Tool Post Counter-Vibration for Turning Surface Roughness Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing automatic lathe machining methods suffer from surface roughness deterioration and equipment durability reduction due to micro vibrations generated during instantaneous direction changes, stops, or accelerations for chip segmentation.
Innovation Solution
A micro vibration damping system for turning, which includes a driving unit, calculation unit, sensor unit, and control unit, artificially controls the tool post to vibrate in the opposite direction of micro vibrations by implementing fine horizontal movements and returning to the original position, thereby damping the vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If instantaneous direction change is used for chip segmentation, then chip segmentation is achieved, but micro vibrations are generated causing surface roughness deterioration
Solution Approach 1:
The system applies preliminary anti-action by generating counter-vibrations in advance to offset the harmful micro vibrations caused by instantaneous direction changes. The vibration generation unit creates vibrations in the opposite direction to those produced during rapid tool post movement, thereby canceling out the detrimental effects on surface roughness while maintaining effective chip segmentation.
Solution Approach 2:
The invention utilizes mechanical vibration by introducing controlled vibrations through the vibration generation unit mounted on the tool post. These vibrations are specifically designed to counteract the micro vibrations caused by instantaneous direction changes, transforming the harmful vibrational effects into beneficial ones that maintain surface quality during chip segmentation.
2Ease of manufacture
If instantaneous stop and acceleration is used for chip segmentation, then chip segmentation is achieved, but vibrations are generated causing fine bands in product
Solution Approach 1:
The system applies preliminary anti-action by generating counter-vibrations in advance to offset the harmful micro vibrations caused by instantaneous direction changes. The vibration generation unit creates vibrations in the opposite direction to those produced during rapid tool post movement, thereby canceling out the detrimental effects on surface roughness while maintaining effective chip segmentation.
Solution Approach 2:
The invention utilizes mechanical vibration by introducing controlled vibrations through the vibration generation unit mounted on the tool post. These vibrations are specifically designed to counteract the micro vibrations caused by instantaneous direction changes, transforming the harmful vibrational effects into beneficial ones that maintain surface quality during chip segmentation.
3Ease of manufacture
If tool forward movement and backward movement is repeated for chip segmentation, then chip segmentation is achieved, but vibrations are generated causing surface roughness deterioration
Solution Approach 1:
The system applies preliminary anti-action by generating counter-vibrations in advance to offset the harmful micro vibrations caused by instantaneous direction changes. The vibration generation unit creates vibrations in the opposite direction to those produced during rapid tool post movement, thereby canceling out the detrimental effects on surface roughness while maintaining effective chip segmentation.
Solution Approach 2:
The invention utilizes mechanical vibration by introducing controlled vibrations through the vibration generation unit mounted on the tool post. These vibrations are specifically designed to counteract the micro vibrations caused by instantaneous direction changes, transforming the harmful vibrational effects into beneficial ones that maintain surface quality during chip segmentation.
4Ease of manufacture
If continuous change of movement speed is used for chip segmentation, then chip segmentation is achieved, but tool movement speed must be continuously changed reducing productivity
Solution Approach 1:
The invention segments the chip through instantaneous direction changes of the tool post while maintaining constant movement speed for the majority of the machining process. This segmentation approach allows chip control without requiring continuous speed adjustments, thereby preserving machining productivity while achieving effective chip segmentation.
Solution Approach 2:
The system employs periodic action by applying instantaneous direction changes at specific intervals during machining to segment chips effectively. These periodic directional adjustments occur while maintaining constant speed, avoiding the need for continuous speed changes and preserving overall machining efficiency and productivity.
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, improving surface roughness and reducing equipment stress, leading to enhanced precision and durability in automatic lathe machining.
Implementation Method 1
capable of controlling micro vibrations generated in a tool post by applying a control algorithm that generates vibrations in an opposite direction to a vibration direction appearing in the tool post
Implementation Method 2
system for cancelling micro vibration during turning processing, and method therefor
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present disclosure relates to a micro vibration damping system for turning and a method thereof, and may include a driving unit implementing driving of a tool post, a calculation unit calculating a fine movement distance of the tool post according to a rotation speed according to the driving of the tool post and a machining condition set according to a workpiece, a sensor unit mounted on the tool post and sensing an acceleration signal for a section in which stop and rapid movement of the workpiece occur, and a control unit receiving the signal of the sensor unit, controlling the driving of the driving unit according to the fine movement distance calculated by the calculation unit, and controlling the tool post so that the tool post is finely moved in a direction different from a vibration direction of the tool post. In addition, the micro vibration damping system for turning and the method thereof as described above may be variously implemented according to an embodiment.