Polygon Machining Device Synchronization Ratio Control
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Solution Overview
Problem
The existing polygon machining process requires multiple steps, including deburring, which increases the number of processes and complicates the synchronization of the workpiece and polygon cutter phases, making it inefficient for forming multiple polygonal shapes on a workpiece.
Innovation Solution
A polygon machining device and method that allows for synchronization ratio adjustment, enabling the main shaft and tool spindle to operate at different rotation speeds, specifically allowing the main shaft to rotate faster than the tool spindle, and changing the synchronization ratio at a predetermined fixed point to maintain phase alignment between the workpiece and polygon cutter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If deburring machining is performed between first and second polygon machining, then burrs are removed from the workpiece, but the number of processes increases
Solution Approach 1:
The invention combines the deburring function with the polygon machining operation by configuring the polygon cutter to perform both polygon formation and burr removal in a single integrated process, eliminating the need for separate deburring steps between machining operations
2Manufacturing precision
If the phase matching between workpiece and polygon cutter is performed manually, then positioning accuracy can be achieved, but the operation complexity increases
Solution Approach 1:
The invention changes the synchronization ratio parameter between the main shaft and tool spindle to achieve automatic phase matching. By adjusting the rotational speed ratio, the system automatically aligns the workpiece phase with the polygon cutter phase without requiring manual positioning operations
Solution Approach 2:
The invention implements automatic phase matching through synchronization control that monitors and adjusts the rotational phases of the main shaft and tool spindle, using feedback mechanisms to maintain precise phase relationships during machining operations
3Device complexity
If the synchronization ratio is fixed, then the machining process is simple to control, but the flexibility to perform multiple polygon machining operations is reduced
Solution Approach 1:
The invention introduces dynamic adjustability of the synchronization ratio between the main shaft and tool spindle. The system can switch between different synchronization ratios depending on the machining requirements, enabling flexible performance of multiple polygon machining operations with different phase relationships while maintaining simple control through automated ratio selection
Data Source
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AI summary
A polygon machining method whereby first polygon machining using a polygon cutter is carried out on a workpiece, followed by machining using tools other than the polygon cutter, then second polygon machining using the polygon cutter again. The polygon machining method comprises: a first polygon machining step in which a main axis and a tool main axis are synchronously rotated such that the rotation speed of the main axis and the tool main axis are at a ratio required for the first polygon machining, and polygon machining is carried out; a machining step in which the ratio is changed to a second synchronization ratio such that the main axis rotates at a rotation speed required for machining after the first polygon machining, the main axis and the tool main axis are synchronously rotated, and machining is carried out on the workpiece that has received the first polygon machining; and a second polygon machining step in which the main axis and the tool main axis are synchronously rotated such that the rotation speed of the main axis and the tool main axis are at a ratio required for the second polygon machining, and polygon machining is carried out.