Chamfer Machining Cross Holes Conical Tool Height Control
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Solution Overview
Problem
Chamfer machining of cross holes in hollow rod materials using conical tools results in non-uniform chamfering due to varying contact angles and shapes, leading to elliptical elongation, especially when the opening edge part is inclined or has a non-cylindrical shape.
Innovation Solution
The method involves controlling the height and position of the conical tool based on the conic section generated by a virtual plane contacting the machining point, ensuring uniform chamfering by adjusting the tool's height and rotation axis to maintain consistent contact with the workpiece, utilizing conical tools with varying blade shapes and orientations for convex and concave arc-shaped parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If chamfer machining is carried out using a conical tool on an opening edge part of a cross hole, then the machining process is simple and efficient, but the chamfer amount becomes non-uniform resulting in elliptical elongation
Solution Approach 1:
The invention changes the geometric parameters of the cutting tool by using a cylindrical cutting blade with a specific radius instead of a conical blade. The cylindrical shape with radius R1 creates a different contact pattern with the workpiece surface, transforming the machining mechanism from point/line contact to face contact, which ensures uniform chamfering while maintaining machining efficiency
Solution Approach 2:
The invention introduces a new dimensional approach by positioning the cutting blade at a specific distance R2 from the center of the cross-hole and using a cylindrical geometry that extends in the axial direction. This dimensional configuration creates a annular cutting path that naturally produces uniform chamfering across the opening edge, solving the elliptical elongation problem while keeping the process simple
2Adaptability or versatility
If the conical tool contacts the opening edge part at varying degrees due to surface curvature, then the machining process adapts to the surface shape, but the chamfer amount varies creating non-uniform results
Solution Approach 1:
The invention changes the contact parameter by using a cylindrical cutting blade with radius R1 that creates a consistent contact width across the opening edge. The cylindrical geometry ensures that the contact length between the cutting blade and the workpiece surface remains constant, producing uniform chamfering regardless of surface curvature variations
Solution Approach 2:
The invention segments the cutting action into a controlled annular path defined by the cylindrical blade geometry and its positioning at distance R2 from the cross-hole center. This segmentation creates discrete, controlled contact zones that ensure consistent chamfering while adapting to the overall surface shape
Data Source
AI summary
A beveling method for beveling the edge of the opening of a cross hole (2-1) formed in a workpiece (W) while rotating a conical tool (1), which has conical cutting blade sections (11-1, 11-2), wherein beveling is carried out so that a surface of the same width is formed on the edge of the opening of the cross hole (2-1) by controlling the height of the conical tool (1) and/or the position of the rotation shaft of the conical tool (1) on the basis of a conic section, which is generated when a cutting blade section (11-1, 11-2) is cut with an imaginary plane (V) that contacts the processing point (P) of the conical tool (1) on the cross hole (2-1), and the shape of the edge of the cross hole (2-1) opening.