Tool Post Counter-Vibration Control for Turning Surface Finish
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Solution Overview
Problem
Existing methods for segmenting machining chips in automatic lathes during the turning process lead to increased surface roughness and reduced equipment durability due to vibrations generated in the tool post during instantaneous direction changes, stops, or accelerations.
Innovation Solution
A micro vibration damping system that uses sensors to detect instantaneous accelerations of the tool post and generates vibrations in an opposite direction to dampen micro vibrations, thereby controlling the tool post to vibrate in the opposite direction of the micro vibrations generated.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If chip segmentation is achieved through instantaneous direction change of the tool, then chip control is facilitated, but vibrations are generated in the tool post causing deteriorated surface roughness
Solution Approach 1:
The system applies preliminary anti-action by generating counter-vibrations in advance to offset the harmful vibrations caused by instantaneous direction changes. The vibration generator produces vibrations in the opposite direction to the tool post vibrations, thereby canceling out the harmful effects before they can deteriorate the surface roughness of the workpiece.
Solution Approach 2:
The system converts the harmful vibrations into a beneficial effect by using the vibration generator to create controlled counter-vibrations. The harmful vibrations from tool post movement are transformed into a useful phenomenon where the generated vibrations oppose and cancel the harmful ones, thereby improving surface roughness while maintaining chip segmentation effectiveness.
2Ease of manufacture
If chip segmentation is achieved through instantaneous stop and acceleration of the tool, then chip segmentation is improved, but vibrations are generated causing fine bands in the product
Solution Approach 1:
The system applies preliminary anti-action by detecting instantaneous stops and accelerations through sensors, and immediately generating counter-vibrations to offset the resulting tool post vibrations. This prevents the formation of fine bands in the machined product while maintaining the chip segmentation benefits from the instantaneous motion changes.
Solution Approach 2:
The system employs feedback by using sensors to detect the tool post vibrations caused by instantaneous stops and accelerations. The detected vibration information is fed back to the vibration generator, which adjusts its output to produce counter-vibrations that cancel the harmful effects, thereby preventing fine band formation while preserving chip segmentation.
3Manufacturing precision
If continuous vibration is applied to dampen tool post vibrations, then surface roughness is improved, but energy consumption increases
Solution Approach 1:
The system applies periodic action by generating vibrations only during specific periods when tool post vibrations are detected, rather than continuous vibration. The vibration generator operates intermittently based on sensor feedback, producing counter-vibrations only when harmful vibrations occur, thereby improving surface roughness while minimizing energy consumption during periods when vibration damping is not required.
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
The system effectively dampens micro vibrations in the tool post, reducing surface roughness and extending equipment durability by mitigating the negative effects of vibrations on machining precision and equipment stress.
Implementation Method 1
generates vibrations in an opposite direction to a vibration direction appearing in the tool post
Implementation Method 2
dampen micro vibrations generated in a tool post by generating vibrations in an opposite direction
Data Source
AI summary
A micro vibration damping system includes: one or more sensors configured to sense an instantaneous acceleration of a tool post during machining of a work piece; and a driver configured to drive the tool post in a direction orthogonal to an axial direction of the work piece according to the instantaneous acceleration of the tool post.