Precision Roll Turning Lathe A-B Axis Tool Orientation
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Solution Overview
Problem
Conventional roll turning lathes are unable to perform ultra-precise machining of three-dimensional patterns of three-sided or four-sided pyramids on the surface of rolls, which are required for producing lenticular lens sheets and prism sheets in extrusion molding.
Innovation Solution
A precision roll turning lathe is designed with a headstock, tailstock, carriage, and tool swivel system that includes a tool post with a turning axis (A axis) for orienting the cutting tool perpendicular to spiral grooves, allowing for precise machining of three-sided pyramids by combining spiral and longitudinal grooves in a matrix pattern.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional roll turning lathe is used to machine three-dimensional patterns of pyramids on the roll surface, then the basic lathe structure is maintained, but ultra-precise machining capability is insufficient
Solution Approach 1:
The patent introduces a dynamically adjustable tool post with A-axis and B-axis rotation capabilities, allowing the cutting tool to be oriented in any direction relative to the roll surface. This dynamic positioning system enables precise machining of three-dimensional pyramid patterns by adjusting tool angles during operation, transforming a static lathe into a dynamically adaptable precision machining system.
Solution Approach 2:
The invention adds rotational dimensions (A-axis and B-axis) to the traditional lathe coordinate system. By incorporating these additional rotational degrees of freedom, the tool post can achieve complex spatial orientations required for machining three-dimensional pyramid patterns, effectively adding dimensional capability to the two-axis (X-Z) conventional lathe system.
2Manufacturing precision
If the cutting tool is oriented perpendicular to spiral groove direction for precise pyramid machining, then machining accuracy is improved, but the tool positioning system becomes more complex
Solution Approach 1:
The tool post incorporates an A-axis rotation mechanism that dynamically adjusts the tool orientation to remain perpendicular to the spiral groove direction during machining. This dynamic adjustment ensures that the cutting face is always properly aligned with the groove direction, maintaining high machining accuracy while automating the complex positioning requirement through a rotational degree of freedom.
Solution Approach 2:
The B-axis rotation mechanism pre-positions the tool at the required angle before machining begins. By calculating and setting the initial tool orientation based on the intended spiral groove parameters, the system prepares the cutting tool in advance at the correct angular position, reducing the complexity of real-time adjustment during the machining process.
3Shape
If spiral grooves and longitudinal grooves are machined in combination to form pyramid patterns, then three-dimensional patterns are achieved, but the machining process becomes more complex
Solution Approach 1:
The complex three-dimensional pyramid pattern is segmented into two simpler groove types: spiral grooves and longitudinal grooves. By dividing the overall pattern formation into these two separate machining operations, each with its own tool path and parameters, the system can machine complex shapes using sequential, manageable steps rather than attempting to machine the complete three-dimensional form in a single operation.
Solution Approach 2:
The machining process employs periodic indexing of the roll between spiral groove machining and longitudinal groove machining operations. The roll is rotated to predetermined angular positions (indexing) to allow the tool to machine different sets of grooves in sequence, creating the periodic pattern of pyramids across the roll surface through repeated cycles of alternating groove types.
Data Source
AI summary
The present invention provides a precision roll turning lathe which can form a pattern including three-dimensionally shaped portions, such as three-sided pyramids, on the surface of a roll, with high accuracy. Specifically, a tool post is provided with a tool turning axis (A axis) which is used to turn a tool such that, when forming a spiral groove cut through the roll, a cutting face of a tip of the tool is oriented perpendicular to a direction along which the spiral groove extends.