Active-Damped Boring Bar Layout for Multi-Direction Vibration
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Solution Overview
Problem
Boring bars used in machining operations experience vibrations due to cutting forces, leading to noise, impaired surface finish, and tool breakage, which existing active damping systems have not adequately addressed.
Innovation Solution
A boring bar with at least two electrically controlled single-axis vibration actuators, each with a moveable damping mass, are arranged with their working axes angularly offset and oriented perpendicularly to the longitudinal axis, allowing for efficient counteraction of radial and tangential vibrations, and are integrated within a damping module for easy adaptation and positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single vibration actuator is used in the boring bar, then the device complexity is reduced, but the ability to counteract vibrations in multiple directions (radial and tangential) is insufficient
Solution Approach 1:
The patent transitions from a single-axis actuator to a two-axis actuator configuration, where two single-axis actuators are arranged with their working axes angularly offset (e.g., perpendicular to each other). This dimensional expansion allows the system to counteract vibrations in both radial and tangential directions simultaneously, resolving the contradiction between device simplicity and vibration damping effectiveness.
2Reliability
If multiple actuators are arranged with angularly offset working axes, then the vibration damping effectiveness is improved, but the device complexity increases
Solution Approach 1:
The patent employs asymmetric arrangement of the actuators' working axes, typically at 90-degree angles to each other, aligned with the radial and tangential directions of the workpiece. This asymmetric configuration optimizes the damping effectiveness for the specific vibration modes encountered during machining, while the modular design keeps the overall system complexity manageable.
3Ease of manufacture
If the actuators are positioned away from the cutting element, then the ease of manufacture and assembly is improved, but the response time and accuracy of vibration damping is reduced
Solution Approach 1:
The actuators are positioned as close as practically possible to the cutting element at the front end of the boring bar, allowing them to detect and counteract vibrations at their source immediately. This preliminary positioning minimizes the time delay in vibration response, while the modular actuator design maintains ease of manufacture and assembly.
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
This configuration effectively dampens vibrations in the boring bar, improving the machining process by reducing noise and tool wear, and allowing for precise control of damping characteristics.
Implementation Method 1
at least two electrically controlled vibration actuators for active vibration damping of the boring bar. Each one of these actuators comprises a moveably arranged damping mass and is configured, by movement of the damping mass, to generate vibratory forces
Data Source
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AI summary
A boring bar (2) for a non-rotating boring tool comprising: - an elongated body (6) configured for attachment to a support structure of a metal cutting machine and arranged to carry a tool part (4) provided with a cutting element (5); and - at least two electrically controlled vibration actuators (16) for active vibration damping of the boring bar (2), each actuator comprising a moveably arranged damping mass (16a) and being configured to generate vibratory forces in parallel with a working axis (17) of the actuator that is perpendicular to a centre axis (15) of the damping mass, wherein each actuator is a single-axis actuator having one single working axis, and wherein these actuators are arranged with their working axes angularly offset from each other. Said actuators (16) are arranged in a longitudinal series in the elongated body (6) with the centre axis (15) of the damping mass (16a) of each actuator coinciding with a longitudinal axis (7) of the elongated body.