Ultrasonic Vibration for Floor Panel Machining Precision
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Solution Overview
Problem
Current methods for producing floor panels lack precision and dimensional accuracy, leading to premature damage, noise, and increased costs due to tool wear and material fiber issues during machining, especially in the edge area, and require additional pre-treatment steps like thermal smoothing.
Innovation Solution
Applying a translational oscillating movement in the ultrasonic range to processing tools during shaping processing, such as dividing, removing, and cutting, reduces tool wear, increases precision, and eliminates the need for pre-treatment steps like thermal smoothing by allowing precise machining with lower feed forces and torque.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If conventional machining tools are used for shaping processing, then tool wear is high and tool life is short, but using expensive polycrystalline diamond tools reduces tool wear
Solution Approach 1:
The patent applies ultrasonic vibration (mechanical vibration in the frequency range of 15-70 kHz) to the machining tool during shaping processing. This vibration reduces the contact time and contact force between the tool and workpiece, significantly decreasing tool wear and extending tool life without requiring expensive polycrystalline diamond tools.
Solution Approach 2:
The patent changes the operational parameters of the machining tool by superimposing ultrasonic oscillating movement on the conventional machining process. This parameter change (adding high-frequency vibration) transforms the machining mechanism, allowing standard tools to achieve the performance previously only attainable with expensive specialized tools.
2Manufacturing precision
If conventional machining is used without pre-treatment, then dimensional accuracy is poor and fibers are torn or pressed, but thermal smoothing pre-treatment improves surface quality
Solution Approach 1:
The ultrasonic vibration applied to the machining tool prevents fiber tearing and pressing during shaping processing by reducing contact time and force. This eliminates the need for thermal smoothing pre-treatment while achieving high dimensional accuracy and clean fiber separation.
Solution Approach 2:
Instead of applying pre-treatment (thermal smoothing) before machining, the patent applies the corrective action (ultrasonic vibration) directly during the machining process itself, eliminating the need for separate pre-treatment steps while achieving the same or better results.
3Manufacturing precision
If conventional machining tools are used, then feed forces and torque are high causing tool deviation, but reducing these forces improves precision
Solution Approach 1:
The ultrasonic vibration reduces the feed force and torque required during machining by facilitating material removal through vibration-assisted cutting. This reduction in forces prevents tool deviation and running off course, thereby improving profile precision without sacrificing machining efficiency.
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 achieves higher dimensional accuracy and precision in floor panel machining, reduces tool wear, and eliminates the need for additional pre-treatment steps, resulting in high-quality panel production with reduced risk of material breakouts and noise.
Implementation Method 1
transmitting a translational oscillating movement in the ultrasonic range to the processing tool
Implementation Method 2
causes the tools to resonate by introducing high-frequency mechanical vibrations
Data Source
Figure 1a
Figure 1b
Figure 2
AI summary
The method involves providing a multi-layer plate (2) with a carrier layer (2a) of wood product. A cover layer (2b) is connected with the carrier layer at an upper side. A layer is provided with directly applied paint, resin, laminate, laminate plastic or veneer. The multi-layer plate is brought in contact with processing tools (3). The processing tools are moved relative to the multi-layer plate for a forming process of the multi-layer plate. The forming process is carried out by causing a translatory pivoting movement in an ultrasound region in the processing tools. The forming process is dividing process, erosive process and machining process. An independent claim is also included for a device for manufacturing a panel.