Single-Workpiece Milling of Discrete Objects With Temporary Fixation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current subtractive manufacturing processes for producing multiple discrete objects from a single workpiece are labor-intensive due to the need for frequent loading and unloading of workpieces, which hampers efficiency and productivity.
Innovation Solution
A method involving the creation of a workpiece computer model with interconnected structures, followed by the installation of a temporary fixating material to stabilize the workpiece, allowing for the removal of interconnecting portions and subsequent liberation of discrete objects, utilizing subtractive manufacturing processes like rotary-tool milling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple discrete objects are manufactured from a single workpiece using traditional subtractive manufacturing processes, then material utilization is improved, but labor intensity increases due to frequent loading and unloading of workpieces
Solution Approach 1:
The workpiece is segmented into multiple discrete objects through the formation of valleys that create interconnecting portions. These interconnecting portions are initially retained to allow the workpiece to remain as a single stable unit during manufacturing, then later removed to liberate the discrete objects. This segmentation approach enables multiple objects to be produced from one workpiece while maintaining operational ease through automated processing.
2Productivity
If multiple discrete objects are manufactured from a single workpiece, then productivity is improved, but the complexity of the manufacturing process increases due to the need for temporary fixating materials and interconnecting structures
Solution Approach 1:
Valleys are formed in the workpiece during the initial subtractive manufacturing process, creating interconnecting portions that preliminarily hold the discrete objects together. Temporary fixating materials are applied in advance to stabilize the workpiece structure before the interconnecting portions are removed. This preliminary action simplifies the overall process by preparing the workpiece structure beforehand, reducing the need for complex intermediate handling steps.
Solution Approach 2:
Temporary fixating materials serve as an intermediary between the interconnecting portions and the discrete objects. These materials are applied to the valleys or interconnecting portions to provide additional stabilization during the manufacturing process. The fixating materials are later removed without damaging the discrete objects, enabling their liberation while maintaining process simplicity.
3Stability of the object's composition
If interconnecting portions are retained in the workpiece during manufacturing, then workpiece stability is improved, but the time required for object liberation increases
Solution Approach 1:
The interconnecting portions are selectively removed from the workpiece after the discrete objects have been manufactured and stabilized. This extraction process liberates the discrete objects from their interconnected state, allowing them to be separated and removed from the workpiece. The removal is performed efficiently using automated subtractive manufacturing processes, minimizing the time required for liberation while maintaining workpiece stability during the critical manufacturing phases.
Data Source
AI summary
Methods involving adding a removable fixating material to a partially manufactured workpiece to stabilize a plurality of partially formed objects therein for subsequent manufacturing. In one example, a workpiece of interconnected structures is manufactured comprising precursors to the discrete objects as a function of a workpiece computer model. Manufacturing the workpiece further includes forming valleys between adjacent partially formed objects so that interconnecting portions remain to interconnect the partially formed objects. Further, the methods include removing the interconnecting portions so as to liberate the plurality of objects from one another. In some embodiments, a temporary frame is formed from the workpiece along with the plurality of objects during manufacturing.