Laser-Started Flow Drilling for Precise Plate and Bar Boreholes
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for cutting plate-shaped or rod-shaped workpieces face challenges in producing precise drill holes with high axial forces and subsequent chip production, particularly when using twist drills, which can lead to inefficiencies and material deformation.
Innovation Solution
A method involving a laser beam to create a recess in the workpiece, followed by expansion with a flow drill, reduces axial forces and allows for precise borehole creation with defined positional accuracy, eliminating the need for chip removal and minimizing bulging during flow drilling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a twist drill is used to create a drill hole, then chip removal is possible, but manufacturing precision deteriorates and axial forces increase
Solution Approach 1:
A pilot hole is drilled first with a small diameter drill bit to establish the correct position and orientation of the hole. This preliminary action allows the subsequent larger diameter drill bit to be guided accurately, maintaining manufacturing precision while enabling chip removal capability.
2Manufacturing precision
If a flow drill is used to create a drill hole with high precision, then manufacturing precision improves, but axial forces increase significantly
Solution Approach 1:
A pilot hole is created first to establish the hole path and position. This preliminary action removes the need for the flow drill to penetrate the material from scratch, significantly reducing the axial forces required while maintaining the high precision positioning capability of the flow drill for the final hole dimensioning.
3Manufacturing precision
If a flow drill is used without a pilot hole, then manufacturing precision improves, but the amount of bulge increases requiring additional machining
Solution Approach 1:
A pilot hole is drilled first to create a cavity that guides the flow drill and contains the material displacement. This preliminary action provides a path for the flow drill to follow, maintaining high positioning accuracy while significantly reducing the amount of bulge created on the workpiece surface, eliminating the need for additional bulge machining.
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
This approach enables precise and efficient production of drill holes with reduced axial forces and minimal bulging, maintaining high positional accuracy and allowing for subsequent thread introduction using thread cutting or forming tools.
Implementation Method 1
a laser beam is directed onto the workpiece to be machined via a processing head of a laser processing device, a recess is created in the workpiece
Data Source
Figure 1
Figure 2
Figure 3~7
AI summary
The invention relates to a method for machine-cutting workpieces (2) in plate form or bar form and also to a machine tool (1), with a laser machining device (4), with a workpiece support (14), by means of which a workpiece (2) to be machined in the laser machining device (4) is received, and with a workpiece moving device (7), by means of which the workpiece (2) to be machined is held and moved in relation to the laser machining device (4), wherein with a machining head (17) a laser beam (16) is directed onto the workpiece (2) to be machined and a clearance (31) is introduced into the workpiece (2) and the clearance (31) is machined with a flow drill (33) and widened to a final size of a borehole (34).