Rotary Surface Machining With Half-Feed Smoothing Passes
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Solution Overview
Problem
Machining of rotationally symmetric faces using traditional turning or milling methods results in a 'peak/valley' surface structure, which can lead to leakage or contamination issues due to mechanical stresses and surface irregularities, particularly in sealed regions of machinery components.
Innovation Solution
A method involving a tool with a cutting edge that is brought into cutting engagement with the workpiece, where both the workpiece and tool are rotated, and moved in a constant feed direction, with specific adjustments in feed direction during surface machining to maintain the cutting position, effectively smoothing the surface by reducing roughness depth.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional turning or milling methods are used to machine rotationally symmetric faces, then the machining process is simple and efficient, but a 'peak/valley' surface structure is created that causes leakage and contamination issues
Solution Approach 1:
The machining process is divided into multiple cutting passes with different feed directions. The first pass machines the surface in one direction, and the second pass machines in a perpendicular direction, similar to how cross-hatching removes peaks and valleys. This segmentation of the cutting process eliminates the harmful peak/valley structure while maintaining machining efficiency.
Solution Approach 2:
The invention performs a second cutting pass immediately after the first pass without removing the workpiece from the machine or changing the tool orientation significantly. This continuous action ensures that the surface is refined in real-time, converting the harmful peak/valley structure into a smooth finish while the workpiece remains in position.
2Productivity
If a single cutting pass is used to machine the surface, then the machining time is short and productivity is high, but the surface structure contains peaks and valleys that reduce reliability
Solution Approach 1:
The machining process uses periodic cutting passes with alternating feed directions. The first pass creates an initial surface, and the second pass periodically intervenes to remove the peak/valley structure. This periodic action maintains high productivity by minimizing idle time while ensuring reliable sealing surfaces.
Solution Approach 2:
The first cutting pass performs a preliminary machining action to remove the bulk material and create the basic surface geometry. The second pass then performs the finishing action to eliminate peaks and valleys. This preliminary action approach ensures that the most time-consuming material removal is done first, maintaining productivity while achieving reliable surface quality.
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 generates a finer and harder surface on the workpiece, potentially eliminating the need for subsequent machining steps like hardening or grinding, thereby optimizing effort and cost by improving the surface finish and reducing mechanical stresses.
Implementation Method 1
the tool has at least one cutting edge that is brought into cutting engagement with the workpiece
Data Source
AI summary
A method for machining a workpiece with at least one tool, wherein the workpiece and/or the tool are driven in rotation, wherein the tool has at least one cutting edge that is brought into cutting engagement with the workpiece, namely into a cutting position, in a cutting operation, and wherein, in the cutting operation, the workpiece or the tool is moved in a feed direction with a constant feed, and wherein, in a surface machining operation, the tool and thus the cutting edge remain in the cutting position and the workpiece or the tool is moved in the feed direction, shifted by half the feed.