Sheet Machining Rollers for Spring Back and Hole Quality Control
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Solution Overview
Problem
Machining operations on sheets often result in uncontrolled spring back, leading to less than desired hole quality and potentially breaking drill bits, due to the initial machining force and resulting elastic energy release.
Innovation Solution
A machining system with a spring back control system that applies a compression force to the sheet using force generators and force loaded members with roller contact surfaces, allowing machining operations to be performed while maintaining contact and reducing spring back.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If machining operations are performed on unsupported portions of a sheet, then productivity is improved by eliminating support requirements, but manufacturing precision deteriorates due to uncontrolled spring back
Solution Approach 1:
The support tool is pre-configured with a support surface that mirrors the shape of the sheet before machining begins. This preliminary shaping allows the sheet to be properly supported during machining operations, preventing spring back and ensuring high hole quality while maintaining productivity.
2Ease of operation
If machining operations are performed on unsupported portions of a sheet, then ease of operation is improved by removing support constraints, but reliability deteriorates due to drill bit breakage
Solution Approach 1:
The support tool surface is pre-shaped to mirror the sheet geometry, providing proper support before machining begins. This preliminary configuration ensures that the sheet remains stable during drilling operations, preventing drill bit breakage and improving reliability while maintaining ease of operation.
3Manufacturing precision
If a rigid support structure is used to prevent spring back, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
Instead of rigid support structures, the invention uses a support tool with a support surface that mirrors the sheet shape. This approach provides the necessary support to prevent spring back and ensure manufacturing precision while avoiding the complexity of rigid, multi-component support systems.
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 application of compression force reduces or eliminates spring back, improving hole quality and extending drill bit life by controlling the elastic energy release during machining.
Implementation Method 1
A compression force is applied to the sheet using a spring back control system
Implementation Method 2
The initial machining force from the drill bit on an unsupported portion of a sheet and the resulting spring back of the sheet
Implementation Method 3
Each material contact surface comprises a roller. Each roller is rolled across the surface of the sheet as the machining tool is moved
Data Source
AI summary
A machining system configured to reduce spring back following machining operations comprising a machining tool and a spring back control system. The spring back control system comprises a number of force generators and a number of force loaded members coupled to the number of force generators, each force loaded member of the number of force loaded members comprising a material contact surface. The material contact surface is a roller, wherein the machining tool is independently moveable relative to the spring back control system.