Mirror Milling Layout for Arched Thin-Walled Ring Thickness Accuracy
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional mirror milling technologies face challenges in accurately machining arched annular thin-walled workpieces due to their large dimensions, weak rigidity, and susceptibility to deformation, leading to difficulties in controlling wall thickness and contour accuracy, and existing solutions are either inaccurate, polluting, or energy-intensive.
Innovation Solution
A mirror milling device comprising an external vertical gantry milling head assembly, an internal support and measurement head assembly, a clamping fixture, and a worktable, with a vertically opposite layout structure allowing for real-time milling and support, and a machining method involving designed surface calculation, reverse surface calculation, coordinate compensation, and synchronous mechanical mirror milling to ensure accurate thickness reduction and feature completion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional mechanical milling is used on arched annular thin-walled workpiece, then the workpiece can be machined, but the wall thickness accuracy and contour accuracy are hard to control due to deformation
Solution Approach 1:
The workpiece is pre-clamped in a fixed position on the worktable before machining begins. The clamping fixture secures the workpiece to prevent deformation during the mirror milling process, ensuring that the wall thickness and contour accuracy are maintained throughout machining operations.
Solution Approach 2:
The patent replaces conventional mechanical milling with mirror milling technology that uses laser measurement and optical feedback systems. The laser scanner continuously measures the workpiece surface, and the control system adjusts the cutter position in real-time to compensate for any deformation, achieving high precision without traditional mechanical cutting forces.
2Manufacturing precision
If chemical milling process is used, then the workpiece can be machined with better accuracy, but the process causes heavy pollution and high energy consumption
Solution Approach 1:
The patent replaces chemical milling with a physical-based mirror milling process that uses laser measurement and controlled mechanical cutting. This substitution eliminates the need for chemical solutions and associated pollution while maintaining high precision through optical feedback and real-time measurement systems.
Solution Approach 2:
The patent changes the machining approach from chemical dissolution to controlled mechanical removal with precise parameter control. By using laser-measured surface data to guide cutter depth and position, the process achieves chemical-milling-level accuracy through mechanical means, reducing energy consumption and environmental impact.
3Stability of the object's composition
If the workpiece is clamped vertically by flexible clamping arm, then the workpiece can be held, but the clamping operation is complicated and rigidity is insufficient
Solution Approach 1:
Instead of clamping the workpiece vertically as in conventional methods, the patent inverts the approach by clamping the workpiece horizontally on a flat worktable. The clamping fixture applies force from above, securing the workpiece in a stable position that provides both simplicity of operation and sufficient rigidity for accurate mirror milling.
Data Source
AI summary
A mirror milling device for machining an arched annular thin-walled workpiece includes an external vertical gantry milling head assembly, an internal support and measurement head assembly, a clamping fixture, and a worktable. The machining method thereof includes: dividing a parallel curve of a theoretical surface and a parallel curve of a reverse surface, performing triangular meshing on a division point of the theoretical surface, using indexes of three points as indexes of a triangle, calculating area coordinates, in triangular meshes, of position points on a machining path, causing points with corresponding indexes on the reverse surface to form a triangle, reversely solving coordinate points by using the area coordinates, and compensating a machining path on a spherical surface from a designed curved surface to an actual curved surface obtained by means of reversing.