Rotor Support Surface Layout for Precise High-Speed Machining
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Solution Overview
Problem
Existing methods for producing a rotor with a screw compressor outer contour face challenges in reducing cycle time while maintaining high precision and reproducibility, especially when dealing with heavy workpieces and machining forces.
Innovation Solution
The use of a support device with angularly offset support surfaces, positioned via linearly guided slides on a Z-slide of the machine tool, allows for precise and quick adjustment of the workpiece, enabling stable and accurate machining by rotating the workpiece around its central axis, and facilitating rapid production of workpieces with varying outer contours.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the workpiece is supported on multiple angularly offset support surfaces to ensure precise positioning under heavy weight and machining forces, then manufacturing precision and reproducibility are improved, but the complexity of the support device and adjustment mechanism increases
Solution Approach 1:
The support surfaces are made adjustable through linearly guided slides that allow dynamic repositioning during the machining cycle. The slides enable the support surfaces to be quickly adjusted to different positions along the Z-axis while maintaining angular offset arrangement, transforming a static complex structure into a dynamically adaptable one that reduces overall system complexity.
Solution Approach 2:
The support device with multiple angularly offset support surfaces serves multiple functions: it supports heavy workpieces, ensures precise positioning, and accommodates different workpiece geometries through adjustable slides. This multi-functional design eliminates the need for multiple specialized fixtures, reducing device complexity while maintaining high positioning accuracy.
2Productivity
If the support surfaces are adjusted using linearly guided slides on a Z-axis slide to enable quick positioning, then cycle time is reduced, but the device complexity and initial setup time increase
Solution Approach 1:
The support surfaces are pre-positioned on linearly guided slides that are already mounted on the Z-axis slide structure. This preliminary arrangement allows the slides to be quickly activated and adjusted during the machining cycle without requiring complex real-time positioning systems, reducing cycle time while keeping the added complexity manageable.
Solution Approach 2:
The linearly guided slides replace traditional manual positioning mechanisms, enabling automated and rapid adjustment of support surfaces. This mechanical substitution with precision-guided slides significantly reduces adjustment time and cycle time, outweighing the initial complexity increase through standard化的 slide components.
3Productivity
If the workpiece is machined by rotating it around the central axis to reduce cycle time, then productivity is improved, but the requirement for precise support stability and positioning accuracy increases
Solution Approach 1:
The support device provides localized precision support at specific angular positions around the workpiece axis. Each support surface is strategically positioned to contact the workpiece at optimal locations, ensuring stability and positioning accuracy specifically where needed during rotation, rather than requiring uniform support throughout the entire circumference.
Solution Approach 2:
The adjustable slides allow the support surfaces to be dynamically positioned to match the specific geometry and balance requirements of different workpieces. This dynamic adjustment capability ensures optimal support stability during high-speed rotation, enabling increased machining speeds without sacrificing precision.
Data Source
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AI summary
A machine tool (1) for manufacturing a workpiece (2) with an outer contour (3), in particular a rotor of a screw compressor, and a method for this purpose are shown. In order to ensure high manufacturing accuracy with short cycle times, it is proposed that the workpiece (2, 200) is supported at its outer contour (3) at least on a first and a second support surface (11, 12a, 12b), in particular a sliding surface, of a support device (10), wherein at least these two support surfaces (11, 12a, 12b) are arranged angularly offset from each other about the axis of rotation (D), wherein the first and/or the second support surface (11, 12a, 12b) is positioned on the workpiece (2, 200) via at least one, in particular linearly, guided slide (13, 14) which is provided on a Z-slide (8) of the machine tool (1).