Adjustable Roller-Guided Machining for Tight Curved-Part Tolerances

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Solution Overview

Problem

Existing manufacturing processes struggle to achieve tight profile tolerances on curved parts, often resulting in undesirable manufacturing artifacts that require manual rework, which is laborious, time-consuming, and imprecise.

Innovation Solution

A system for surface machining of curved parts, comprising a chassis with rollers and a cutting tool, where the distance between the cutting tool and the chassis is adjustable, allowing for precise removal of material to achieve the desired curvature or surface profile.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If known manufacturing processes are used to machine curved parts, then production can proceed with existing equipment, but tight profile tolerances cannot be achieved and manufacturing artifacts are created

Engineering Contradiction:

Improveprofile toleranceVSAvoidmanufacturing process complexity

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The system employs dynamic adjustment of the cutting tool position relative to the chassis through adjustable distance mechanisms, allowing the tool to adapt to varying surface curvatures and achieve tight profile tolerances on complex curved geometries that static systems cannot handle

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The invention changes the key parameter of cutting tool-to-chassis distance to enable precise control over the machining process, allowing the system to accommodate different curvature radii and achieve desired surface profiles by varying this critical dimension

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If manual rework is performed to remove manufacturing artifacts, then surface quality can be improved, but labor time and costs increase

Engineering Contradiction:

Improvesurface qualityVSAvoidrework time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The system performs preliminary precision machining to achieve the desired surface quality and profile tolerances in the initial manufacturing pass, preventing the formation of manufacturing artifacts that would otherwise require subsequent manual rework

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention replaces manual rework operations with an automated cutting tool system that can precisely remove material and achieve target surface quality, eliminating the need for labor-intensive manual intervention

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If manual rework is used to achieve desired tolerances, then surface precision can be improved, but worker safety and ergonomics deteriorate

Engineering Contradiction:

Improvetolerance achievementVSAvoidworker safety

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The system performs the precision machining task autonomously through automated cutting tools and control mechanisms, eliminating the need for workers to manually perform hazardous rework operations on curved parts

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The invention substitutes manual worker operations with an automated mechanical system that handles the precision machining, transferring the task from human operators to machine-based solutions that improve safety

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS20250114892A1System for surface machining a curved part

Publication Date: 2025.04.10 THE BOEING CO

AI summary

A system for surface machining of a curved part, the system including a chassis, a first and second roller, and a cutting tool. The first and second rollers each being coupled to the chassis and configured to contact the surface of a curved part. The cutting tool is disposed between the first and second rollers and coupled to the chassis such that a distance between the cutting tool and the chassis is adjustable.