Grinding Machine with Hydro-Expansion Clamping for Precision Bore and Surface Machining
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Solution Overview
Problem
Existing grinding machines are unable to completely machine workpieces with central bores and both-side planar and non-planar external surfaces on a single machine, requiring additional machines and processes, which increases production costs and precision issues due to environmental temperature changes and complex process planning.
Innovation Solution
A grinding machine with two grinding headstocks, one for external and one for internal grinding, and a clamping device that moves between these headstocks to allow for simultaneous machining of internal and external surfaces, using CNC control for precise positioning and hydro-expansion clamping for efficient and precise clamping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If workpieces are machined on multiple separate machines, then each machine can be optimized for its specific function, but production costs increase and precision deteriorates due to environmental temperature changes and complex process planning
Solution Approach 1:
The patent combines multiple grinding functions (external cylindrical grinding, internal cylindrical grinding, and planar surface grinding) into a single grinding machine. The machine features a workpiece holder with a workpiece receiving device and at least one grinding device that can perform all these operations, eliminating the need for multiple separate machines and thereby improving precision by keeping the workpiece in a constant thermal environment.
2Productivity
If workpieces are moved between multiple machines for complete machining, then each machine can specialize in specific operations, but production time increases and thermal environmental influences affect precision
Solution Approach 1:
The grinding machine enables continuous machining operations by keeping the workpiece clamped in the workpiece holder throughout the entire machining process. The grinding device can perform external cylindrical grinding, internal cylindrical grinding, and planar surface grinding in sequence without requiring workpiece removal or re-clamping, thereby eliminating idle time and thermal cycles.
3Productivity
If a single grinding machine performs all operations, then production efficiency improves and thermal stability is maintained, but the machine structure becomes more complex
Solution Approach 1:
The grinding device is designed as a multi-functional unit that can perform external cylindrical grinding, internal cylindrical grinding, and planar surface grinding operations. This universal grinding device eliminates the need for multiple separate grinding machines while maintaining production efficiency and thermal stability, as it can complete all machining operations on a workpiece in a single setup.
4Manufacturing precision
If workpieces are re-clamped between machines, then each machine can be optimized for its operation, but positioning precision deteriorates and setup time increases
Solution Approach 1:
The workpiece is clamped in the workpiece holder at the beginning of the machining process and remains clamped throughout all grinding operations. This preliminary clamping action eliminates the need for repeated clamping and positioning operations, thereby maintaining high positioning precision and reducing setup time.
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
Enables complete machining of workpieces with high precision and reduced cycle times, maintaining precise clamping and positioning, thus improving production efficiency and reducing costs by eliminating the need for multiple machines and minimizing thermal environmental influences.
Implementation Method 1
using CNC control for precise positioning and hydro-expansion clamping for efficient and precise clamping
Data Source
AI summary
A grinding machine for machining workpieces includes a workpiece headstock and two grinding headstocks. A first grinding headstock has two grinding spindles each with one grinding wheel for grinding first and second planar and non-planar external surfaces. A second grinding headstock has a grinding spindle having a grinding wheel for grinding a central bore in the workpiece, and a clamping device to clamp the workpiece. First, the bore and the first planar and any non-planar external surface are ground on one side of the workpiece. Then, the workpiece is clamped in the bore. The second planar external surface can then be ground in the same grinding machine with one of the grinding wheels of the first headstock. The clamping device attached to the second grinding headstock is such that the central axis of the clamping device is exactly aligned with the central axis of the workpiece headstock.