Rotary Workhead Device with External Biasing for Turbine Blade Machining
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing rotary workhead systems for machine tools processing turbine blades are complex and costly due to the need for hydraulic cylinders and specialized tailstocks, leading to increased production costs and potential downtime.
Innovation Solution
A rotary workhead device with two opposing rotary workheads and a biasing mechanism using a fluid pressure-operated cylinder and pressure control device, allowing for tensile or compressive force application, which simplifies configuration and reduces costs by eliminating the need for hydraulic cylinders in the tailstock, and using commercial rotary workheads for reduced production costs and ease of maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a hydraulic cylinder is incorporated in the tailstock to apply tensile force, then the workpiece rigidity is improved, but the device complexity and production cost increase
Solution Approach 1:
The hydraulic cylinder is extracted from the tailstock and relocated to an external position. The tailstock now only contains the simple tension member engagement mechanism, while the hydraulic cylinder is positioned externally to apply tensile force to the workpiece through the tension member, thereby simplifying the tailstock configuration while maintaining workpiece rigidity enhancement
Solution Approach 2:
A tension member is introduced as an intermediary element between the tailstock and the workpiece. The tension member transmits the tensile force from the externally positioned hydraulic cylinder to the workpiece, enabling force application without requiring the hydraulic cylinder to be integrated into the tailstock structure
2Strength
If a pressing mechanism is incorporated in the sub-chuck head to apply compressive force, then the workpiece rigidity is improved, but the device complexity and production cost increase
Solution Approach 1:
The pressing mechanism is extracted from the sub-chuck head and repositioned externally. The sub-chuck head now only contains the gripping mechanism for holding the workpiece, while the pressing mechanism is positioned externally to apply compressive force, thereby simplifying the sub-chuck head configuration while maintaining workpiece rigidity enhancement
3Strength
If specialized tailstocks and sub-chuck heads with integrated pressing mechanisms are used, then the workpiece can be processed under increased rigidity, but the production cost increases
Solution Approach 1:
The standard tailstock and sub-chuck head are designed to perform multiple functions: the tailstock serves both as a support structure and a tension member engagement point, while the sub-chuck head serves both as a gripping device and a mounting point for external pressing mechanisms. This multi-functionality eliminates the need for specialized, expensive components while maintaining the ability to process workpieces under increased rigidity
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
The solution enables efficient processing of thin, low-rigidity workpieces like turbine blades with minimal bending and vibrations, reducing production costs and downtime by using commercially available rotary workheads and allowing for easy replacement, while providing adjustable force application based on workpiece dimensions and materials.
Implementation Method 1
biasing means for biasing one of the rotary workheads in the direction away from or toward the other of the rotary workheads
Data Source
AI summary
The rotary workhead device, which is loaded on the table of a machine tool and onto which a workpiece to be machined is rotatably mounted, is equipped with: a base plate that is attached to the table of the machine tool; two rotary workheads that are provided on the base plate and disposed so that the axes of rotation coincide and the workpiece-fixing parts face each other; a guide means that is provided so as to be capable of moving at least one of the rotary workheads back and forth in the direction of the rotation axes; and an impelling means for impelling the one rotary workhead in a direction that separates or brings together the two rotary workheads. The rotary workhead device applies a tensile force or a compressive force on a workpiece, the respective ends of which are fixed between the two rotary workheads.