Process for precision grinding and carving using a horizontal-type multi-spindle machine

Abstract

The present invention discloses a horizontal-type multi-spindle CNC grinding machine (100) for processing non-ferrous metal parts, the machine comprising a sliding table (105) driven by linear actuators for part positioning, a centralized tooling center (110) configured to securely hold parts and enable all-side grinding, a multi-spindle arrangement (115) for simultaneous grinding on multiple planes, a CNC controller (120) configured to manage spindle motion, speed, and feed rate, and a feedback system (125) using sensors for monitoring positional accuracy and process parameters, wherein the machine (100) is configured to operate without requiring coolant, utilizing heat-resistant tool paths to maintain dimensional stability. [FIG. 1]

Description

FIELD OF THE INVENTIONThe present invention, in general, relates to CNC grinding and machining, specifically for brass or other nonferrousmaterials as per their profiles. Further, the present invention focuses on optimizing grinding processeswith defined accuracy and efficiency for non-ferrous components.BACKGROUND OF THE INVENTIONThe manufacturing industry has long relied on traditional horizontal-type machining systems to perform grindingand shaping tasks. These machines often require extensive manual intervention, including the use of customizedpart holders or cavities for each unique component. The conventional process typically involves grinding partsfrom three planes, followed by manual repositioning or reversing of the part to enable grinding on additionalsides. This multi-step approach not only increases the overall processing time but also introduces the risk oferrors, inconsistencies, and inefficiencies.Additionally, existing machines are limited in their adaptability. The need for specific fixtures or part holdersfor every design restricts their versatility, particularly when handling a diverse family of products. Moreover,coolant systems, commonly employed in these machines to manage heat during grinding, add complexity tomaintenance and operational costs, further reducing the efficiency of such systems.The limitations of current technologies highlight the demand for a more streamlined, adaptable, and efficientsolution. The present invention introduces a revolutionary machine aimed at eliminating the bottlenecksassociated with traditional methods. By integrating a centralized holding mechanism and CNC-controlled multi25spindle operations, the machine of the present invention facilitates simultaneous grinding from multiple planes,enabling precise and efficient processing of non-ferrous materials.The innovative approach taken in the present invention allows for grinding operations to be carried out withoutthe need for multiple fixture changes. By centralizing the part holding mechanism, the machine reduces setuptimes, improves accuracy, and enhances the overall productivity of the grinding process. Furthermore, anelimination of coolant requirements simplifies maintenance and reduces the environmental footprint of themachine, making it a more sustainable choice for industrial applications.Therefore, the present invention addresses critical inefficiencies in existing grinding systems and offers a robustsolution designed to meet the evolving needs of modern manufacturing. Its ability to streamline operations, adaptto diverse part profiles, and maintain high precision sets it apart as a significant advancement in the field of CNCgrinding and machining.OBJECTIVE OF THE INVENTIONThe primary objective of the present invention is to provide a precision grinding and carving process for nonferrousmetal parts that ensures high accuracy, efficiency, and consistency. The present invention aims tostreamline operations by eliminating the need for multiple fixtures and manual repositioning, thereby reducingprocessing times and potential errors. Additionally, the invention seeks to enhance sustainability through acoolant-free operation while maintaining superior quality and ease of maintenance. By leveraging advancedCNC programming and innovative mechanical designs, this process enables manufacturers to achieve improvedproductivity and adaptability across diverse part profiles.Another objective of the present invention is to simplify the overall machining workflow by integrating multi15spindle grinding with centralized part holding. The integration ensures that parts can be machined from multipleplanes in a single operation, eliminating the need for repositioning and fixture changes. This reduces operatorintervention, minimizes human error, and enhances throughput, making the process highly efficient for largescalemanufacturing environments.Furthermore, the invention seeks to offer a scalable and flexible solution adaptable to different part geometriesand material types. By utilizing customizable CNC programming and modular machine components, the processis capable of handling a wide variety of product families without extensive retooling. This adaptability not onlyimproves operational efficiency but also reduces downtime, making the system suitable for industries withdynamic production requirements.Therefore, it is the objective of the present invention is to provide a precision grinding and carving process fornon-ferrous metal parts that ensures high accuracy, efficiency, and consistency. The present invention aims tostreamline operations by eliminating the need for multiple fixtures and manual repositioning, thereby reducingprocessing times and potential errors.Additionally, the present invention seeks to enhance sustainability through a coolant-free operation whilemaintaining superior quality and ease of maintenance. By leveraging advanced CNC programming andinnovative mechanical designs, this process enables manufacturers to achieve improved productivity andadaptability across diverse part profiles.SUMMARY OF THE INVENTIONThe present invention provides a detailed process for precision grinding and carving using a horizontal-typemulti-spindle CNC machine. The process begins with part placement in a centralized tooling center 110,followed by simultaneous multi-plane grinding. The CNC-driven system ensures defined accuracy and reducesmanual intervention. Adjustable mechanisms in the process design allow flexibility, ensuring adaptability tovarious part profiles while incorporating safety features for reliable operation.BRIEF DESCRIPTION OF THE DRAWINGSThe accompanying figures illustrate several embodiments of the disclosure and, together with the description,serve to explain the principles of the disclosure. One of ordinary skill in the art readily recognizes that theembodiments illustrated in the figures are merely exemplary, and are not intended to limit the scope of the presentdisclosure.FIG. 1 illustrates a block diagram of an exemplary architecture of horizontal-type multi-spindle CNC grindingmachine according to an embodiment of the present invention.FIG. 2 discloses a flow diagram of an exemplary method for precision grinding and carving of non-ferrous metalparts using a horizontal-type multi-spindle CNC machine according to an embodiment of the present invention.It may be noted by those skilled in the art that the diagrams, schematics, illustrations, and similar representationsprovided are conceptual views or processes demonstrating systems and methods embodying the presentinvention. The functionalities of the various elements depicted may be implemented using dedicated hardwareor hardware that can run corresponding software.Further areas of applicability of the present disclosure will become apparent from the complete descriptionprovided hereinafter.It should be understood that the complete description of exemplary embodiments is intended for illustrationpurposes only and is, therefore, not intended to necessarily limit the scope of the present disclosure.DETAILED DESCRIPTION OF THE INVENTIONThe present invention is more particularly described in the following present specification that is intended asillustrative only since numerous modifications and variations therein will be apparent to those skilled in the art.Various embodiments of the present disclosure are now described in detail. Referring to the drawings, likenumbers, if any, indicate like components throughout the views. As used in the description herein and throughoutthe claims that follow, the meaning of "a", "an", and "the" includes plural reference unless the context clearlydictates otherwise. Also, as used in the description herein and throughout the claims that follow, the meaning of"in" includes "in" and "on" unless the context clearly dictates otherwise. Moreover, titles or subtitles may beused in the specification for the convenience of a reader, which shall have no influence on the scope of thepresent disclosure. Additionally, some terms used in this specification are more specifically defined below.The terms used in this specification generally have their ordinary meanings in the art, within the context of thepresent disclosure, and in the specific context where each term is used. Certain terms that are used to describethe present disclosure are discussed below, or elsewhere in the specification, to provide additional guidance tothe practitioner regarding the description of the disclosure.For convenience, certain terms may be highlighted, for example using italics and / or quotation marks. The use ofhighlighting has no influence on the scope and meaning of a term; the scope and meaning of a term are the same,in the same context, whether or not it is highlighted. It will be appreciated that the same thing may be said inmore than one way. Consequently, alternative language and synonyms may be used for any one or more of theterms discussed herein, nor is any special significance to be placed upon whether or not a term is elaborated ordiscussed herein. Synonyms for certain terms are provided. A recital of one or more synonyms does not excludethe use of other synonyms.The use of examples anywhere in this specification including examples of any terms discussed herein isillustrative only, and in no way limits the scope and meaning of the disclosure or of any exemplified term.Likewise, the disclosure is not limited to various embodiments given in this specification.Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonlyunderstood by one of ordinary skill in the art to which this disclosure pertains. In the case of conflict, the presentdocument, including definitions will control.As used herein, "around", "about" or "approximately" shall generally mean within 20 percent, preferably within10 percent, and more preferably within 5 percent of a given value or range. Numerical quantities given hereinare approximate, meaning that the term "around", "about" or "approximately" can be inferred if not expresslystated.As used herein, "plurality" means two or more.As used herein, the terms "comprising," "including," "carrying," "having," "containing," "involving," and thelike are to be understood to be open-ended, i.e., to mean including but not limited to.As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A or B or C), usinga non-exclusive logical OR. It should be understood that one or more steps within a method may be executed ina different order (or concurrently) without altering the principles of the present disclosure.The following description of the present invention provides a horizontal-type multi-spindle CNC grindingmachine (100) and a comprehensive process for the precision grinding and carving of non-ferrous metalcomponents / parts, specifically tailored for post-casting manufacturing. The primary objective of the presentinvention is to maintain the product's outer profile or shape with unmatched accuracy, efficiency, andconsistency through advanced CNC programming and innovative mechanical design.CNC Controller 120A CNC controller 120 is a command center of the machine disclosed in the present invention, responsible forcoordinating all machining operations with unparalleled precision and consistency. The CNC controller 120 ofthe present invention is a complete control system that integrates computational, hardware, and communicationcomponents to manage and execute machining operations. While a CPU (Central Processing Unit) may form apart of the CNC controller 120, the controller 120 may also include a plurality of peripherals such as but notlimited to servo drives, feedback systems 125, and communication interfaces to perform the following:1. Computation and Command Generation: The CPU may be configured to process input data(e.g., tool paths, feed rates) and generates commands for machine actuation.2. Communication Interfaces: To send one or more signals to and receive feedback fromsubsystems such as motors, sensors, and / or drives.3. Subsystem Coordination: To ensures synchronization of components such as spindles, tables,and clamps, driven by its computational and feedback capabilities.4. Operator Interface: Including HMIs (Human-Machine Interfaces) for input and monitoring bythe operator.The CNC controller 120 of the present invention is an advanced orchestration system configured to enableprecision and automation. While acting as the interface between the operator and the mechanical components ofthe machine, the CNC controller 120 translates programmed tool paths into commands that guide a motion andoperation of the machine. It is critical for executing simultaneous multi-plane grinding, synchronizing thespindles, sliding table 105, and hydraulic systems to ensure high-quality machining outcomes. By managingvariables such as speed, feed rate, and / or tool positioning, the CNC controller 120 may be configured to ensureadherence to predefined dimensions and profiles.Integrated feedback systems 125, including encoders and position sensors, may allow the CNC controller 120 tocontinuously monitor and adjust operations. Such dynamic adaptability prevents errors, enhances accuracy, andensures uniformity across production runs. The controller's intuitive interface simplifies programming andoperation, enabling operators to configure complex grinding tasks efficiently.Essential Functions of the CNC Controller 1201. Motion Control: The controller 120 may be configured to regulate a precise movements of thespindles, sliding table 105, and hydraulic clamps, adhering strictly to the programmed dimensionsand profiles.2. Feed Rate Management: The CNC controller 120 may be configured to dynamically adjust a feedrate to optimize the grinding process, balancing speed with a required surface finish and toollongevity.3. Real-Time Monitoring: With an integrated feedback from a plurality of sensors and encoders, theCNC controller 120 may continuously evaluate a positional accuracy, load levels, and toolperformance, making real-time adjustments as necessary.Additional Hardware and AccessoriesTo support an operation of the CNC controller 120, the following hardware components may be required:1. Servo Motors and Drives: Servo Motors and Drives are the actuators of the machine of the presentinvention, converting a plurality of electrical signals from the CNC controller 120 into precisemechanical movements. High-resolution servo drives may ensure smooth and accurate motion ofspindles and tables.2. Encoders and Feedback Sensors: These devices may be configured to provide real-time data onposition, velocity, and / or acceleration. Encoders may help the CNC controller 120 to maintain anexact alignment of parts and tools, ensuring consistent machining results.3. Power Supply Unit: A reliable power source is vital for maintaining an uninterrupted operation,especially for the CNC controller 120 and servo drives. The system may further includes voltageregulation to protect against fluctuations.4. Human-Machine Interface (HMI): The HMI simplifies programming and monitoring by providingan intuitive visual interface. Operators may use touchscreens or graphical displays to set parameters,view process progress, and make adjustments in real time.5. Cooling Systems: While the machining process itself is coolant-free, the electronic components ofthe CNC controller 120 may require heat management through cooling fans or heat sinks to ensureoperational stability.6. Error Detection and Alarms / Notifications: The CNC controller 120 may be equipped withdiagnostic tools that may be configured to detect deviations from the programmed parameters,triggering alarms or pausing operations to prevent errors or damage.7. Networking and Connectivity: The CNC controller 120 may be configured to support connectivitythrough Ethernet or wireless modules, enabling remote monitoring, diagnostics, and softwareupdates for enhanced machine management.Initialization and SetupThe process begins with the initialization of a CNC system, which activates all necessary subsystems. The CNCmachine may comprise a plurality of essential subsystems that work in harmony to ensure precise control andmonitoring throughout the operation. These essential subsystems may include one or more motion control unitsconfigured to interpret programmed commands and direct a movement of spindles and tables; one or morefeedback systems 125 configured to use sensors and encoders to monitor positions and velocities for accurateadjustments; one or more power supply unit to deliver consistent energy to the machine components; and at leastone user interface configured to provide one or more operators with control and monitoring capabilities.The CNC interface may ensure precise control and monitoring throughout an operation. The operators mayprepare the machine by ensuring that a tooling center 110 is calibrated to align with a desired profile. An initialsetup is critical for maintaining dimensional accuracy and repeatability across multiple parts.Hydraulic Cylinder SystemThe process may further integrate a hydraulic cylinder system as a critical component for clamping and declampingparts securely during grinding. The hydraulic cylinder may ensure the clamped part remains stationaryand aligned, even under high machining forces. The hydraulic cylinder may be activated to release or tighten itsgrip on the fastened part, enabling seamless transitions between loading, processing, and unloading. Thismechanism is essential for maintaining precision throughout the workflow.Part PlacementThe machine of the present invention comprises a sliding table 105, powered by a plurality of linear actuators,moves outward to provide an accessible platform for part placement. The operators may position a part within acentralized tooling center 110, ensuring alignment with pre-marked guides or reference points. The centralizedtooling center 110 is a key innovation, allowing secure holding and eliminating the need for multiple fixtures,even for a family of parts with minor dimensional variations.Grinding ProcessOnce the part is secured within the centralized tooling center 110, the sliding table 105 transitions back into amachining zone. A multi-spindle system 115 may be configured to engage, with each spindle programmed toperform specific grinding tasks. The spindles may be configured to operate simultaneously on a same plane orone or more different planes, enabling comprehensive all-side grinding in a single operation. The CNCprogramming may govern the spindles' motion, ensuring precise adherence to the predefined dimensions andprofiles.Multi-Spindle ConfigurationThe multi-spindle arrangement 115 is highly customizable, capable of accommodating tools of varying diametersand materials. This flexibility allows the process to adapt to a wide range of part geometries, from simplecontours to intricate carvings. Each spindle's speed and feed rate may be optimized through CNC algorithms,minimizing wear and maximizing efficiency.Coolant-Free OperationUnlike traditional grinding systems, the grinding process of the present invention is not dependent on coolant.The advanced tool-path algorithms and heat-resistant materials ensure thermal stability, reducing a likelihood ofpart deformation or tool degradation. The present invention simplifies maintenance and contributes toenvironmentally sustainable operations.Additionally, for the purpose of the present invention, the tools and equipment utilized in the precision grindingand carving process are of superior quality, ensuring consistent performance, durability, and the higheststandards of accuracy. This commitment to quality not only enhances the reliability of the grinding operationsbut also contributes to the overall efficiency and sustainability of the system.Maintenance and ServicingThe process incorporates a plurality of modular components, enabling a quick and easy maintenance. Spindles,actuators, and other critical parts may be replaced and / or serviced without a significant downtime. Themodularity of the machine ensures the machine's long-term reliability and cost-effectiveness.Detailed Workflow of the ProcessThe process begins with powering on the machine, initializing one or more subsystems, and ensuring readinessfor an operation. An operator may activate the sliding table 105 by pressing the designated slide-out button,causing the sliding table 105 to move in an outward direction to an external position. This movement may providean easy access for a placement of a part onto the sliding table 105. A plurality of sensors integrated into themachine may be configured to confirm a precise positioning of the sliding table 105, ensuring alignment andpreventing further actions until proper placement is verified.With the sliding table 105 at the outer external position, an automatic gate opens to provide the operator with anaccess to an internal workspace. An electric motor may be configured to control the automatic operation of thegate is equipped with safety interlocks, ensuring operator safety by preventing accidental closure during parthandling. The operator may then deactivate the hydraulic cylinder via the de-clamping system, releasing theholding mechanism to allow the secure placement of the part on the sliding table 105.Once the part is correctly positioned, the operator may press a cycle start button, triggering the machine'sautomated sequence. The hydraulic clamping system re-engages, firmly securing the part in place to preventmovement during the grinding or machining process. With the part securely clamped, the sliding table 105transitions inward, moving the part into the machining area with precise positioning ensured by built-in sensors.The automatic gate then closes, isolating the machining area to activate safety interlocks and ensure secureoperation. The grinding cycle begins, with the machine performing simultaneous multi-plane grinding or carvingoperations as programmed into the CNC system. The multi-spindle arrangement 115 allows for consistentprocessing across all required surfaces, minimizing time and enhancing precision.At the conclusion of the operation cycle, the machine signals an end of the process. The automatic gate opens,and the sliding table 105 moves outward, returning to its initial accessible position. The operator may retrievethe processed part, completing the cycle and preparing the machine for the next part. This streamlined workflowensures efficiency, safety, and high-quality output.Workflow EfficiencyThe streamlined process of the present invention eliminates a need for manual repositioning or additional fixturechanges. This not only reduces processing time but also minimizes the potential for human error. The CNCdrivenautomation ensures consistent performance across multiple parts, enhancing productivity in high-volumeproduction scenarios.ApplicationsThe present invention is specifically suited for high-precision grinding and carving processes across multipleindustrial sectors.For a non-limiting example, in the automotive industry, the machine disclosed in the present invention mayprovide an unparalleled accuracy for components such as valve bodies, housing assemblies, and other criticalparts requiring precise dimensional tolerances. By enabling all-side grinding in a single operation, the machineminimizes production bottlenecks and ensures consistency across high-volume manufacturing runs. Theadaptability of the present invention to various part geometries may allow manufacturers to streamline operationsfor a diverse range of automotive components without extensive retooling.In another non-limiting example, in aerospace manufacturing, the present invention may address a demand forlightweight, intricately designed non-ferrous parts. These components, which are often subjected to extremeoperational conditions, require machining with high precision and superior surface finishes. The multi-spindleconfiguration facilitates complex shaping and contouring, while the centralized holding mechanism ensurespositional stability throughout the process. The coolant-free operation further reduces contamination risks,meeting the stringent quality standards of the aerospace industry.Further, for electronics assembly, where precision brass fittings and connectors are prevalent, the presentinvention may enhance productivity by efficiently handling small-scale, intricate parts. The capability of thepresent invention to handle varying profiles without significant downtime makes it an invaluable tool for meetingthe dynamic demands of the electronics sector.Additionally, the industrial tools industry may also benefit from the present invention's flexibility in creatingcustom tools with exact profiles. The process's ability to grind parts from all sides in a single cycle ensures fasterturnaround times, making it ideal for toolmakers working with non-ferrous metals. Its modular design and easeof maintenance further enhance its suitability for operations requiring frequent customization or partreplacements.Innovations and BenefitsThe present invention may introduce several groundbreaking innovations that may significantly enhance theefficiency, accuracy, and versatility of precision grinding and carving processes. At a core of the presentinvention is the ability to eliminate traditional machining inefficiencies through centralized part holding andsimultaneous multi-plane grinding. The innovation of the present invention ensures that parts are machinedcomprehensively in a single cycle, dramatically reducing processing time while maintaining consistent quality.One of the key benefits is the introduction of a coolant-free operation. Conventional grinding processes typicallyrely on coolant systems to manage heat and debris, which adds complexity and operational costs. By utilizingheat-resistant tool paths and advanced material handling, this invention achieves thermal stability withoutrequiring coolant, simplifying maintenance and reducing environmental impact.The multi-spindle configuration of the machine of the present invention further enhances its adaptability. Eachspindle may accommodate tools of varying diameters and materials, allowing the process to handle a wide rangeof part geometries, from simple contours to intricate carvings. The integration of CNC automation ensuresprecision and repeatability, even in high-volume production settings, while minimizing operator interventionand potential errors.Another significant innovation of the present invention is the centralized tooling center 110, which secures partswithout requiring multiple fixtures. The design structure of the present invention allows seamless transitionsbetween parts within the same product family, reducing downtime and increasing throughput. The modularconstruction of the machine also ensures quick servicing and part replacement, enhancing long-term reliabilityand cost efficiency.- Comprehensive Grinding in One Operation: Eliminates the need for repositioning, drastically reducingcycle times.- Tooling Center Design: Centralized part holding improves accuracy and flexibility.- Environmentally Friendly: Coolant-free operation reduces waste and simplifies maintenance.- CNC Automation: Guarantees repeatability and precision across multiple production runs.- User-Friendly Interface: Intuitive controls simplify training and operation.It will be clear to those skilled in the art for the above description that further modifications beyond thosediscussed may be made without departing from the inventive concepts presented. As a result, the scope of theinvention is not limited to the details provided, but is instead defined by the claims. Furthermore, wheninterpreting the specification and claims, all terms should be understood in their broadest sense, consistent withthe context. Specifically, the terms "include", "including", "comprise" and "comprising" are meant to indicatenon-exclusive inclusion of elements, components, or steps, suggesting that additional elements, components, orsteps may also be included or combined, even if not explicitly listed. Additionally, when the specification orclaims refer to selecting at least one item from a group such as A, B, C, …, and N, it should be understood asrequiring only one item from the group, not necessarily a combination of items.The embodiments described hereinabove are exemplary of the present invention. The disclosure may enablethose skilled in the art to make and use embodiments having alternative elements that likewise correspond to theelements of the invention. The intended scope of the invention may thus include other embodiments that do notdiffer or that insubstantially differ from the literal language of the invention. However, the scope of the presentinvention is accordingly defined as set forth in the present complete specification.

Claims

1. A horizontal-type multi-spindle CNC grinding machine (100) for processing non-ferrous metal parts, the machine comprising: a sliding table (105) driven by linear actuators for part positioning; a centralized tooling center (110) configured to securely hold parts and enable all-side grinding; a multi-spindle arrangement (115) for simultaneous grinding on multiple planes; a CNC controller (120) configured to manage spindle motion, speed, and feed rate; and a feedback system (125) using sensors for monitoring positional accuracy and process parameters; wherein the machine (100) is configured to operate without requiring coolant, utilizing heat-resistant tool paths to maintain dimensional stability.

2. A method for precision grinding and carving of non-ferrous metal parts using a horizontal-type multispindle CNC machine (100), the method comprising: initializing a CNC system to activate subsystems and prepare the machine; positioning a part within a centralized tooling center via a sliding table; aligning the part with predefined guides to ensure proper orientation; engaging multi-spindles for simultaneous grinding on multiple planes; controlling spindle motion, speed, and feed rate through CNC programming to achieve defined profiles; and retrieving the processed part after completion.

3. The method as claimed in claim 2, wherein the sliding table transitions outward to facilitate part placement and inward for machining, driven by linear actuators.

4. The method as claimed in claim 2, wherein the centralized tooling center eliminates the need for multiple fixtures within a product family.

5. The method as claimed in claim 2, wherein the process operates without coolant, using optimized tool paths and heat-resistant materials to maintain thermal stability.

6. The method as claimed in claim 2, wherein the multi-spindle arrangement accommodates tools of varying diameters and materials, enabling adaptation to different part geometries.

7. The method as claimed in claim 2, wherein the CNC programming includes automated error detection to flag deviations in dimensional accuracy and correct them in subsequent cycles.

8. The method as claimed in claim 2, further comprising a maintenance protocol wherein modular components, including spindles and actuators, are replaced or serviced without significant downtime.