Dual Tool Post Vibration Cutting for Independent Vibration Settings
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Solution Overview
Problem
Existing machine tools with dual tools on a single tool post limit the flexibility in setting the number of vibrations per rotation for segmented chip production, making it difficult to achieve optimal machining conditions.
Innovation Solution
The machine tool design allows independent reciprocal movement of two tool posts along the feed direction, enabling separate control of the number of vibrations for each cutting tool, allowing for different settings and reducing the limitation to a single vibration value.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If two tools are installed on one tool post, then the tool can perform turning in both directions, but the number of vibrations per rotation is limited to a single value
Solution Approach 1:
The single tool post is segmented into two independent tool posts (first tool post and second tool post), each capable of holding a cutting tool and performing vibration cutting independently. This segmentation allows each tool post to have its own vibration control parameters, enabling different numbers of vibrations per rotation for each tool, thus resolving the limitation of having only one vibration value while maintaining dual-directional cutting capability.
2Ease of manufacture
If one cutting tool is used for vibration cutting, then the setup is simple, but chips cannot be segmented when the number of vibrations is set to an integer value
Solution Approach 1:
By providing two independent cutting tools (first cutting tool and second cutting tool) on separate tool posts, the system can achieve chip segmentation even when the number of vibrations per rotation is set to an integer value. Each tool can be controlled independently, allowing one tool to perform cutting while the other is positioned to receive the reaction force, thereby segmenting the chips effectively.
Solution Approach 2:
The invention changes the operational parameters by allowing different vibration frequencies, amplitudes, and phases for each cutting tool. This parameter differentiation enables optimal chip segmentation for integer vibration values, as the independent control of each tool's parameters allows for fine-tuning to achieve the desired cutting效果.
3Reliability
If one cutting tool performs all the cutting, then the setup is simple, but the tool life is reduced and machining accuracy fluctuates
Solution Approach 1:
The cutting workload is segmented between two independent cutting tools. Each tool performs cutting for a portion of the workpiece rotation, allowing the tools to share the load and reduce individual wear. This segmentation of the cutting function extends tool life while maintaining simple operational setup.
Solution Approach 2:
The two cutting tools operate in a periodic alternating manner during workpiece rotation. One tool cuts while the other is positioned to receive reaction force, then they alternate as the workpiece rotates. This periodic action distributes the mechanical stress and heat generation, thereby extending tool life and reducing fluctuations in machining accuracy.
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 design enhances machining flexibility, improves tool life, and increases machining accuracy by allowing independent control of vibration parameters, reducing tool and workpiece fluctuations, and enabling easier condition settings for vibration cutting.
Implementation Method 1
vibration means for relatively vibrating the workpiece holding means and the tool post so that the cutting tool is fed in the feed direction while reciprocally vibrating along the feed direction
Data Source
Figure 1
Figure 2(A)~2(B)
Figure 3
AI summary
A control device for a machine tool and a machine tool, for which settings of the number of vibrations per rotation become easy, is provided. The control device (180) of the machine tool controls a relative rotation between a workpiece and a cutting tool and a relative reciprocal movement between the workpiece and the cutting tool in a feed direction to perform vibration cutting to the workpiece. The control device (180) comprises a control section (181) for controlling a spindle headstock (110), a first tool post (130A), and a second tool post (230A), the workpiece W being installed on the spindle headstock (110), the first tool post (130A) being provided to be reciprocally movable along the feed direction with respect to the spindle headstock and installed with a first cutting tool (130) for cutting the workpiece, and the second tool post (230A) being provided to be reciprocally movable along the feed direction with respect to the spindle headstock independently of the first tool post and installed with a second cutting tool (230) for cutting the workpiece.