Ultrasonic Machining Module Vibration Isolation
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Solution Overview
Problem
Existing machining systems are not compatible with the incorporation of ultrasonic energy, limiting the application of ultrasonic-assisted machining for difficult-to-machine materials like armor plates and composites.
Innovation Solution
A detachable ultrasonic machining module that includes an ultrasonic transducer housed in a compatible housing with a tool holder, capable of isolating vibrations except axial ones, and compatible with CAT or HSK machining systems, featuring a shrink-fit collet and cooling vanes for air circulation and vibration isolation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional ultrasonic machining systems are used, then material removal is achieved, but the system occupies large space and requires frequent maintenance
Solution Approach 1:
The patent combines the ultrasonic vibration source, tool holder, and machining tool into a single integrated ultrasonic machining module. The ultrasonic converter is directly coupled to the tool holder, eliminating separate components and reducing the number of parts that require maintenance. This merging of functions into one compact module directly addresses the maintenance frequency issue while simplifying the overall system structure.
Solution Approach 2:
The patent employs a nested structure where the ultrasonic converter is housed within the tool holder assembly, and the tool is mounted within the converter. This nested arrangement allows the entire ultrasonic machining system to be contained within a compact footprint, reducing the space occupation while maintaining all necessary functional components in a space-efficient configuration.
2Productivity
If traditional ultrasonic machining equipment is employed, then machining capability is provided, but the equipment occupies large space
Solution Approach 1:
By merging the ultrasonic vibration source, tool holder, and tool into a single integrated module, the patent achieves full machining capability within a compact form factor. The integration eliminates the need for separate ultrasonic generators and tool holders that would occupy additional space, thereby maintaining productivity while dramatically reducing the equipment footprint.
Solution Approach 2:
The patent transitions from a distributed, multi-component ultrasonic machining system to a compact, three-dimensionally optimized integrated module. The nested arrangement of components in vertical and radial dimensions allows the system to maintain its functional volume while presenting a much smaller horizontal footprint, effectively utilizing spatial dimensions to reduce overall equipment area.
3Reliability
If conventional ultrasonic systems are used, then material removal is achieved, but the system is difficult to control and maintain
Solution Approach 1:
The integration of the ultrasonic converter directly with the tool holder creates a unified control system where vibration generation and tool positioning are inherently coordinated. This merging eliminates the complexity of coordinating separate ultrasonic generators and tool holders, improving controllability while reducing the number of interfaces that require maintenance.
Solution Approach 2:
The integrated ultrasonic machining module is designed with self-aligning features where the converter, tool holder, and tool automatically maintain proper positioning during operation. This self-service capability reduces the need for external adjustment mechanisms and simplifies maintenance, as the system automatically compensates for minor positioning variations without requiring complex control interventions.
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
Enables the application of ultrasonic energy to machining tools within existing systems, enhancing tool life and accuracy while maintaining compatibility with standard tooling systems, thus improving machinability of hard materials.
Implementation Method 1
an ultrasonic vibration source configured to generate ultrasonic vibrations
Implementation Method 2
a fluid delivery system configured to deliver fluid to the workpiece
Data Source
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AI summary
A device for use in a machining system, including an ultrasonic transducer, wherein the ultrasonic transducer is adapted to receive a tool bit; a housing adapted to be both compatible with the machining system and to receive the ultrasonic transducer, wherein the housing is operative to isolate all radial and other vibrations generated by the ultrasonic transducer except the axial vibrations transmitted to the tool bit; and a tool holder, wherein the tool holder and the top portion of the housing are mechanically coupled to one another.