Internal Chip Cutting Nozzle Alignment and Damping
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Solution Overview
Problem
Internal machining processes face challenges with continuous chip evacuation due to instability and vibration issues, particularly when using adjustable cutter heads with lateral movement, which complicates the precise adjustment of high-pressure flushing nozzles for chip breaking.
Innovation Solution
A device with a movable cutter head and integrated high-pressure flushing system, where the nozzle is fixed to the cutter head to maintain precise jet alignment, and a damping system to stabilize the structure and reduce vibrations, allowing for efficient chip breaking and removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a movable cutter head with lateral adjustment is used for internal machining, then the adaptability and versatility of the tool is improved, but the stability and vibration control deteriorate
Solution Approach 1:
The tool is divided into separate functional modules: a principal element (drill rod), a movable cutter head, and a damping system. This segmentation allows the cutter head to be independently adjusted for adaptability while the principal element and damping system maintain overall structural stability.
Solution Approach 2:
A damping system with damping mass is introduced to counterbalance the vibrations and instability caused by the movable cutter head. The damping mass absorbs vibrational energy, stabilizing the tool during internal machining operations.
2Productivity
If high-pressure flushing is used for chip breaking, then the productivity and chip removal efficiency is improved, but the device complexity and precision adjustment requirements increase
Solution Approach 1:
The high-pressure flushing system is merged with the movable cutter head assembly. The nozzle is integrated into the cutter head structure, and the fluid duct is combined with the linear movement mechanism, reducing overall system complexity while maintaining high-pressure chip breaking capability.
Solution Approach 2:
The cutter head assembly serves multiple functions: it provides lateral adjustment for adaptability, houses the high-pressure nozzle for chip breaking, and includes the linear movement mechanism for positioning. This multi-functionality reduces the need for separate components.
3Adaptability or versatility
If long overhang lengths are used for internal machining, then the adaptability to reach deep bores is improved, but the stability and vibration control deteriorate
Solution Approach 1:
The damping system with damping mass is specifically designed to counterbalance the vibrations caused by long overhang lengths. The damping mass absorbs vibrational energy, allowing the tool to maintain stability even when reaching into deep bores with extended overhang.
Solution Approach 2:
The damping system provides dynamic stabilization by absorbing and dissipating vibrational energy in real-time during machining operations. This allows the tool to maintain stability under varying operational conditions, including long overhang configurations.
4Manufacturing precision
If the nozzle is fixed to the cutter head for precise jet alignment, then the chip breaking effectiveness is improved, but the device complexity increases
Solution Approach 1:
The nozzle is merged with the cutter head structure as an integrated component. The fluid duct is combined with the linear movement mechanism, creating a unified assembly that maintains precise jet alignment without requiring separate mounting fixtures or adjustment mechanisms.
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 ensures stable machining conditions by maintaining precise jet alignment and reducing vibrations, enabling effective chip breaking and evacuation even with long overhang tools, using pressures up to 400 bar for efficient chip removal.
Implementation Method 1
a high pressure flushing of liquid coolant is used
Implementation Method 2
breaking up chips requires precise adjustment of the jet relative to the cutter
Implementation Method 3
use of a damped tool is often a solution to dampen the vibrations
Data Source
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AI summary
The present invention is related to a device for internal chips cutting machining in a bore with a unit for breaking up chips by internal chips cutting machining in the bore. The device comprises a principal element (2) with a longitudinal axis and with at least one movable cutter head (1) with a cutter (3) that can be moved essentially perpendicular to the longitudinal axis of the principal element (2). The device comprises a mechanism for linear motion. A nozzle (9) for flushing of the cutter fluid on the cutter (3) is located onto and can be moved together with the cutter head (1). A fluid duct (5) is in connection with the nozzle and with a source for cutter fluid at high pressure.