Inner Housing Machining With Angle-Drive Circular Tool Motion

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Solution Overview

Problem

Existing methods for machining the inside of engine housings with multi-axis machine tools face challenges in achieving high dimensional accuracy and surface quality due to movement axis tolerances and potential damage from tool holder contact.

Innovation Solution

A method utilizing a multi-axis movable tool holder with an actuating head driven by an angle drive, allowing the tool to be inserted and moved along a circular path independently of the machine tool's axes, ensuring high accuracy and reducing contact risks, combined with a non-rotatably connected tool for reduced vibration and wear.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a multi-axis machine tool is used to machine the inside of a housing, then the tool can access the inner surface through an opening, but the tolerances of the machine tool axes prevent achievement of high dimensional accuracy and surface finish

Engineering Contradiction:

Improveaccess to inner surfaceVSAvoiddimensional accuracy and surface finish

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The machining system is segmented into two independent parts: the machine tool responsible for positioning and the tool holder with angle drive responsible for the actual circular machining path. This segmentation allows the tool holder to operate independently of the machine tool's axis tolerances, achieving high precision without requiring the entire system to be ultra-precise.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The tool holder acts as an intermediary between the machine tool and the workpiece. It receives positioning from the machine tool but generates its own precise circular motion through the angle drive mechanism, mediating the rough positioning into fine precision machining.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If the tool holder is moved along machine tool axes to guide the tool along a circular path, then machining can be performed, but the loads on the machine tool axes cause tolerance deviations and require frequent reworking

Engineering Contradiction:

Improvemachining capabilityVSAvoiddimensional accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The mechanical system is replaced by substituting the machine tool's axis movement for circular path generation with a dedicated angle drive mechanism on the tool holder. This eliminates the need for the machine tool axes to bear the loads of circular machining, transferring the function to a specialized component designed for it.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If forming tools are used to achieve high surface finish, then surface quality can be improved, but the process becomes costly and uneconomical

Engineering Contradiction:

Improvesurface finishVSAvoidprocess cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The cutting parameters are optimized through the independent angle drive system, allowing precise control of cutting speed, feed rate, and depth of cut. This enables conventional cutting tools to achieve surface finishes previously only attainable with expensive forming tools, by optimizing the machining parameters rather than changing the tool type.

Inventive Principle:

Principle #35Parameter changes

4Measurement precision

If the tool holder contacts the housing during machining, then positioning can be maintained, but damage to the inside of the housing may occur

Engineering Contradiction:

Improvepositioning accuracyVSAvoiddamage risk to housing

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The system is designed with built-in tolerance for positioning variations through the angle drive mechanism. The independent circular motion generation allows the tool to maintain accurate machining path even with slight positioning variations, cushioning against potential damage from contact while preserving positioning accuracy.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentEP2569124B1Method for processing an inner face of a housing having an opening

Publication Date: 2022.03.30 WFL MILLTURN TECH

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AI summary

The invention relates to a method for processing an inner face (1) of a housing (2) having an opening (17), in particular a housing of a driving mechanism, by means of a machine tool (3), which has a multiaxially movable tool retainer (7), wherein a tool (8) retained by the tool retainer (7) is introduced through the opening (17) into the housing (2), which is stationary relative to the machine tool, and said tool is moved along a circular path (13) and in the direction of the housing (2) in order to process the inner face (1). In order to create advantageous method conditions, the control head (9) of the tool retainer (7) that accommodates the tool (8) is driven in a rotational manner by means of an angle drive (12) on the tool retainer (7) in order to move the tool (8) independently of the axes (4, 5, 6) of motion of the machine tool (3) along a circular path (13) in order to process the inner face (1).