Slotted Workpiece Holder for Precise Rotary Tool Machining
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Solution Overview
Problem
The manufacturing of rotational-symmetrical tools like drills and milling cutters, particularly ball track milling cutters, faces challenges in achieving high precision due to errors caused by holding mechanisms, thermal changes, and inaccuracies in clamping and alignment, which affect the repeatability and accuracy of the machining process.
Innovation Solution
A workpiece holder is designed to securely clamp and measure rotational-symmetrical workpieces, allowing for precise positioning and orientation adjustments, with accessible reference surfaces for direct measurement, reducing runout errors and enabling high-precision machining by integrating a clamping system and measuring device within the machining process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If temporarily holding means are used to hold the workpiece during machining, then the workpiece can be processed in different machining devices, but multiple errors are introduced affecting precision and repeatability
Solution Approach 1:
The workpiece holder is divided into distinct functional segments: a clamping mechanism for securing the workpiece, a measuring device for detecting position and orientation, and a correction mechanism for compensating errors. This segmentation allows each component to perform its specific function optimally while working together to maintain high precision across multiple machining devices.
Solution Approach 2:
The measuring device continuously monitors the position and orientation of the workpiece holder, providing real-time feedback to the correction mechanism. This closed-loop feedback system detects and compensates for errors introduced by thermal effects, clamping variations, and alignment tolerances, thereby maintaining manufacturing precision across different machining devices.
2Measurement precision
If the workpiece is measured externally and machining is interrupted, then measurement can be performed, but repeatability of clamping is compromised and errors increase
Solution Approach 1:
The measuring device is integrated directly into the workpiece holder, merging the measurement function with the clamping function. This allows measurements to be taken in-situ without removing the workpiece from the holder or interrupting the machining process, thereby maintaining clamping repeatability while achieving high measurement precision.
Solution Approach 2:
The measuring device operates continuously during the machining process, enabling real-time detection of position and orientation without interrupting the workflow. This continuous measurement approach eliminates the need to interrupt machining for external measurements, maintaining both measurement accuracy and clamping repeatability throughout the process.
3Productivity
If thermal effects occur during machining, then the position of holding means changes, but this affects the repeatability and accuracy of manufacturing
Solution Approach 1:
The correction mechanism dynamically adjusts physical parameters such as the position and orientation of the workpiece holder in response to thermal effects. By continuously monitoring temperature-induced changes and compensating through parameter adjustments, the system maintains manufacturing precision despite continuous machining operations that generate heat.
Solution Approach 2:
The measuring device detects position changes caused by thermal effects and provides feedback to the correction mechanism, which automatically compensates for these changes. This feedback loop ensures that thermal expansion or contraction of the holding means does not compromise manufacturing accuracy during continuous machining.
4Ease of manufacture
If fitting tolerances and clamping tolerances are present in the holding means, then assembly is easier, but these tolerances accumulate and reduce the quality and precision of the finished tool
Solution Approach 1:
The measuring device detects cumulative errors resulting from fitting tolerances and clamping tolerances, providing feedback to the correction mechanism. This allows real-time compensation for tolerance accumulation, enabling easy assembly with standard tolerances while maintaining high final precision through active error correction.
Solution Approach 2:
The correction mechanism dynamically adjusts operational parameters such as clamping force and position to compensate for tolerance variations in the holding means. This allows the system to accommodate standard manufacturing tolerances in assembly while maintaining high precision in the finished tool through parameter optimization during operation.
Data Source
AI summary
Workpiece holder (3) for coupling a workpiece (2) provided with reference surfaces (30) to a machining device (200) for manufacturing a rotational-symmetrical tool (1) with at least one geometrically defined cutting edge (10), the workpiece holder (3) comprises a machine part (31) configured to be connectable to the machining device (200) in a releasable rotationally fixed manner, a clamping part (32) configured to receive and clamp the workpiece (2) in a releasable manner. The clamping part (32) of the workpiece holder (3) comprises at least one slot (40) provided at a circumference thereof and configured to provide access to the reference surfaces (30) of the clamped workpiece (2) therethrough.