Chilled Workpiece Machining to Prevent Adhesive Curing
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Solution Overview
Problem
Conventional methods for producing shims in manufacturing, such as using moldable plastic or film adhesives, are time-consuming and prone to errors, requiring multiple cuts and separate handling of materials, which increases manufacturing costs and waste.
Innovation Solution
A machining apparatus and method that simultaneously cuts a film adhesive and a chilled workpiece, using a cooling system to maintain the adhesive below its curing temperature, allowing for automated processing and reducing the need for separate material handling and storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If film adhesive is used to bond sacrificial material to reduce mess and clean-up, then ease of operation is improved, but device complexity increases because the adhesive must be kept chilled and cut separately from the sacrificial material
Solution Approach 1:
The patent combines the film adhesive and sacrificial material into a single integrated workpiece that is chilled together and cut together as one unit, eliminating the need for separate handling, chilling, and cutting operations for each material
Solution Approach 2:
The workpiece is chilled in advance before machining to prevent adhesive curing during the cutting operation, ensuring the adhesive remains workable throughout the entire machining process
2Manufacturing precision
If the workpiece is chilled to prevent adhesive curing during machining, then manufacturing precision is improved, but loss of energy increases due to cooling requirements
Solution Approach 1:
The chilling is applied locally to the workpiece area rather than cooling the entire environment, and the cooling system is activated only when needed during machining operations, minimizing energy consumption while maintaining precision
Solution Approach 2:
The cooling system operates periodically during machining operations rather than continuously, maintaining the workpiece temperature below the adhesive curing threshold only when the machining tool is actively cutting
3Ease of manufacture
If conventional methods cut the adhesive and sacrificial material separately, then ease of manufacture is improved, but productivity decreases due to time-consuming separate handling and multiple cuts
Solution Approach 1:
The patent merges the film adhesive and sacrificial material into a single integrated workpiece that is cut together in one operation, eliminating multiple cutting steps and separate handling operations to significantly improve productivity
Solution Approach 2:
The machining operation continues uninterrupted by cutting through both the adhesive and sacrificial material in a single continuous process, eliminating the downtime and repositioning required by separate cutting operations
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 approach reduces manufacturing time and costs, minimizes waste, and ensures precise cutting of shims without curing the adhesive during machining, enhancing the manufacturing process efficiency.
Implementation Method 1
The cooling system may include a cooling fluid that radiantly cools the chilled workpiece via the support surface while the chilled workpiece is supported by the support surface
Data Source
AI summary
Machining apparatus for machining a chilled workpiece include a support surface that supports the chilled workpiece during machining by a machining tool of the machining apparatus, and further include a cooling system operatively coupled to the support surface. The cooling system prevents a machining temperature of an adhesive coupled to the chilled workpiece from rising beyond a predetermined threshold temperature during machining of the chilled workpiece, such that the cooling system prevents curing of the adhesive during machining of the chilled workpiece. The cooling system includes a cooling fluid that radiantly cools the chilled workpiece via the support surface while the chilled workpiece is supported by the support surface, such that the cooling system maintains the machining temperature of the adhesive (and of the chilled workpiece) below an ambient temperature. Related methods include machining the chilled workpiece using such machining apparatus.