Machine Tool Tool Head for Cylinder Block Boring and Honing
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Solution Overview
Problem
Current machine tools for boring cylinder blocks face challenges such as misalignment, reduced productivity due to the need for dummy heads, and difficulty in achieving high-speed rotation and reciprocation of the main shaft, leading to inefficiencies and inaccuracies in the machining process.
Innovation Solution
A machine tool with a tool head featuring a boring cutter and grinding tool, equipped with a rotating mechanism and linear motors for high-speed rotation and reciprocation, along with a power converting system using servomotors and gear sets to accurately control expanding forces and positions of grinding stones, allowing for precise machining without the need for dummy heads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the main shaft diameter is changed between boring and honing processes, then the tool can be adapted for different operations, but the structure becomes complex and requires multiple mechanisms
Solution Approach 1:
The main shaft is designed with universal functionality to perform both boring and honing operations without changing its diameter or basic structure. The tool head is made interchangeable to accommodate different tools, while the main shaft itself remains constant, providing multi-functionality through tool versatility rather than shaft transformation.
Solution Approach 2:
The invention merges the boring and honing functions into a single main shaft system by making the tool head interchangeable. Instead of having separate shafts for different operations, both functions are combined in one shaft through tool replacement, simplifying the overall structure while maintaining versatility.
2Speed
If the main shaft is made lightweight for high-speed reciprocation during honing, then the reciprocation speed increases, but the rigidity decreases causing flexing and resonance
Solution Approach 1:
The main shaft system employs dynamic characteristics optimized for reciprocating motion rather than continuous rotation. The shaft and tool head combination is designed with appropriate mass and stiffness distribution to achieve high-speed reciprocation without excessive flexing, utilizing dynamic response characteristics suitable for honing operations.
Solution Approach 2:
The system changes operational parameters by switching between different tool head configurations and adjusting operating conditions for boring versus honing. During honing, the main shaft operates in reciprocating mode with optimized parameters for high-speed back-and-forth motion, while maintaining sufficient rigidity through proper structural design and material selection.
3Strength
If a dummy head is used to maintain rigidity during honing, then the rigidity is sufficient, but the productivity decreases due to additional setup time
Solution Approach 1:
The invention extracts and eliminates the dummy head requirement by integrating the necessary rigidity directly into the main shaft and tool head assembly. The support units are designed to provide adequate support during honing operations without requiring an additional dummy head component, thereby removing the productivity bottleneck associated with dummy head installation and removal.
Solution Approach 2:
The main shaft system is designed to be self-sufficient by incorporating integrated support units that provide necessary rigidity during honing operations. The system serves itself by having built-in support mechanisms rather than requiring external dummy heads, enabling continuous operation without interruption for dummy head changes.
4Strength
If the support units are pressed against each other for increased rigidity during boring, then the rigidity is sufficient for high-speed rotation, but the mechanism for separating them adds complexity
Solution Approach 1:
The support units are designed with dynamic characteristics that allow them to be pressed together during boring operations for high rigidity and separated during honing operations for lightweight reciprocation. The mechanism utilizes dynamic adjustment of support unit positions and contact forces to optimize performance for each specific operation type.
Solution Approach 2:
The support system is segmented into multiple independent support units that can be individually adjusted and positioned. This segmentation allows flexible configuration where support units can be pressed together for boring rigidity or separated for honing lightness, with each unit independently controllable to optimize the overall system performance for different operations.
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 high-speed machining with improved accuracy and productivity by maintaining the main shaft's diameter constant during both boring and honing processes, reducing machining time and eliminating the need for complex mechanisms, thus enhancing the overall efficiency and precision of the cylinder block machining.
Implementation Method 1
a moving means for moving the support in an axial direction of the main shaft
Implementation Method 2
a power converting system using servomotors and gear sets to accurately control expanding forces and positions of grinding stones
Data Source
AI summary
The spindle drive unit of a combined machine tool drives the spindle. The tip end of the spindle is provided with a boring tool and a tool head having a rough grinding stone and a finishing grinding stone. The spindle drive unit has a first support unit and a second support unit capable of receiving the spindle therethrough and supporting it rotatably, a linear motor and a column slide mechanism for moving the first and second support unit in the axis direction of the spindle, and a spindle motor for rotating the spindle.