Tool Holder Vibration Damping via Electrochemical Pulse Plating
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Solution Overview
Problem
Existing tool holders in manufacturing machines experience vibrations and noise, leading to inaccurate results, increased wear, and potential damage, as previous solutions involving damping materials and designs are complex and inefficient.
Innovation Solution
A tool holder with a surface covering of metal or alloy (Cu, Ti, Zn, Al, Ni) applied through electrochemical pulse plating, allowing the cutter to contact the machine only through the vibration-damping material, which is arranged between the tool holder and the machine, effectively reducing vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a vibration-damping material is arranged in a longitudinal track on a tool holder, then vibrations are dampened, but the device complexity increases
Solution Approach 1:
The patent applies vibration-damping material specifically in longitudinal tracks at predetermined positions on the tool holder shaft, rather than uniformly across the entire surface. This localized application provides effective vibration damping at critical areas while minimizing material usage and structural complexity.
Solution Approach 2:
The damping solution is divided into discrete longitudinal tracks positioned at specific locations on the shaft, allowing independent optimization of each track's position and dimensions. This segmentation enables precise placement of damping material where vibrations occur most intensely.
2Object-affected harmful factors
If weights and fluids in cavities are used to oscillate with inverted phase to cancel vibrations, then vibration cancellation is achieved, but the device complexity and difficulty of dimensioning increase
Solution Approach 1:
The patent converts the harmful vibrations directly into beneficial damping effects by using vibration-damping material that dissipates vibrational energy through internal friction and hysteresis. This approach eliminates the need for complex active control systems with weights and fluids, achieving vibration cancellation through passive energy dissipation.
Solution Approach 2:
The vibration-damping material acts as an intermediary between the tool holder shaft and the vibrations, absorbing and dissipating vibrational energy. This intermediate damping layer simplifies the overall system by replacing complex active control mechanisms with a passive material-based solution.
3Object-affected harmful factors
If material is arranged on the surface of the tool holder to oscillate with inverted phase for cancellation, then vibration cancellation is possible, but troublesome dimensioning and testing procedures are required
Solution Approach 1:
The patent optimizes the parameters of the damping material (such as loss factor, thickness, and positioning) to achieve effective vibration damping. By changing these parameters systematically and using standardized material properties, the complex dimensioning and testing procedures are simplified into a more manageable design process.
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 approach achieves significant vibration reduction, with damping effects improved by increasing the number of layers, resulting in a 500 to 600% improvement compared to conventional tool holders, while maintaining mechanical properties.
Implementation Method 1
a vibration-damping material arranged such that the cutter is in contact with the manufacturing machine solely through the vibration-damping material
Implementation Method 2
The vibrations also give rise to a troublesome disturbing noise that worsens the environment around the manufacturing machine
Implementation Method 3
the surface covering is created by electrochemical pulse plating through the tool holder, when functioning as an electrode, being lowered into an electrolyte containing ions of at least one metal from the group comprising Cu, Ti, Zn, Al and Ni
Data Source
AI summary
A tool holder 1 has a shaft 2 intended to be arranged in a tool holder in a manufacturing machine, a head 3 on which a cutter is intended to be arranged and a vibration-damping material 4 arranged between, and attached to, the shaft 2 and the head 3 such that the cutter is in contact with the manufacturing machine solely through the vibration-damping material 4, where the vibration-damping material is a metal or an alloy of metals selected from the group consisting of Cu, Ti, Zn, Al and Ni. A method for manufacturing a tool holder in which the surface covering of vibration-damping material is created by electrochemical pulse plating through the tool holder, when functioning as an electrode, being lowered into an electrolyte containing ions of at least one metal selected from the group consisting of Cu, Ti, Zn, Al and Ni.