Hydraulic Active Element Insert for Multi-Speed Machining
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Solution Overview
Problem
Existing machine tools face challenges in simultaneously performing multiple machining steps with different active element speed requirements, leading to unsatisfactory compromises and quality losses due to conflicting machining processes.
Innovation Solution
A machine tool equipped with a speed-translating shear-cutting or forming active element insert and a method utilizing a hydraulic force/displacement converter, which allows for active element-specific force/speed transmission and damping of vibrations, enabling the combination of diverse machining processes in a single step without quality losses by adjusting the relative speed between active elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple active elements are guided in one movement against the workpiece to perform several machining steps in parallel, then throughput is increased, but machining quality deteriorates due to conflicting speed requirements of different machining processes
Solution Approach 1:
The active element holder is segmented into multiple independent active elements (shearing active element and forming active element), each capable of independent movement and speed control. This allows each active element to operate at its optimal speed for its specific machining process while being part of the same holder system, resolving the conflict between parallel processing and individual speed requirements.
Solution Approach 2:
The system transitions from a static, unified movement cycle to a dynamic system where each active element can have independent speed and movement characteristics. The control system enables dynamic adjustment of each active element's movement parameters, allowing the shearing active element to move faster than the forming active element during the same overall cycle, thereby maintaining both high throughput and machining quality.
2Device complexity
If a common drive system is used for multiple active elements, then device complexity is reduced, but adaptability to different machining process requirements deteriorates
Solution Approach 1:
The active element holder serves multiple functions: it holds multiple different types of active elements (shearing and forming), provides independent movement control for each element, and maintains structural integrity as a unified component. This multi-functionality allows a single holder design to accommodate various machining processes with different speed requirements without requiring entirely separate drive systems.
Solution Approach 2:
The control system acts as an intermediary between the common drive system and the multiple active elements. It receives the drive signal and distributes/adjusts it to each active element according to its specific requirements, enabling independent speed control while maintaining system integration. This intermediary layer provides adaptability without requiring completely separate drive systems.
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 the simultaneous execution of multiple machining processes, such as dividing and forming, with improved geometry quality and reduced burr formation, by adapting active element speeds and damping vibrations, thus enhancing throughput and product quality.
Implementation Method 1
The force/displacement converter (28) has a first piston (36) which is connected to the first active element receptacle (18) as a first connecting means (30), and a second piston (38) which forms a second connecting means (32) to which the second active element (26) is connected
Implementation Method 2
In cyclic processes, emerging vibrations can be damped by selecting the fluid flow in the force/displacement converter
Implementation Method 3
by selecting the hydraulic fluid with regard to its compressibility, the effect of a force on the workpiece can be dampened
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a speed-changing shearing or forming active element insert which is designed to be detachably connected to an active element receptacle of a machine tool, the speed-changing shearing or forming active element insert having a speed-changing unit which is in the form of a hydraulic force/distance transducer, the force/distance transducer comprising a housing, the housing interior of which is supplied with a hydraulic fluid, and the force/distance transducer comprising a first piston which is in contact with the hydraulic fluid via one piston end and a second piston which is in contact with the hydraulic fluid via one piston end and the cross-sectional area of which is smaller than the cross-sectional area of the first piston. The invention also relates to the use of the speed-changing shearing or forming active element insert in a machine tool.