5-Axis Double-Housing Machine Tool Boring Large Workpieces
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Solution Overview
Problem
Conventional methods for machining large workpieces face challenges with imbalance, requiring counterweights that increase energy consumption and limit machining accuracy, necessitating machine tool changes during the machining process.
Innovation Solution
A 5-axis machining double-housing machine tool with a spindle unit that can revolve about a C-axis and a spindle head that can rotate about a B-axis, allowing for precise boring of large workpieces without changing tools, enabling variable hole diameters and shapes without sacrificing accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large vertical lathe is used to turn a large workpiece, then the workpiece can be machined with proper balance, but the machine tool size and overall machining time are significantly extended
Solution Approach 1:
Instead of rotating the workpiece vertically as in conventional lathe operations, the invention inverts the approach by rotating the spindle unit horizontally about the C-axis while the workpiece remains fixed on the table. This allows boring operations without requiring the workpiece to be balanced for vertical rotation, eliminating the need for large vertical lathes and reducing machining time.
Solution Approach 2:
The invention segments the machining functions by using a 5-axis machining center with independent rotational axes (B-axis and C-axis) that can be controlled separately. The spindle unit's C-axis rotation and the spindle head's B-axis rotation are independently controllable, allowing complex boring operations to be performed without moving the entire workpiece or requiring vertical lathe configuration.
2Productivity
If circularity machining is performed instead of turning, then the same machine tool can be used without changeover, but the machining accuracy and machined surface quality are inferior
Solution Approach 1:
The invention inverts the conventional approach by having the tool rotate (spindle unit about C-axis) while the workpiece remains stationary on the table, rather than having the workpiece rotate. This allows the use of a horizontal machining center for boring operations that previously required vertical lathes, maintaining high machining accuracy while improving machine utilization and eliminating changeovers.
3Adaptability or versatility
If the spindle head position about the B-axis is adjusted, then variable hole diameters can be achieved, but the system complexity increases
Solution Approach 1:
The invention employs dynamic positioning of the spindle head about the B-axis, allowing the angle of the spindle head to be changed during the machining process. This dynamic adjustment enables variable hole diameters and different hole shapes to be machined using the same tool and setup, providing versatility without requiring multiple specialized tools or fixtures.
Solution Approach 2:
The invention combines multiple functions (boring, facing, and angular machining) into a single spindle unit that can rotate about the C-axis and position the spindle head at various B-axis angles. This merging of functions into one integrated system achieves versatility while actually reducing overall system complexity compared to using separate machines or tools for each operation.
Data Source
AI summary
A slip ring is accommodated in a ram 34. The slip ring includes a fixed portion 72 having a feed element connected to a power source and a movable portion 73 electrically connected to the feed element. The movable portion 73 includes a contact 75 for supplying electricity to a spindle unit 100 and an electric device of a spindle head 118. After determining the position of a saddle 32 in a Y-axis direction and the position of a table in an X-axis direction, the position of the spindle head 118 about a B-axis is determined. Then, the ram 34 is moved along the Z-axis direction with the spindle unit 100 revolved about the C-axis, and, with a non-rotational cutting tool 170 attached to the spindle unit 100, a hole is bored in a workpiece W on the table.