Single-Clamping Deep-Hole Drilling for Slender Forged Workpieces
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Solution Overview
Problem
The existing method for machining slender, forged workpieces in engine injection systems is inefficient and prone to machining inaccuracies due to the need for multiple machine tools and separate clamping, leading to increased costs and reduced quality, particularly in deep-hole drilling where material hardening causes axial deflection issues.
Innovation Solution
A method and machine tool design that allows for single-tool machining with a quill that can move in X, Y, Z directions and rotate, using axially fixed cutting tools and programmable spindle offset for deep-hole drilling, enabling precise control and oblique drilling, along with a turret arrangement for multiple cutting tools, including deep-hole drills and radial drills, to improve accuracy and reduce re-clamping errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple machine tools are used for different machining steps, then each operation can be performed with specialized equipment, but the workpiece must be repeatedly removed and re-clamped, leading to increased processing time and machining inaccuracies
Solution Approach 1:
The patent combines multiple machining functions (turning, milling, deep-hole drilling, and connection bore creation) into a single machine tool with a unified working space. This allows all machining operations to be performed on the workpiece without removal, eliminating re-clamping errors and improving manufacturing precision while integrating previously separate specialized equipment into one comprehensive system.
Solution Approach 2:
The machine tool is designed with multi-functionality to perform various machining operations including turning, milling, and deep-hole drilling using different cutting tools mounted on the same spindle or tool holder. This universal capability replaces multiple specialized machine tools, reducing device complexity while maintaining machining accuracy through consistent workpiece positioning.
2Adaptability or versatility
If the workpiece is re-clamped for each machining step, then different operations can be performed on different machine tools, but machining inaccuracies occur due to separate clamping
Solution Approach 1:
The patent merges multiple machining operations into a single clamping sequence by providing a unified working space where turning, milling, and deep-hole drilling can all be performed without removing the workpiece. This eliminates positioning errors from repeated clamping while maintaining the versatility to perform different machining operations through tool changes or multi-functional cutting tools.
3Ease of manufacture
If deep-hole drilling is performed on forged workpieces with hardened transition areas, then connection bores can be created, but the deep-hole drill deflects in its axial guide, failing to meet tolerance requirements
Solution Approach 1:
The patent introduces a pilot hole as an intermediary step before creating the final deep-hole bore. The pilot hole serves as a guide that prevents drill deflection when encountering hardened transition areas, ensuring axial accuracy is maintained throughout the deep-hole drilling process while still enabling connection bore creation in difficult-to-machine regions.
4Manufacturing precision
If machining operations are performed sequentially on different machine tools, then each operation can be optimized, but the overall processing time increases due to workpiece handling
Solution Approach 1:
The patent enables continuous machining operations by providing a unified working space where turning, milling, and deep-hole drilling can be performed sequentially without interrupting the workpiece clamping state. This eliminates non-productive time for workpiece handling and positioning between operations, significantly reducing total processing time while maintaining operation quality through consistent positioning.
Data Source
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AI summary
A method for machining at least one slender, in particular forged, workpiece (15), into which a central bore (18) is drilled along a longitudinal axis by deep-hole drilling and a connecting bore (19) is drilled into at least one laterally projecting connecting nipple (17), is designed such that both the central bore (18) and the connecting bore (19) are drilled into the workpiece (15) in a single clamping position.