Polygon Machining Synchronization Reduces Process Steps
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Solution Overview
Problem
The existing polygon machining process requires multiple steps, including deburring and additional machining, increasing the number of processes needed to achieve the desired polygonal shapes on a workpiece's outer and inner surfaces.
Innovation Solution
A polygon machining device and method that synchronizes the rotation of a workpiece with a polygon cutter mounted on a tool spindle, allowing for simultaneous phase matching and machining of multiple polygonal shapes on the outer peripheral surface, reducing the number of processes by controlling the main shaft and tool spindle rotations independently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple polygon machining processes are performed sequentially with deburring operations, then the desired polygonal shapes can be formed on the workpiece surface, but the number of machining processes increases and production efficiency decreases
Solution Approach 1:
The patent combines multiple polygon machining operations into a single synchronized machining process. The control unit coordinates the rotation of the workpiece and the polygon cutter to perform multiple polygonal shape formations simultaneously, eliminating the need for separate deburring operations and reducing the total number of machining processes while maintaining precision.
Solution Approach 2:
The patent employs dynamic synchronization between the workpiece rotation and the polygon cutter rotation. The control unit dynamically adjusts the rotation speeds and phases of both components to achieve precise polygonal shape formation in a single pass, enabling flexible and efficient multi-polygon machining without fixed sequential operations.
2Manufacturing precision
If the phase matching between workpiece and polygon cutter is performed manually between each machining operation, then polygonal shapes can be formed, but the complexity of operation increases and time is lost in phase adjustment
Solution Approach 1:
The control unit implements automatic phase matching by monitoring and coordinating the rotation positions of both the workpiece and the polygon cutter. This feedback-based synchronization system automatically adjusts and maintains the correct phase relationship between the two rotating components, eliminating manual phase matching operations while ensuring precise polygonal shape formation.
Solution Approach 2:
The system performs self-synchronization of phases through the control unit, which automatically manages the coordination between workpiece rotation and cutter rotation. The system serves itself by internally managing the phase relationship without requiring external manual intervention, thereby simplifying operation and reducing adjustment time.
3Manufacturing precision
If deburring machining is performed between polygon machining operations, then burrs can be removed from the workpiece surface, but the total machining time increases
Solution Approach 1:
The patent merges the deburring function into the main polygon machining operation. By carefully coordinating the rotation phases and using the polygon cutter's geometry and cutting edges, the system performs both polygonal shape formation and burr removal in the same machining pass, eliminating separate deburring operations and reducing total machining cycle time while maintaining surface quality.
Data Source
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AI summary
A polygon machining method whereby first polygon machining is carried out on a workpiece held by a main axis, by using a polygon cutter attached to a tool main axis, then machining using a tool other than the polygon cutter is carried out, and second polygon machining after said machining is carried out, using the polygon cutter. The polygon machining method comprises: a synchronized stopping step in which the main axis is stopped at a predetermined prescribed rotation position, in a state in which the main and the tool main axis during polygon machining are synchronously rotated when the first polygon machining has been completed; a synchronization release step in which the synchronization of the main axis and the tool main axis is released when starting machining after the first polygon machining; a main axis stopping step in which the main axis is stopped at a prescribed rotation position when the machining after first polygon machining has been completed; and a synchronization starting step in which the main axis and the tool main axis are synchronously rotated when starting second polygon machining.