Multi-Axis Lathe Spindle Heat Management for Metal Machining

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Solution Overview

Problem

Forging and deep drawing techniques for metallic structures lead to hardening, making subsequent material removal operations like cutting difficult and costly, and require multiple assembly steps, which is undesirable for mass production with tight tolerances.

Innovation Solution

A multi-axis lathe tool with multiple spindles is used to perform cutting and machining operations, allowing for efficient material removal by engaging and disengaging the cutting tool to manage heat and reduce deformation, enabling faster processing and higher throughput with minimal product deformation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If forging and deep drawing techniques are used to deform metallic structures, then the metallic structure is strengthened through plastic deformation, but the metallic structure becomes more difficult to cut and requires expensive high-end cutting tools

Engineering Contradiction:

Improvestrength of metallic structureVSAvoidease of subsequent cutting operation

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The cutting tool performs periodic contact cycles with the substrate, engaging to remove material and disengaging to allow heat dissipation. This periodic engagement-disengagement pattern prevents continuous heat buildup that would cause work hardening, thereby maintaining ease of cutting throughout the machining process while still achieving the desired material removal.

Inventive Principle:

Principle #19Periodic action

2Shape

If forging and deep drawing techniques are used, then the metallic structure is formed, but multiple assembly steps are required which is undesirable for mass production with tight tolerances

Engineering Contradiction:

Improveformed metallic structureVSAvoidproduction efficiency for mass production

Core Design Contradiction:

ShapeVSProductivity

Solution Approach 1:

Multiple cutting operations that would traditionally require separate assembly steps are merged into a single machining process using a multi-axis lathe tool with multiple spindles. The system performs interior recess cutting, exterior region cutting, and finishing operations in sequence without requiring transfer between different machines or assembly steps, thereby dramatically improving productivity for mass production.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The multi-axis lathe tool is designed with multiple spindles and tools that can perform various cutting operations (roughing, finishing, interior recess cutting, exterior region cutting) on the same substrate without requiring changeover to different specialized machines. This multi-functional capability eliminates multiple assembly steps and maintains tight tolerances throughout the entire production process.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Productivity

If continuous cutting operation is performed, then material is removed efficiently, but heat is generated which causes deformation of the substrate

Engineering Contradiction:

Improvematerial removal efficiencyVSAvoiddeformation of substrate

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The cutting tool operates in periodic contact cycles, engaging the substrate to remove material efficiently and then disengaging to allow heat dissipation. This periodic action pattern maintains high productivity during the engagement phase while preventing excessive heat buildup and deformation during the disengagement phase, thereby resolving the contradiction between material removal efficiency and manufacturing precision.

Inventive Principle:

Principle #19Periodic action

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 method allows for efficient cutting and machining of metallic substrates with reduced heat generation and deformation, enabling the production of cosmetic housings for charging devices with improved finish and reduced waste, while maintaining high precision and throughput.

Implementation Method 1

disengaging the cutting surface from the first cutting tool to allow dissipation of at least some heat generated from the engaging the cutting surface with the first cutting tool

Methodology Applied

Scientific EffectHeat dissipation: Conduction (thermal)

Data Source

PatentUS10220447B2Polishing and brushing techniques for cylindrical and contoured surfaces

Publication Date: 2019.03.05 APPLE INC

AI summary

Material removal processes of a structure are disclosed. These processes can define several features. For example, metal structure can include an interior recess surrounded by a sidewall. The structure can further include a base portion integrally formed with the sidewall. The sidewall can include an opening extending through the sidewall and into the interior recess. The sidewall can undergo a material removal process to include multiple curved regions. The sidewall, the first curved region, and the second curved region can be polished to include a reflectivity different than a reflectivity of an exterior region of the base portion. A single multi-axes lathe having multiple spindles performs several material removal processes under a continuous machine cutting process. The spindles may include clamping features that allow a first spindle to perform a first operation then pass the metal structure to a second spindle. Additional processes include lapping, polishing, and linear brushing.