Hydraulic Workpiece Stabilizers for Thin-Wall Milling Vibration
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Solution Overview
Problem
Machining thin-walled aerospace components, such as turbine blades, is challenging due to deflection and vibration caused by milling cutting forces, which can result in dimensional errors and damage, especially when the workpiece is not optimally supported.
Innovation Solution
A device with multiple hydraulically driven stabilizing elements is used to support thin-walled workpieces in machine tools, providing damping through friction and ensuring even support across the workpiece surface, featuring a base with elongated bodies and cylindrical stabilizing elements that can move axially to contact the workpiece, with optional pneumatic control for easy mounting and dismounting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the workpiece is clamped only at both ends in the machine tool, then the clamping structure is simple, but the workpiece deflects locally under high cutting forces
Solution Approach 1:
The support device is divided into multiple independent stabilizing elements (at least ten, preferably at least 20) distributed in at least two rows on the base. Each stabilizing element can independently contact the workpiece surface, providing distributed support rather than concentrated clamping at endpoints only.
Solution Approach 2:
A base with multiple stabilizing elements is introduced as an intermediary support structure between the workpiece and the machine tool. This mediator provides continuous support across the workpiece surface, preventing local deflection while maintaining the simplicity of endpoint clamping.
2Ease of operation
If the workpiece is clamped at both ends, then the setup is simple, but vibrations occur during machining
Solution Approach 1:
The support function is segmented into multiple stabilizing elements distributed across the base surface. This segmentation provides continuous support that dampens vibrations while keeping the overall setup simple through the modular nature of the stabilizing elements.
Solution Approach 2:
The stabilizing elements are designed with hydraulic or pneumatic actuation, allowing dynamic adjustment of support parameters. This enables the support force to be optimized for vibration damping while maintaining ease of setup through automated adjustment.
3Manufacturing precision
If the whole surface of the workpiece is supported, then deflection is prevented, but the device complexity increases
Solution Approach 1:
The continuous support surface is achieved through segmentation into multiple discrete stabilizing elements. These elements are distributed in at least two rows across the base, providing comprehensive support without requiring a complex continuous structure.
Solution Approach 2:
Hydraulic or pneumatic actuation systems are used to control the stabilizing elements, enabling automated adjustment and reduction of mechanical complexity. The fluid power system provides precise control with simple actuation mechanisms.
4Device complexity
If stabilizing elements are made fixed, then the structure is simple, but they cannot adapt to workpiece deflection
Solution Approach 1:
The stabilizing elements are designed with dynamic adjustment capability through hydraulic or pneumatic actuation. This allows the support force to adapt dynamically to workpiece deflection during machining, maintaining reliability while managing complexity through automated control.
Solution Approach 2:
The stabilizing elements can automatically adjust their position and support force in response to workpiece deflection, providing self-regulating support. This self-service capability enhances reliability without requiring complex external control 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
The device effectively stabilizes thin-walled workpieces during machining, reducing deflection and vibration, thereby improving the surface quality and preventing damage by providing uniform support and damping across the entire workpiece surface.
Implementation Method 1
The stabilizing element comprises a cylinder and a rod arranged therein and the rod can be hydraulically driven to move in the axial direction of the stabilizing element
Implementation Method 2
The movement of the stabilizing elements in the axial direction can damp the local vibration through the friction of the flow of the oil
Data Source
AI summary
A device for stabilizing a workpiece, in particular a thin-walled workpiece mounted in a machine tool, comprises at least one base; and a plurality of stabilizing elements. The stabilizing elements protrude away from one surface of the base, wherein the stabilizing element comprises a cylinder and a rod arranged therein and the rod can be driven hydraulically to move in the axial direction of the stabilizing element such that the rod of at least two of the stabilizing elements can be brought into contact with one surface of the workpiece.