Magnetorheological Jet Support for Large Thin-Walled Part Milling
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Solution Overview
Problem
Current methods for machining large thin-walled parts, such as mirror milling and magnetorheological fluid support, face challenges including high equipment complexity, large space requirements, difficulty in maintaining mirror symmetry, surface scratching, and limited flexibility in processing complex shapes, due to stiffness issues and deformation during machining.
Innovation Solution
A supporting device and method combining magnetorheological fluid technology with jet supporting technology, where a nozzle ejects magnetorheological fluid to offset milling forces with a controlled jet impact and magnetic field, allowing for flexible and precise support without exceeding the yield strength of the fluid, and enabling recycling of the fluid.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If magnetorheological fluid is used in a pool filled mode to support the workpiece, then clamping reliability is improved, but equipment size increases and flexibility is reduced
Solution Approach 1:
The patent divides the magnetorheological fluid support system into localized jet streams rather than a continuous pool. Multiple nozzles喷射磁流变流体 to specific areas where support is needed, transforming the continuous fluid pool into segmented, targeted jets that maintain reliability while reducing overall equipment size and increasing flexibility.
Solution Approach 2:
The patent replaces the mechanical pool-filled magnetorheological fluid system with a jet-based system. Instead of submerging the workpiece in a large pool of fluid, jet nozzles deliver controlled streams of magnetorheological fluid to specific support points, substituting a bulky mechanical system with a more compact, flexible jet delivery mechanism.
2Force
If magnetorheological fluid is used in extrusion mode to support the workpiece, then support force is provided, but elastic deformation occurs in magnetic particle chains affecting machining precision
Solution Approach 1:
The patent employs periodic or pulsed jet delivery of magnetorheological fluid rather than continuous extrusion. By controlling the jet in periodic bursts and timing it with the machining cycle, the system provides necessary support force while allowing magnetic particle chains to stabilize and avoid elastic deformation that would compromise precision.
Solution Approach 2:
The system incorporates feedback control to monitor the state of the magnetorheological fluid and adjust jet parameters in real-time. This feedback mechanism detects when magnetic particle chains are forming and adjusts the jet timing and intensity to prevent excessive elastic deformation, thereby maintaining machining precision while providing adequate support force.
3Force
If traditional jet fluid is used to offset milling force, then support is provided, but surface scratching occurs due to embedded chips and impurities
Solution Approach 1:
The patent changes the fundamental parameter of the supporting fluid from traditional jet fluid to magnetorheological fluid. This parameter change transforms the fluid from a passive carrier that can embed chips and impurities into an active, controllable medium with magnetic properties. The magnetic field control allows the fluid to solidify and support the workpiece without the surface contact and embedding problems of traditional fluids, while still providing the necessary offset force against milling forces.
4Productivity
If two five-axis horizontal machine tools are used for mirror milling processing, then machining capability is improved, but device complexity and space requirements increase
Solution Approach 1:
The patent introduces magnetorheological fluid jets as an intermediary support mechanism between the workpiece and the machining system. Instead of requiring a complex second five-axis machine tool to provide counterbalancing support, the magnetorheological fluid jets act as a flexible intermediary that can be positioned and controlled to provide the necessary support force, thereby eliminating the need for the second complex machine tool while maintaining machining capability.
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 reduces the need for complex machine tools, allows for flexible movement and precise control, prevents surface scratching, and maintains high machining precision by accurately offsetting milling forces without exceeding the yield strength of the magnetorheological fluid, facilitating the processing of complex shapes and sizes.
Implementation Method 1
uses the impact force of the jet to offset most of a milling force
Implementation Method 2
the intensity of the magnetic field is controlled to instantly cure the magnetorheological fluid; a magnetic particle chain is formed to support the workpiece
Implementation Method 3
Under the action of a magnetic field, the magnetorheological fluid can rapidly and irreversibly realize the conversion between liquid and solid
Implementation Method 4
The magnetorheological fluid has high damping and can prevent flutter during processing
Data Source
AI summary
A supporting device and method for a large thin-walled part is disclosed. The supporting device comprises a processing device and a supporting device. A workpiece is positioned between the processing device and the supporting device and is clamped at a periphery in a flexible clamping mode. A cutter in the processing device is connected with an iron core. A coil is wound on the iron core. When the coil is energized, a magnetic field is generated around the coil. A blade part of the cutter is in contact with a processing side of the workpiece. The supporting method combines the magnetorheological fluid technology with the jet supporting technology, and uses a jet impact force to offset part of a milling force. The current magnitude and winding mode of the coil are changed to control magnetic field intensity. The magnetorheological fluid is cured instantly to support the workpiece.