Non-Rotating Boring Tool With Angled Actuator Vibration Damping
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Solution Overview
Problem
Existing non-rotating boring tools experience vibrations during internal turning operations due to tangential and radial cutting forces, leading to noise, impaired surface finish, and tool breakage, which current active damping systems struggle to efficiently mitigate.
Innovation Solution
A non-rotating boring tool design featuring a single-axis or dual-axis electrically controlled vibration actuator aligned with the expected orientation of resultant cutting forces, integrated within the boring bar's elongated body, to effectively dampen vibrations caused by cutting forces, with optional adjustable positioning for optimized damping characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional boring bar without active damping is used, then the device complexity is low, but vibrations occur during internal turning operations causing noise, impaired surface finish, and tool breakage
Solution Approach 1:
The vibration actuator is pre-positioned in the elongated body at an angle of 10-40 degrees relative to the cutting edge, aligning it with the expected direction of resultant cutting forces before machining begins. This preliminary positioning enables the actuator to effectively counteract vibrations as soon as cutting forces are applied, without requiring complex real-time orientation adjustments
Solution Approach 2:
The actuator is configured to generate vibratory forces dynamically in response to cutting conditions. The system adapts to varying cutting forces by adjusting the magnitude and frequency of counter-vibrations, allowing the damping system to remain effective across different machining parameters while maintaining a relatively simple fixed geometric configuration
2Object-affected harmful factors
If an active damping system with vibration actuators is added to the boring bar, then vibration damping is improved, but the device complexity increases
Solution Approach 1:
The actuator is positioned at a specific location and angle (10-40 degrees) within the elongated body, optimizing its effectiveness for counteracting vibrations in the critical region where cutting forces are applied. This localized, angle-specific positioning concentrates the damping effect where it is most needed, reducing the need for multiple actuators or complex distributed damping structures
Solution Approach 2:
The angle parameter of the actuator (10-40 degrees) is optimized to match the expected orientation of resultant cutting forces. By tuning this geometric parameter, the system achieves effective vibration damping without requiring complex active adjustment mechanisms, as the fixed angle is sufficient to counteract the predominant vibration directions
3Reliability
If the actuator angle is optimized to 10-40 degrees relative to the cutting edge, then vibration counteraction effectiveness is improved, but the manufacturing precision requirements increase
Solution Approach 1:
Instead of requiring precise positioning at a single optimal angle, the design specifies a range of 10-40 degrees that provides effective vibration damping across the entire range. This partial optimization approach accepts a broader angular tolerance, reducing manufacturing precision requirements while still achieving sufficient damping effectiveness for practical machining operations
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 tool achieves efficient vibration damping, reducing noise and improving surface finish by aligning actuators with the expected orientation of cutting forces, thereby enhancing machining stability and tool longevity.
Implementation Method 1
an electrically controlled vibration actuator for active vibration damping of the boring bar and configured to generate vibratory forces in parallel or at least substantially in parallel with a working axis of the actuator
Data Source
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AI summary
A non-rotating boring tool for internal turning comprising: - a boring bar (2) comprising an elongated body (6); - a cutting element (5) with a rake side (30), a relief surface (32) and a cutting edge (33); and - an electrically controlled vibration actuator (8) for active vibration damping of the boring bar. When seen in a cross-sectional plane that is perpendicular to a longitudinal axis (7) of the elongated body and intersects the cutting edge in a radially outermost point (39), straight and imaginary first and second reference lines L1, L2 intersect the cutting edge in the radially outermost point with: • the first reference line L1 extending at an angle of 6° to the relief surface (32) on the outside of the cutting element, and • the second reference line L2 extending between the rake side (30) and the relief surface (32) at an angle of 10-40° to the first reference line L1. Said actuator is arranged with its working axis (10) extending in parallel with the second reference line L2.