Modular Additive Tool Assembly for Faster Machining Validation
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Solution Overview
Problem
The validation of machining process equipment is often costly and time-consuming, and existing methods for producing tool holders and spindle connections are expensive and time-consuming due to the need for precise materials and high precision finishing, which hinders the efficient deployment of prototypes for equipment validation.
Innovation Solution
A modular additive manufactured tool assembly is developed, using additive manufacturing to create a perishable tool and tool holder from polymeric materials, along with a metallic spindle connection and support structures, allowing for rapid and cost-effective validation of machining processes by simulating machining operations with a CNC program.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional machining processes are used to produce tool holders and spindle connections with precise materials and high precision finishing, then manufacturing precision and reliability are improved, but manufacturing time and cost increase significantly
Solution Approach 1:
The tool assembly is divided into distinct functional segments: the tool holder (made with additive manufacturing for rapid prototyping), the spindle connection (made with traditional precision processes for accuracy), and support structures. This segmentation allows each component to be manufactured using the most appropriate process for its specific requirements, resolving the contradiction between speed and precision.
Solution Approach 2:
Different manufacturing qualities are applied to different parts of the assembly. The tool holder uses additive manufacturing with acceptable tolerances for validation purposes, while the spindle connection uses high-precision traditional machining. This local differentiation of quality levels allows rapid validation without compromising critical interface precision.
2Reliability
If traditional machining processes are used with precise materials and high precision finishing, then reliability of the tool assembly is improved, but manufacturing cost increases
Solution Approach 1:
The assembly is segmented into high-reliability components (spindle connection) that use traditional precision manufacturing, and lower-criticality components (tool holder) that use cost-effective additive manufacturing. This segmentation maintains overall reliability while reducing total manufacturing cost.
Solution Approach 2:
The tool holder is designed as a disposable or single-use component made through additive manufacturing, accepting lower material and finish quality. Since it is not intended for long-term repeated use in production, the reduced manufacturing cost is acceptable while maintaining reliability for the validation purpose.
3Productivity
If additive manufacturing is used to produce the tool holder and perishable tool, then productivity and validation speed are improved, but manufacturing precision may be compromised
Solution Approach 1:
The critical interface components (spindle connection and holder locating features) are either additively manufactured with sufficient precision for validation or finished with traditional methods. Non-critical portions of the tool holder maximize additive manufacturing benefits for speed while accepting appropriate tolerances for the application.
4Adaptability or versatility
If the tool holder is made with perishable material through additive manufacturing, then adaptability for validation purposes is improved, but structural strength is reduced
Solution Approach 1:
The tool holder uses composite construction combining perishable polymeric material (for adaptability and cost-effectiveness) with metallic reinforcement elements (for strength). The metallic longitudinal and radial supports are embedded within or attached to the polymeric structure, creating a composite that achieves both flexibility for validation and sufficient structural strength.
Data Source
AI summary
A modular additive manufactured tool assembly includes a perishable tool and a tool holder coupled to the perishable tool. The tool assembly is configured to be coupled to a machine spindle. The tool assembly also includes a spindle connection coupled to the tool holder. The spindle connection is configured to be coupled to a machine spindle. Each of the tool holder and the perishable tool includes a perishable material. Each of the tool holder and the perishable tool is manufactured using an additive manufacturing process.