Machine Tool Frame Assembly Using Filled Aluminum Extrusions
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Solution Overview
Problem
Traditional machine tool construction techniques require high precision machining and costly materials to achieve precise alignment and damping, making them expensive and difficult to produce for the mass market.
Innovation Solution
A lightweight aluminum extrusion profile and construction technique using a precision jig filled with cement or epoxy to create a machine tool frame, allowing for precise alignment and damping without significant post-machining, and utilizing inexpensive structural materials and fabrication processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional precision machining techniques are used to achieve precise alignment and stiffness, then manufacturing precision and structural rigidity are improved, but production cost and manufacturing complexity increase significantly
Solution Approach 1:
The patent applies preliminary action by pre-machining the aluminum extrusion profiles to precise tolerances before assembly. The profiles are machined with precision features (flat surfaces, perpendicular faces, locating holes) in advance, allowing for accurate alignment during assembly without requiring high-precision machining of all components. This approach achieves precise alignment while reducing overall manufacturing complexity and cost.
Solution Approach 2:
The patent uses precision-machined aluminum extrusion profiles as reusable templates or copies of precise geometric forms. These profiles serve as master references that can be repeatedly used in multiple machine tool constructions, eliminating the need to perform high-precision machining on each individual component assembly. The precise geometry is copied from the machined profiles to the final assembled structure.
2Strength
If traditional bulky castings and forgings are used to achieve stiffness and damping, then structural rigidity and vibration suppression are improved, but weight and manufacturing cost increase
Solution Approach 1:
The patent employs composite construction by filling aluminum extrusion profiles with cement or epoxy material. This creates a composite structure where the aluminum profile provides structural framework and the filling material provides mass for damping and stiffness. The combination achieves the rigidity and vibration suppression traditionally associated with bulky castings and forgings, while significantly reducing weight compared to solid metal constructions.
Solution Approach 2:
The patent applies local quality by strategically placing filling material (cement or epoxy) only in specific regions of the aluminum extrusion profiles where mass is needed for damping and stiffness. Rather than using solid bulky materials throughout, the filling is concentrated in areas that provide maximum structural benefit, optimizing the stiffness-to-weight ratio and damping characteristics of the frame.
3Manufacturing precision
If precision machining of multiple components is performed to achieve proper alignment, then alignment accuracy between shafts and bearings is improved, but manufacturing time and production cost increase
Solution Approach 1:
The patent applies preliminary action by pre-machining alignment features directly into the aluminum extrusion profiles before assembly. The profiles are manufactured with precise locating surfaces, perpendicular faces, and positioned holes that ensure correct alignment of shafts and bearings. This eliminates the need for time-consuming precision machining and alignment operations during final assembly, significantly improving manufacturing efficiency while maintaining high alignment accuracy.
Solution Approach 2:
The patent merges multiple functions into the aluminum extrusion profiles themselves. The profiles incorporate structural support, alignment reference surfaces, bearing mounting features, and shaft locating features all in one component. This consolidation eliminates the need for separate precision-machined alignment components and reduces the number of machining operations required, thereby improving productivity without sacrificing alignment precision.
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 production costs and simplifies the manufacturing process while maintaining high precision and stiffness, enabling the production of affordable multi-axis machine tools with improved damping and alignment.
Implementation Method 1
one of the key challenges facing machine tool designers is to create rigid machine frames which resist tool deflection and which are also damped sufficiently to suppress vibrations
Implementation Method 2
create rigid machine frames which resist tool deflection
Data Source
AI summary
Cement or other liquid-like material fills the hollow tubes of a machine tool under construction. The machine tool structures are held rigidly against a fixture while the substance dries. The machine tool so constructed is relatively lightweight and rigid, and obviates the need for precision machining of large portions of the apparatus.