Silicone Workholding Layer for Clamp-Free Milling Access
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Solution Overview
Problem
Existing workholding methods for milling machines face challenges such as obstruction of the rotary cutter, material limitations, high costs, noise, and residue issues, particularly when dealing with complex shapes and cut-out workpieces.
Innovation Solution
A workholding device utilizing a sacrificial support with a curable silicone rubber workpiece holding layer that secures the workpiece via atmospheric pressure, allowing for secure positioning without obstructing the rotary cutter and easy separation, using a curing processing unit to control the curing rate and a collector for detached material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If vertical clamps are used to secure the workpiece, then the workpiece is held firmly in place, but the clamp obstructs the rotary cutter from reaching certain parts of the workpiece
Solution Approach 1:
The invention extracts the workpiece securing function from the traditional clamp structure and transfers it to the workpiece itself through vacuum ports and sealing surfaces. The workpiece is sealed directly to the vacuum table, eliminating the need for external clamps that obstruct the cutter.
Solution Approach 2:
The vacuum table acts as an intermediary between the workpiece and the milling machine table. It provides securing force through atmospheric pressure differential without requiring physical clamps, allowing the cutter to access all surfaces of the workpiece freely.
2Length of moving object
If horizontal clamps are used to secure the workpiece, then the rotary cutter can reach more of the workpiece, but the clamps may be damaged or the cutter damaged when cutting through
Solution Approach 1:
The invention removes the horizontal clamps entirely from the system. Instead, the workpiece is secured through vacuum ports integrated into its structure, eliminating the risk of clamp or cutter damage during through-cuts.
Solution Approach 2:
The vacuum table surface and workpiece sealing surfaces are designed to be sacrificial or easily replaceable, allowing aggressive cutting operations without concern for damaging expensive clamps or the cutter.
3Adaptability or versatility
If magnetic clamps are used to secure the workpiece, then even cut-out workpieces can be secured, but they only work for magnetic materials
Solution Approach 1:
The vacuum table provides universal workpiece securing that works with any material that can form a seal with the vacuum ports, including wood, plastic, metal, and composite materials. The securing mechanism is material-agnostic, relying on atmospheric pressure rather than magnetic attraction.
4Reliability
If vacuum tables are used to secure the workpiece, then the workpiece is held securely, but the system is expensive and noisy
Solution Approach 1:
Instead of creating a full vacuum chamber, the invention uses localized vacuum ports at specific points on the workpiece. This localized approach reduces the complexity and cost of the vacuum system while maintaining secure workpiece holding through atmospheric pressure differential at the seal interface.
5Reliability
If adhesives are used to secure the workpiece, then the workpiece is held firmly, but adhesive residue is left on the workpiece and platform
Solution Approach 1:
The invention replaces the chemical bonding mechanism of adhesives with a mechanical/physical securing mechanism using vacuum pressure. This eliminates adhesive residue while providing firm workpiece holding through atmospheric pressure differential.
6Reliability
If bridges and tabs are used to prevent workpiece detachment, then the workpiece remains secured, but additional machining steps and post-processing are required
Solution Approach 1:
The vacuum ports and sealing surfaces are built into the workpiece structure during the initial machining operations. This preliminary integration of securing features eliminates the need for additional bridge/tab structures and subsequent post-processing removal steps.
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 silicone rubber workholding device provides secure, non-obstructive, and residue-free fixation of workpieces across various materials, reducing machining steps and costs, while enabling efficient separation and handling of cut-out pieces without damaging the milling cutter.
Implementation Method 1
a curable material applied onto the sacrificial support, which secures the workpiece at a predetermined position on the sacrificial support after completion of the curing
Implementation Method 2
The silicone rubber workholding device provides secure, non-obstructive, and residue-free fixation of workpieces across various materials
Data Source
AI summary
A workholding device for positioning a workpiece on a machining equipment, comprising a sacrificial support for supporting the workpiece, a workpiece holding layer formed of a curable material applied onto the sacrificial support, a curable material collector, a curing processing unit which comprises a controller and a curing rate regulator, and a bearing assembly for supporting the sacrificial support, the curable material collector and the curing processing unit, wherein the curable material is a solid which is viscous before curing and elastic after curing and has a melting point above 1000° C.