Ultrasonic Machining Module Housing for Spindle Vibration Isolation

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Solution Overview

Problem

Existing machining systems are not designed to accommodate ultrasonic energy, leading to challenges in incorporating ultrasonic machining modules without damaging or negatively impacting system performance.

Innovation Solution

An ultrasonic machining module with a vibration-isolating housing and transducer assembly that includes piezoelectric ceramics, a spring-like feature to absorb unwanted vibrations, and precision geometry for alignment, allowing compatibility with existing machining systems while preventing vibration transmission back into the spindle.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If ultrasonic machining module is incorporated into existing machining systems, then machining performance is improved, but system damage or negative impact may occur

Engineering Contradiction:

Improvemachining performanceVSAvoidsystem integrity

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

A vibration isolating housing acts as an intermediary between the ultrasonic machining module and the existing machining system. This housing includes vibration isolating features that prevent ultrasonic vibrations from being transmitted back into the machining system, thereby protecting the system while enabling ultrasonic machining functionality.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The ultrasonic machining module is extracted as a separate, self-contained unit with its own vibration isolation system. By isolating the ultrasonic components within a dedicated housing that includes vibration isolating features, the harmful vibrations are contained and prevented from affecting the parent machining system.

Inventive Principle:

Principle #2Taking out (Extraction)

2Reliability

If vibration isolation is implemented to protect the machining system, then system reliability is improved, but vibration transmission to the tool bit may be reduced

Engineering Contradiction:

Improvesystem protectionVSAvoidaxial vibration transmission

Core Design Contradiction:

ReliabilityVSForce

Solution Approach 1:

The vibration isolating housing employs localized vibration isolation features at specific locations where vibrations would otherwise be transmitted to the machining system. The housing is designed to be rigid in directions that maintain tool bit coupling while being compliant in directions that isolate vibrations from the system, creating different mechanical properties in different spatial directions.

Inventive Principle:

Principle #3Local quality

3Productivity

If high power ultrasonic vibrations are applied to improve machining performance, then productivity increases, but harmful vibrations are generated

Engineering Contradiction:

Improvemachining efficiencyVSAvoidunwanted vibrations

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The vibration isolating housing converts the harmful ultrasonic vibrations into a beneficial isolation mechanism. The vibration isolating features are designed to allow axial vibrations to pass through to the tool bit while absorbing and isolating unwanted vibrational modes, effectively transforming the harmful vibration energy into a protective function.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 solution effectively isolates ultrasonic vibrations, preventing damage to machining systems and ensuring efficient tool operation by maintaining axial vibrations for machining while absorbing other vibrational modes, thus enhancing tool life and accuracy.

Implementation Method 1

a transducer assembly that includes piezoelectric ceramics

Methodology Applied

Scientific EffectPiezoelectric effect: Piezoelectric Effect

Implementation Method 2

a spring-like feature to absorb unwanted vibrations

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 3

a vibration-isolating housing... preventing vibration transmission back into the spindle

Methodology Applied

Scientific EffectVibration isolation: Damping

Data Source

PatentEP3188864B1Devices for isolating acoustic vibrations in metalworking systems

Publication Date: 2024.11.06 EDISON WELDING INSTITUTE INC

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AI summary

An ultrasonic machining module that includes an ultrasonic transducer, wherein the ultrasonic transducer is adapted to receive a machining tool and a vibration-isolating housing adapted to be both compatible with a machining system and to receive the ultrasonic transducer therein, wherein the housing further includes at least one modification for isolating all vibrations generated by the ultrasonic transducer when the device is in operation except axial vibrations transmitted to the machining tool, thereby preventing unwanted vibrations from traveling backward or upward into the machining system.