Machining Process Axial Oscillation Control
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Solution Overview
Problem
Current vibration-assisted machining technologies face challenges in achieving precise dimensional and geometric tolerances during shape machining, particularly in axial form machining, due to the generation of undulations on the machined surface.
Innovation Solution
The method involves performing machining with a cutting tool subjected to axial oscillations, followed by reducing or canceling the amplitude of these oscillations while continuing to rotate the tool, allowing for precise shape machining without surface undulations. This can be achieved by deactivating or passivating the vibratory system, either by stopping the generation of oscillations or using an elastic damping member to absorb them.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If axial oscillations are applied during form machining, then chip evacuation is improved and material removal is facilitated, but undulations are generated on the machined surface which compromise dimensional and geometric tolerances
Solution Approach 1:
The patent applies periodic axial oscillations during the majority of the machining stroke to enhance chip evacuation and material removal, then periodically deactivates the oscillations during the final portion of the stroke to eliminate undulations and achieve precise dimensional tolerances. This time-based periodic activation and deactivation of vibrations resolves the contradiction between productivity improvement and precision maintenance.
Solution Approach 2:
The machining stroke is segmented into two distinct phases: a first portion where axial oscillations are active to maximize material removal efficiency, and a second portion where oscillations are deactivated to achieve precise surface finish and dimensional accuracy. This segmentation allows each phase to optimize for its specific objective without compromising the other.
2Productivity
If vibratory drilling is used to facilitate chip evacuation, then machining efficiency is improved, but the axial oscillations generate undulations on the surface that prevent guaranteeing dimensional and geometric tolerances
Solution Approach 1:
The patent implements periodic control of the vibratory system by activating axial oscillations during the initial and intermediate phases of the machining stroke to maximize chip evacuation efficiency, then deactivating the oscillations during the final phase to eliminate surface undulations and achieve the required dimensional and geometric tolerances.
Solution Approach 2:
The patent dynamically adjusts the state of the vibratory system during the machining operation, transitioning from an active oscillating state that enhances chip evacuation to an inactive state that ensures precision surface finish. This dynamic control allows the system to adapt its behavior to the specific requirements of different machining phases.
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 the production of surfaces with guaranteed dimensional and geometric tolerances, essential for non-cylindrical shapes like countersinks and tapered bores, by ensuring the tool's position and stabilizing the machining process, thus improving the quality of machined parts.
Implementation Method 1
using an elastic damping member to absorb them
Data Source
Figure 1
Figure 1A~1D
Figure 2
AI summary
The present invention relates to a machining process involving at least a shape machining, comprising: c) carrying out machining over a first distance using a cutting tool subjected, as it advances, to axial oscillations, then d) the reduction, in particular cancellation, of the amplitude of the axial oscillations, while continuing to drive the cutting tool in rotation.