Crankshaft Oil Hole Drilling via Workpiece Rotation and Pivoting Head
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Solution Overview
Problem
Existing machining methods for crankshafts and camshafts require multiple stations to drill oil holes at precise angles, leading to complex software programming and positioning errors due to orthogonal X and Y axis movements, which complicates the drilling process and reduces accuracy.
Innovation Solution
A method and apparatus where the workpiece is rotated about its longitudinal axis, and a machining head is pivoted to position a cutting tool along a plunging axis Z at an oblique angle, allowing for simplified programming by shifting the tool parallel to the crankshaft axis and reducing errors through arcuate travel with a curved rack and pinion drive, enabling precise location of holes at desired angles and offsets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If orthogonal X and Y axis movements are used to position the tool, then the tool can reach various drilling locations, but positioning errors and complex software programming occur
Solution Approach 1:
Instead of moving the tool along orthogonal X and Y axes to position it, the invention inverts the approach by rotating the workpiece about its longitudinal axis and pivoting the machining head to bring the tool to the desired location. This inversion eliminates the need for complex coordinate transformations and reduces positioning errors associated with orthogonal axis movements.
Solution Approach 2:
The invention transitions from two-dimensional orthogonal positioning (X and Y axes) to a three-dimensional approach involving workpiece rotation about its longitudinal axis and machining head pivoting. This dimensional change allows the tool to reach various drilling locations through rotational and angular movements, simplifying the positioning logic and improving accuracy.
2Adaptability or versatility
If the crankshaft is turned to desired inclined angles using orthogonal axis movement, then holes can be drilled at acute angles, but multiple stations and complex positioning are required
Solution Approach 1:
The machining head is designed with multi-functionality, capable of both drilling operations and milling operations with cutters that cut at acute angles. This universal machining head can perform multiple functions that previously required separate stations, including drilling oil holes at various angles and milling cam profiles, thereby reducing the overall number of stations required.
Solution Approach 2:
The machining head is made dynamic through its ability to pivot about a horizontal axis, allowing it to assume various angular positions. This dynamic capability enables the same machining head to drill holes at different acute angles and perform milling operations, eliminating the need for multiple fixed stations with different configurations.
3Productivity
If multiple cutting tools are disposed side-by-side for simultaneous machining, then production increases, but tool positioning and synchronization complexity increases
Solution Approach 1:
Multiple cutting tools are merged into a single universal machining head that can perform both drilling and milling operations. Instead of having separate tool holders and changers for each tool, the invention combines multiple tool functions into one pivoting head, reducing the complexity of tool changing and synchronization mechanisms while maintaining high productivity.
Data Source
AI summary
An apparatus and method are provided for performing multiple machining operations on a workpiece such as a crankshaft. Oil holes may be drilled in a crankshaft by a tool shifted along a curved path between successive, acute angle tool plunging locations. The tool's carrier is shifted parallel to the crankshaft axis and the tool carrier is rotated to the desired acute angle about a point on the crankshaft axis for each of successive oil hole drilling locations thereby reducing programming needed to drill the oil holes at the specified angles. Offset tolerance errors are reduced by a large factor as the tool is plunged from an outer initial position toward the crankshaft axis.