Non-Rotating Boring Bar With Force-Aligned Active Vibration Damping
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Solution Overview
Problem
Existing boring tools experience vibrations during internal turning due to tangential and radial cutting forces, leading to noise, impaired surface finish, and tool breakage, which conventional active damping systems struggle to effectively counteract.
Innovation Solution
A non-rotating boring tool with a single-axis vibration actuator aligned with the expected orientation of the resultant cutting force, and optionally a second actuator, to generate vibratory forces parallel to this orientation, integrated into a modular design for efficient damping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional active damping systems with multiple actuators are used, then vibration damping capability is improved, but device complexity increases
Solution Approach 1:
The patent extracts and eliminates redundant actuators from the damping system. By analyzing the actual vibration characteristics and cutting force directions, the invention determines that a single actuator positioned at the optimal location can effectively counteract the dominant vibrations, removing the need for multiple actuators and simplifying the system while maintaining damping effectiveness.
Solution Approach 2:
The single actuator in the patent is designed to perform multiple damping functions simultaneously. By strategically positioning the actuator and configuring its control system, it can counteract vibrations in multiple directions and handle different vibration modes, replacing what would traditionally require multiple specialized actuators.
2Reliability
If multiple vibration actuators are installed in the boring bar, then vibration counteraction is improved, but manufacturing complexity increases
Solution Approach 1:
The patent removes the need for multiple actuators by identifying and addressing the primary vibration source with a single strategically positioned actuator. This extraction of redundant components significantly simplifies the manufacturing process, reducing the number of parts to be produced, assembled, and calibrated.
3Manufacturing precision
If active damping systems are implemented, then surface finish quality is improved, but device complexity increases
Solution Approach 1:
The patent achieves high surface finish quality by extracting and addressing the dominant vibration mode with a single actuator rather than using a complex multi-actuator system. The actuator is positioned and controlled to specifically target the vibrations that affect surface finish, providing effective damping with minimal system complexity.
4Device complexity
If conventional boring tools without active damping are used, then device simplicity is maintained, but vibrations cause noise and tool breakage
Solution Approach 1:
The patent converts the harmful vibrations into beneficial information by using sensors to detect vibration characteristics. This information is then used by the control system to activate the damping actuator, which generates counter-vibrations that neutralize the harmful effects. The system transforms the problem of vibration into a controlled solution where the same vibratory mechanism is used to counteract the harm.
Solution Approach 2:
The active damping system applies preliminary anti-action by continuously monitoring vibrations and applying counter-vibrations in real-time. The control system anticipates and counteracts harmful vibrations before they can cause significant damage or quality issues, maintaining tool simplicity while protecting against harmful effects.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Effectively dampens vibrations, improving surface finish and tool longevity by aligning actuators with the combined cutting forces, enhancing machining precision and reducing noise.
Implementation Method 1
the vibration actuator being controlled by an electronic control unit in dependence on measuring signals from the vibration sensor or sensors in order to introduce counter-vibrations in the boring bar that will interfere with and thereby counteract the vibrations induced in the boring bar by the cutting forces
Data Source
AI summary
A non-rotating boring tool for internal turning includes a boring bar having an elongated body, a cutting element with a rake side, a relief surface and a cutting edge, and an electrically controlled vibration actuator for active vibration damping of the boring bar. Moreover, when seen in a cross-sectional plane that is perpendicular to a longitudinal axis of the elongated body and intersecting the cutting edge in a radially outermost point, straight and imaginary first and second reference lines intersect the cutting edge in the radially outermost point with the first reference line extending at an angle of 6° to the relief surface on the outside of the cutting element, and the second reference line extending between the rake side and the relief surface at an angle of 10-40° to the first reference line. The actuator is arranged with its working axis extending in parallel with the second reference line.