Synchronized CNC Machining Reduces Workpiece Deflection
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Solution Overview
Problem
Conventional CNC machining centers face inefficiencies due to sequential operation of multiple tools, leading to excessive time consumption and potential workpiece deflection or chatter during milling operations, especially when performing complex machining tasks like forming asymmetrical parts.
Innovation Solution
A CNC machining system with a computer control system that allows simultaneous control of a workpiece retainer and two tool retainers, enabling simultaneous movement along multiple axes to engage multiple cutting tools on opposite sides of the workpiece, thereby balancing forces and reducing deflection, and allowing for synchronized machining of complex surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple tools are operated sequentially in conventional machining centers, then the control system remains simple, but the machining time increases significantly
Solution Approach 1:
The patent combines multiple tool retainers (first and second tool retainers) with independent cutting tools into a single machining center, allowing simultaneous operation of multiple tools on different workpieces or different features of the same workpiece, thereby reducing total machining time while maintaining coordinated control through the control system
2Productivity
If a single cutting tool is used to machine the entire workpiece, then the tooling setup is simple, but the machining time increases due to sequential operations
Solution Approach 1:
The patent divides the tooling system into multiple independent tool retainers (first tool retainer and second tool retainer), each capable of holding and operating with a separate cutting tool simultaneously, allowing parallel machining operations that reduce total machining time while maintaining individual control over each tool retainer
3Shape
If material is removed from the workpiece during milling, then the desired shape is achieved, but the workpiece stiffness decreases causing deflection and chatter
Solution Approach 1:
The patent applies preliminary action by using the first cutting tool to perform rough milling operations that remove the majority of material, then using the second cutting tool for finish milling operations that achieve the final precise geometry. This staged approach allows the workpiece to maintain adequate stiffness during roughing while achieving high precision during finishing when the workpiece geometry is closer to the final shape
Data Source
AI summary
Machine tool systems and methods include methods of synchronizing cutting tools with a workpiece retainer. In some embodiments, the methods and systems provide at least two cutting tools that are synchronized to machine a common surface of a workpiece in a quick and efficient manner. A controller having a single line of code for controlling both cutting tools and the workpiece retainer may be used. The cutting tools may be synchronized such that they engage substantially opposite portions of the workpiece, thereby to reduce resulting forces in the workpiece that may tend to induce workpiece deflection and/or chatter. In other embodiments, a cutting tool is synchronized with a split workpiece holder that may be controlled to induce a compression, tension, or torsion pre-load in the workpiece.