High-Frequency Tool Oscillation for Tilted Honeycomb Machining
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Solution Overview
Problem
High-frequency machining methods face challenges such as tool and workpiece damage, especially when machining honeycomb structures like aluminum, and inefficient tool usage due to tilted machining axes, leading to localized wear and reduced tool lifespan.
Innovation Solution
A high-frequency machining method involving simultaneous vibration and oscillation motions between the tool and workpiece, with vibration frequencies above 10 kHz and oscillation frequencies below 10 kHz, allowing for precise cutting on tilted axes without deforming honeycomb structures and optimizing tool usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If high-frequency machining is performed on a honeycomb structure with a tilted machining axis, then cutting capability and versatility are improved, but the risk of tool damage and workpiece deformation increases
Solution Approach 1:
The patent applies high-frequency vibration (above 10 kHz) to the cutting tool during machining operations. This vibration reduces the risk of tool damage and honeycomb cell deformation by preventing the tool from getting stuck in the material, thereby enabling safe machining on tilted axes while maintaining reliability
Solution Approach 2:
The patent employs periodic oscillation motion at frequencies below 10 kHz in addition to the high-frequency vibration. This periodic action creates a reciprocating cutting motion that ensures continuous contact between the tool and workpiece, optimizing tool usage and preventing localized wear while maintaining the ability to machine on tilted axes
2Productivity
If the entire available operating portion of the tool is fully exploited, then productivity is improved, but localized wear increases leading to reduced tool lifespan
Solution Approach 1:
The patent uses periodic oscillation motion below 10 kHz that causes the tool to reciprocate along the penetration direction. This periodic action ensures that the entire operating portion of the tool continuously engages with the workpiece, distributing wear evenly across the tool surface rather than concentrating it at a single point, thereby extending tool life while maintaining full productivity
3Manufacturing precision
If high-frequency vibration is applied during machining, then machining precision is improved, but device complexity increases
Solution Approach 1:
The patent implements high-frequency vibration above 10 kHz using a vibration generator integrated into the machining system. This vibration improves machining precision by reducing tool chatter and achieving cleaner cuts, particularly on honeycomb structures. The system maintains relatively simple construction by using standard vibration generation technology combined with numerical control
Solution Approach 2:
The patent employs numerical control systems that coordinate the vibration frequency, oscillation amplitude, and feed rate based on the specific machining conditions. This feedback control ensures optimal machining precision while managing system complexity through automated parameter adjustment rather than mechanical complexity
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 method significantly reduces the risk of tool and workpiece damage, prevents cell deformation during machining, and ensures full exploitation of the tool's operational portion, resulting in extended tool life and improved machining accuracy on honeycomb structures.
Implementation Method 1
simultaneously activating relative vibration between a workpiece and a tool at a vibration frequency above 10 kHz
Implementation Method 2
a relative oscillation motion between the tool and workpiece along a direction of penetration of the tool into a thickness of the workpiece at an oscillation frequency below 10 kHz
Data Source
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AI summary
A high-frequency machining method and device are disclosed, in which, during the machining, vibration of a tool at a vibration frequency above 10 kHz is activated and simultaneously also a relative feed motion along a machining path between the tool and the workpiece and a relative oscillation motion between the tool and the workpiece along an oscillation direction are activated, coinciding with a direction of penetration of the tool into a thickness of the workpiece, with an oscillation frequency below 10 kHz.