: The sealing layer is an epoxy resin coating, uniformly coated on the inner wall of the flow channel hole, with a thickness of 0.5-1.5mm, used to prevent the cooling medium from seeping into the interior of the foamed ceramic base.

6. The foamed ceramic composite machine tool bed with integrated cooling channels according to claim 1, characterized in that: Metal pipe joints are pre-embedded at the medium inlet and medium outlet, and the metal pipe joints are integrated with the sealing layer of the inner wall of the flow channel hole.

7. The foamed ceramic composite machine tool bed with integrated cooling channels according to claim 6, characterized in that: The reinforcing ribs completely fill the rib holes, and the material of the reinforcing ribs penetrates into the micropores on the inner wall of the rib holes of the foamed ceramic base, forming a mechanically interlocking structure.

8. The foamed ceramic composite machine tool bed with integrated cooling channels according to claim 7, characterized in that: The workbench surface and the reinforcing rib form a T-shaped anchoring structure at the opening of the rib hole.

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