5-Axis Grinding Machine Circular Base Thermal Deformation
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Solution Overview
Problem
Existing grinding machines face issues with thermal deformation due to heat generation during the grinding process, leading to reduced machining accuracy, stability, and efficiency, as well as a shorter service life.
Innovation Solution
A 5-axis grinding machine with a symmetric design featuring a circular base, curved pillar, and vertically arranged torque motors driving grinding wheels that can rotate 360 degrees, allowing for improved stability, error compensation, and efficient heat dissipation, while the symmetric structure and dual motor drive enhance machining accuracy and extend the machine's service life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high speed rotating grinding wheel is used, then grinding efficiency is improved, but heat generation increases causing thermal deformation
Solution Approach 1:
The grinding wheel is divided into multiple independent grinding elements that can rotate separately, allowing distributed heat generation and improved heat dissipation. Each grinding element operates independently, reducing cumulative heat accumulation compared to a single large grinding wheel.
Solution Approach 2:
The patent introduces vertical rotation capability to the traditional horizontal grinding setup. The grinding wheels can rotate in both horizontal and vertical planes, creating a five-axis configuration that adds a new dimension to heat dissipation pathways and improves thermal management while maintaining high grinding efficiency.
2Ease of manufacture
If traditional bed body structure is used, then manufacturing simplicity is maintained, but machining accuracy deteriorates due to thermal deformation
Solution Approach 1:
The bed body is designed with asymmetric thermal compensation features including curved surfaces and non-uniform thickness distribution. These asymmetric geometries are specifically engineered to counteract thermal deformation patterns, allowing the bed body to maintain machining accuracy despite heat generation during operation.
Solution Approach 2:
The bed body material properties and geometric parameters are optimized to change thermally. The design incorporates materials and structures that exhibit controlled thermal expansion characteristics, allowing the bed body to adapt its dimensions in response to temperature changes while maintaining precision machining surfaces.
3Device complexity
If single motor drive is used, then device complexity is reduced, but machining stability deteriorates due to vibration
Solution Approach 1:
The dual motor configuration is arranged to provide counterbalancing forces that cancel out vibrations and instability. The motors are positioned and oriented to create opposing rotational forces that compensate for mechanical imbalances and reduce vibration during machining operations, thereby improving stability without requiring complex active damping systems.
Solution Approach 2:
The motor drive system is designed with preliminary synchronization mechanisms that pre-align the rotational phases of multiple motors before operation begins. This preliminary coordination ensures that the combined driving forces are harmonically balanced, preventing vibration and instability from the outset without requiring complex real-time control.
4Device complexity
If grinding wheels are constrained in rotation, then structural simplicity is maintained, but adaptability deteriorates
Solution Approach 1:
The grinding wheel assembly is designed with dynamic rotation capabilities, allowing the wheels to change their orientation and rotation axis during operation. This dynamic configuration enables the system to adapt to different workpiece geometries and machining requirements without requiring multiple fixed grinding assemblies, thereby improving versatility while maintaining reasonable structural complexity.
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
The symmetric design reduces machining errors, improves stability and accuracy, extends the service life of the grinding machine, and facilitates efficient heat dissipation, resulting in enhanced machining performance and reduced vibration.
Implementation Method 1
the grinding wheel head bracket includes torque motors vertically provided, a lower part of the torque motor is connected to a horizontally provided spindle by means of a bearing of a rotation table
Implementation Method 2
the big pulley is connected to a spindle pulley by a wide synchronous belt, the spindle pulley is disposed around a middle of the spindle so as to drive the spindle to rotate
Implementation Method 3
A grinding machine can be used to grind a surface of a workpiece by a grinding tool
Implementation Method 4
the two symmetrical spindle motors are used for synchronously driving the center shaft of the big pulley to rotate... the stability of the grinding machine is improved, which specially solves the problem of heat dissipation and machining error caused by heat deformation, and reduces the vibration of the grinding machine during the machining
Implementation Method 5
the upper horizontal surface of the base is circular... the symmetric design reduces machining errors, improves stability and accuracy... and facilitates efficient heat dissipation
Data Source
AI summary
A grinding machine with 5-axis for cutters is disclosed, the grinding machine includes a grinding machine base (12) with an circular upper horizontal surface and a pillar (56) provided on one side of the grinding machine base, the pillar is curved with a radian of 180° along a side edge of the base, a groove body (63) on the circular base is enclosed by a curved vertical plate on the another side edge, and the height of vertical plate is lower than that of the pillar. The center of a circle is used as machining center of the grinding machine, so that heat is dissipated outwards uniformly and radially from the center of the grinding machine, the deformation caused by heat in all direction is approximate, and it is easy for temperature compensation, the influence on the machining quality caused by heat deformation is reduced, errors are reduced, the grinding machine is specially suitable for machining cutters with high accuracy requirements, the bed body with the circular base has good stability and balance performance.