Angled Clamping of Ring Blanks to Prevent Chip and Coolant Buildup
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Solution Overview
Problem
Existing methods for producing ring disc-shaped components, such as railroad wheels, often result in material removal issues and cooling fluid accumulation, leading to inefficiencies and challenges in the processing and cooling of the raw materials.
Innovation Solution
A novel procedure for manufacturing ring disc-shaped components involves tensioning the raw part in a clamping situation where the central axis is not parallel to the vertical axis, allowing for improved material processing and cooling efficiency by preventing chip and fluid accumulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the blank is clamped with its central axis in a vertical axis or plane, then the machining setup is simple and straightforward, but material removal accumulates and coolant accumulates on the blank, negatively affecting the machining process
Solution Approach 1:
The patent applies asymmetry by tilting the blank's central axis at an angle between 5° and 45° relative to the vertical axis, deviating from the conventional vertical alignment. This asymmetric positioning prevents chip and coolant accumulation while maintaining effective machining capability, resolving the contradiction between setup simplicity and harmful factor generation.
Solution Approach 2:
The patent introduces a new dimensional aspect by adding the tilt angle parameter to the traditional vertical clamping arrangement. This dimensional change transforms the clamping configuration from a single-axis vertical alignment to a multi-dimensional angled positioning, enabling chips and coolant to be directed away from the machining area while preserving manufacturing ease.
2Object-generated harmful factors
If the blank is clamped with its central axis at an angle to the vertical axis, then chip and coolant accumulation is prevented, but the clamping setup becomes more complex
Solution Approach 1:
The asymmetric tilt angle configuration prevents chip and coolant accumulation by directing material removal away from the machining zone. The clamping device incorporates this asymmetry through adjustable tilting mechanisms or pre-positioned angled clamps, achieving harmful factor prevention with controlled complexity.
Solution Approach 2:
The patent changes the geometric parameter of the blank's orientation from vertical (0°) to an angled position (5°-45°). This parameter modification fundamentally alters chip flow and coolant distribution patterns, preventing accumulation while the clamping device complexity is managed through standardized angular adjustments or fixed-angle fixtures.
3Productivity
If the central axis of the blank is at an angle to the vertical axis during machining, then cooling efficiency is improved and optical monitoring is enhanced, but the machining process requires specialized equipment configuration
Solution Approach 1:
The patent modifies the orientation parameter of the blank from vertical to angled (5°-45°), which fundamentally improves cooling efficiency by enabling better coolant penetration and flow through the workpiece. Optical monitoring is enhanced due to improved line-of-sight access to the machining interface. The equipment configuration complexity is managed through programmable positioning systems and standardized angular fixtures.
Solution Approach 2:
The patent employs dynamic positioning capabilities in the clamping device, allowing the blank to be tilted to optimal angles during different machining operations. This dynamic adjustability enables the system to adapt to various workpiece geometries and machining requirements, improving cooling and monitoring while maintaining operational flexibility despite increased equipment complexity.
Data Source
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AI summary
A method is proposed for manufacturing at least one disc- or ring-shaped component (2), in particular a disc- or ring-shaped wheel, characterized by the steps of: - providing at least one blank (1) having a central axis (ZA) and requiring mechanical machining, in particular by cutting; - arranging or clamping the blank (1) in at least one clamping situation (AS) in which the central axis (1) of the blank (1) is perpendicular to a vertical axis (VA); - machining the clamped blank (1) mechanically, in particular by cutting, to manufacture the disc- or ring-shaped component (2). A machining center is also proposed.