Hole Drilling Method Using Inverted Tool-Workpiece Tracking
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Solution Overview
Problem
Existing hole drilling methods face challenges in maintaining high machining accuracy, especially when drilling deep holes with small diameters, as the drill becomes less rigid, leading to reduced accuracy and requiring frequent repositioning of the workpiece, which is time-consuming and prone to unbalance issues.
Innovation Solution
A method where the rotary tool and workpiece move relative to each other with the workpiece rotating in the opposite direction to the tool, using multiple linear feed axes to track the tool's position, allowing for continuous drilling of holes without repositioning and maintaining high accuracy even for deep holes with a depth-to-diameter ratio of 7 or more.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the workpiece is repositioned for each hole drilling, then the hole position accuracy is improved, but the work time and operational complexity increase
Solution Approach 1:
Instead of moving the workpiece to align holes with the rotation axis, the invention inverts the approach by moving the rotary tool to track the rotating workpiece. The workpiece rotates on the rotation axis while the rotary tool moves in synchronization to maintain proper positioning over each hole location, eliminating repeated workpiece repositioning operations
Solution Approach 2:
The invention implements dynamic positioning where the rotary tool's position is continuously adjusted to track the rotating workpiece. The control device coordinates the rotary tool's movement with the workpiece rotation, enabling the tool to dynamically follow the workpiece rotation and maintain accurate positioning without static repositioning operations
2Manufacturing precision
If the workpiece is fastened for hole alignment, then the hole drilling accuracy is improved, but unbalance and striking issues occur
Solution Approach 1:
The invention reverses the traditional approach by keeping the workpiece stationary on the rotation axis and instead moving the rotary tool to track the workpiece rotation. This eliminates the need to fasten the workpiece for alignment, preventing unbalance and striking problems while maintaining drilling accuracy through dynamic tool positioning
Solution Approach 2:
The rotary tool's movement trajectory copies or mirrors the workpiece rotation motion. The control device ensures the rotary tool follows a path that corresponds to the workpiece rotation, maintaining proper positioning without physically constraining the workpiece in potentially unbalanced positions
3Length of moving object
If a drill with small diameter and long axial direction is used for deep holes, then the hole depth capability is improved, but the drill rigidity and machining accuracy deteriorate
Solution Approach 1:
Instead of rotating the drill and moving it linearly into the workpiece, the invention rotates the workpiece and moves the rotary tool in tracking motion. This inverted approach allows the rotary tool to engage the workpiece in a manner that maintains better rigidity and control, even for deep hole drilling applications
Solution Approach 2:
The dynamic tracking motion of the rotary tool, coordinated with workpiece rotation, enables controlled engagement that maintains machining accuracy. The system dynamically adjusts the rotary tool's position and motion to optimize cutting conditions throughout the deep hole drilling process, compensating for the challenges of long axial direction drilling
Data Source
AI summary
A hole drilling method includes a rotating step of attaching a workpiece to a rotary table to make the workpiece rotate in an opposite direction to the rotating direction of the rotary tool and a drilling step of making the rotary tool and the workpiece move relative to each other in a direction in which they approach each other so as to drill a hole. The hole drilling step comprises making a position of the rotary tool track the rotation of the workpiece while drilling the hole so that the rotary tool is arranged at a position for drilling a hole in the workpiece.