Spindle Shaft Microvibration Control for Chip Shape in Drilling
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Solution Overview
Problem
Current chip-forming machining methods face challenges in controlling and monitoring vibration introduction, are complex in construction, wasteful of space, and inefficient, particularly in deep hole drilling and composite material processing, where chip size and shape control are difficult and burring issues arise.
Innovation Solution
A tool drive with a spindle shaft featuring an electromagnetic axial actuator and a control apparatus that generates microvibration movements independently of feed movements, allowing adaptive adjustment of axial and radial vibrations to optimize chip formation based on material and process parameters, using magnetic bearings for precise control and reduced friction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mechanical vibration systems are used for chip-forming machining, then chip size control is improved, but device complexity increases due to additional oscillation-generating elements
Solution Approach 1:
The patent combines the oscillation-generating function with the existing spindle shaft by equipping the spindle shaft itself with oscillation capability. This merges the feed mechanism and vibration generation into a single integrated component, eliminating the need for separate oscillation-generating elements and reducing overall device complexity while maintaining precise chip size control
Solution Approach 2:
The spindle shaft is designed to perform multiple functions simultaneously: it provides the primary rotating feed movement for material removal and generates controlled oscillating movements for chip formation. This multi-functionality allows the spindle shaft to serve as both the drive shaft and the vibration source, simplifying the overall system architecture
2Manufacturing precision
If separate oscillation-generating elements are added to existing tool systems, then vibration control is improved, but space consumption increases
Solution Approach 1:
The oscillation-generating function is merged into the spindle shaft structure itself, utilizing the existing spatial envelope of the spindle assembly. This integration eliminates the need for additional external oscillation-generating components and avoids increasing the overall space consumption of the tool system
3Device complexity
If mechanical systems with fixed oscillation frequency are used, then construction is simplified, but adaptability to different materials decreases
Solution Approach 1:
The system transitions from fixed-frequency mechanical oscillation to dynamically controllable oscillation through electromagnetic actuation. The oscillation frequency and amplitude can be adjusted in real-time based on material properties and machining conditions, providing adaptability across different materials while maintaining relatively simple construction through the use of standard electromagnetic components
4Productivity
If high-frequency vibrations are generated for small chip sizes, then chip removal is improved, but energy consumption increases
Solution Approach 1:
The electromagnetic actuator utilizes the existing electrical power supply infrastructure of the spindle drive system, drawing power directly from the same source that drives the motor. This self-service approach eliminates the need for separate high-power oscillation generation systems and reduces overall energy consumption by efficiently coupling the oscillation generation with the existing drive electronics
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
This solution enables precise control of chip size and shape, reduces burring, improves drilling efficiency, and allows for deburring and counterboring without additional oscillation-generating elements, enhancing energy efficiency and tool life through adaptive vibration management.
Implementation Method 1
at least one electromagnetic axial actuator... for the generation of microvibration movement of the spindle shaft
Implementation Method 2
Axial and radial magnetic bearings for supporting the spindle shaft
Data Source
AI summary
A tool drive with spindle shaft for a chip-forming machining includes at least one electromagnetic axial actuator and a control and/or regulation apparatus for the operation of the axial actuator for changing the position of the spindle shaft along the longitudinal axis, wherein the control and/or regulation apparatus is designed to drive the axial actuator for the generation of microvibration movement of the spindle shaft, independently of and superimposable on a feed movement, in order to affect the chip size and chip shape of the removed material, wherein at least one axial magnetic bearing and/or one linear motor is provided as at least part of the axial actuator, wherein the regulation and/or control apparatus includes a memory unit and/or a function generation unit, and is configured to specify setpoint values of the oscillation curve of the microvibration movement depending on geometrical and or physical data of the workpiece and/or process variables that are measured or determined indirectly and/or control inputs, so that the control and/or regulation apparatus is configured to adjust an axial microvibration movement of the spindle shaft, independently of and superimposed on a feed movement, in such a way as to affect the chip size and chip shape of the removed material created when drilling.