Hybrid Milling and Boring Head Layout for Speed and Rigidity
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Solution Overview
Problem
Current hybrid machine tools face limitations in both milling and boring capabilities due to speed restrictions, access issues, and maintenance complexities, particularly with existing boring head configurations that compromise on speed and rigidity, leading to reduced machining efficiency and reliability.
Innovation Solution
A hybrid machine tool design featuring a first carriage with a second carriage that can move along guide means, allowing for interchangeable milling and boring heads, where the boring head's bearings are housed within the casing, enabling higher milling head speeds and optimizing both deep hole boring and milling capacities without compromising on rigidity or requiring complex gearboxes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the motor and gearbox are positioned on the same axis as the boring bar (in line drive), then space is reduced, but the gearbox becomes very complex and maintenance becomes complicated
Solution Approach 1:
The invention extracts the gearbox from the in-line configuration and positions it on a parallel axis instead. This eliminates the complex epicyclic and hollow shaft gearbox design while maintaining compact space utilization. The motor remains on the same axis as the boring bar, but the gearbox is relocated to avoid the complexity issues.
Solution Approach 2:
The invention nests the gearbox within the casing structure in a parallel axis configuration, allowing the drive mechanism to be compact without requiring complex in-line gear arrangements. The gearbox is integrated into the overall housing design, achieving space efficiency without sacrificing maintainability.
2Speed
If the speed of rotation is increased in a boring head, then milling capacity improves, but the rigidity of the bar bearings must be lessened, reducing boring capacity and surface quality
Solution Approach 1:
The invention introduces a variable preload system for the bearings that can dynamically adjust the preload based on the operating mode. In milling operations, the preload is reduced to allow higher rotation speeds (up to 6,000 rpm). In boring operations, the preload is increased to maximize bearing rigidity and support the heavy cutting loads, thereby maintaining both high-speed milling capability and rigid boring performance.
3Adaptability or versatility
If the boring bar fails in a hybrid machine with interchangeable heads coupled to the outside of the boring bar, then the machine stops and becomes unusable
Solution Approach 1:
The invention segments the drive system into independent components: the motor and gearbox are mounted on the carriage rather than on the boring bar itself. This segmentation allows the boring bar to be replaced or repaired independently without affecting the drive mechanism. The motor and gearbox remain functional and positioned correctly regardless of which boring bar is installed, thereby maintaining machine availability and reliability.
4Reliability
If traditional drive with motor and gearbox on parallel axis is used, then tool clamping is simple and reliability is high, but space is required and gears need lubrication
Solution Approach 1:
The invention nests the parallel-axis motor and gearbox configuration within the carriage structure, integrating the drive mechanism into the existing carriage volume. This maintains the simplicity and reliability of traditional parallel-axis drives with simple tool clamping, while minimizing the space occupied by efficiently utilizing the carriage's internal volume and positioning components compactly.
Data Source
Figure 1~2
Figure 3
AI summary
Hybrid machine tool for milling and boring that comprises a first carriage (1) with movement in X, Y or Z, with a longitudinal axis (A), a second carriage (2) arranged in the first carriage with guide means (1.1), the second carriage being able to move on the guide means, the second carriage having rotation drive means with a first shaft (2.1) and a working axis (W) and a coupling (2.2) arranged at the end of the first shaft; a boring head (3) with a first support (3.1), a casing (3.3), bearings (3.2) and a boring bar (3.4); a milling head (4) with a second support (4.1) and a second shaft (4.2); the boring bar or the second shaft is aligned with the first shaft and its working axis, the coupling is configured to join to the boring bar of the boring head or the second shaft of the milling head.