BORING BAR AND A NON-ROTATING BORING TOOL AND A BORING ARRANGEMENT COMPRISING SUCH A BORING BAR

Abstract

A boring bar for a non-rotating boring tool includes an elongated main part configured for attachment to a support structure of a metal cutting machine. A front part is arranged to carry a tool part provided with a cutting element and at least one damping module, which is arranged between a front end of the main part and a rear end of the front part and which is provided with an electrically controlled vibration actuator configured to generate vibratory forces for active vibration damping of the boring bar. The front part is connected to the main part via the at least one damping module, wherein the main part, the front part and the at least one damping module together form an elongated body, and wherein the at least one damping module constitutes a length section of the elongated body.

Claims

1. A boring bar for a non-rotating boring tool, the boring bar comprising: an elongated main part configured for attachment to a support structure of a metal cutting machine, the main part having a rear end and an opposite front end; a front part having a rear end facing the front end of the main part and an opposite front end, the front end of the front part being arranged to carry a tool part provided with a cutting element; and at least one damping module arranged between the front end of the main part and the rear end of the front part, wherein the at least one damping module has a rear end facing the main part, an opposite front end facing the front part and a centre axis extending between the rear end and the front end of the damping module, wherein the at least one damping module is provided with an electrically controlled vibration actuator for active vibration damping of the boring bar, wherein this actuator is configured to generate vibratory forces, wherein the front part is connected to the main part via the at least one damping module, wherein the main part, the front part and the at least one damping module together form an elongated body, and wherein the at least one damping module constitutes a length section of the elongated body.

2. The boring bar according to claim 1, wherein the at least one damping module has the same cross-sectional outer peripheral shape as the main part and/or the front part.

3. The boring bar according to claim 1, wherein the main part and/or the front part and/or the at least one damping module are cylindrical.

4. The boring bar according to claim 1, wherein an external periphery of the main part and an external periphery of the at least one damping module are flush or substantially flush with each other.

5. The boring bar according to claim 1, wherein the at least one damping module is arranged with its centre axis aligned or substantially aligned with a longitudinal axis of the main part.

6. The boring bar according to claim 1, wherein at least one damping module is clamped between the main part and the front part by means of tie rods, which prefer-ably extend through passages in the at least one damping module.

7. The boring bar according to claim 1, wherein said actuator is a single-axis actuator configured to generate vibratory forces in parallel or at least substantially in parallel with one single working axis of the actuator.

8. The boring bar according to claim 7, wherein said working axis extends in a cross-sectional plane that is perpendicular to the centre axis of the at least one damping module.

9. The boring bar according to claim 1, wherein the boring bar includes at least two damping modules arranged in series with each other between the front end of the main part and the rear end of the front part.

10. The boring bar according to claim 9, wherein the at least two damping modules abut against each other.

11. The boring bar according to claim 9, wherein the actuator in each of the at least two damping modules is a single-axis actuator configured to generate vibratory forces in parallel or at least substantially in parallel with one single working axis of the actuator, wherein the at least two damping modules are arranged with the working axes of the actuators angularly offset from each other.

12. The boring bar according to claim 11, wherein the at least two damping modules are arranged with the working axes of the actuators extending perpendicularly to each other.

13. A non-rotating boring tool comprising: a boring bar according to claim 1; and a tool part provided with a cutting element, wherein this the tool part is detachably attached to or integrally formed with the front part of the boring bar.

14. The non-rotating boring tool according to claim 13, wherein the front part of the boring bar is adjustable in its rotary position in relation to the at least one damping module, and/or that said tool part is adjustable in its rotary position in relation to the front part of the boring bar.

15. The non-rotating boring tool according to claim 13, wherein the actuator in each damping module of the at least one damping module or of the at least two damping modules is a single-axis actuator configured to generate vibratory forces in parallel or at least substantially in parallel with one single working axis of the actuator, and wherein the cutting element includes a rake side, a relief surface and a cutting edge formed at an intersection between the rake side and the relief surface, wherein when seen in a cross-sectional plane that is perpendicular to a longitudinal axis of the boring bar and intersects the cutting edge in a radially outermost point, a straight and imaginary reference line intersects the cutting edge in the radially outermost point and extends in this cross-sectional plane at an angle of 6° to the relief surface on the outside of the cutting element, and wherein when seen in this cross-sectional plane, the working axis of the actuator in the damping module closest to the front part of the boring bar forms an angle of 90°±10° to said reference line or forms an angle of 0°±10° to said reference line.

16. The non-rotating boring tool according to claim 13, further comprising at least one vibration sensor mounted to the front part of the boring bar or to said tool part.

17. A boring arrangement comprising: a boring bar according to claim 9; and an electronic control unit configured to control the electric current to the actuator in each damping module of the at least one damping module or of the at least two damping modules in order to control the generation of vibratory forces in the actuator in each damping module of the at least one damping module or of the at least two damping modules.

18. The boring arrangement according to claim 17, further comprising at least one vibration sensor configured to generate measuring signals related to the vibration of the boring bar and to send the measuring signals to the electronic control unit, wherein the electronic control unit is configured to receive the measuring signals from the at least one vibration sensor, wherein the electronic control unit is configured to control the electric current to the actuator in each damping module of the at least one damping module or of the at least two damping modules in dependence on the measuring signals from the at least one vibration sensor in order to control the generation of vibratory forces in the actuator in each damping module of the at least one damping module or of the at least two damping modules in dependence on these measuring signals.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0034] With reference to the appended drawings, a specific description of embodiments of the invention cited as examples follows below. In the drawings:

[0035] FIG. 1 is a lateral view of a non-rotating boring tool according to an embodiment of the present invention,

[0036] FIG. 2 is a longitudinal section according to the line II-II in FIG. 1,

[0037] FIG. 3 is an exploded view of the boring tool of FIG. 1,

[0038] FIG. 4 is an exploded view from another direction of the boring tool of FIG. 1,

[0039] FIG. 5 is a perspective view of a front end of the boring tool of FIG. 1,

[0040] FIGS. 6a and 6b are front views of the boring tool of FIG. 1,

[0041] FIG. 7a is a perspective view from above of a cutting element included in the boring tool of FIG. 1,

[0042] FIG. 7b is a perspective view from below of the cutting element of FIG. 7a,

[0043] FIG. 7c is a lateral view of the cutting element of FIG. 7a,

[0044] FIG. 8a is a perspective view from above of an alternative cutting element,

[0045] FIG. 8b is a perspective view from below of the cutting element of FIG. 8a,

[0046] FIG. 8c is a lateral view of the cutting element of FIG. 8a,

[0047] FIG. 9 is an outline diagram of a boring arrangement according to an embodiment of the invention,

[0048] FIG. 10 is an outline diagram of a boring arrangement according to an alternative embodiment of the invention, and

[0049] FIG. 11 is an outline diagram of a boring arrangement according to another alternative embodiment of the invention.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

[0050] A non-rotating boring tool 1 according to an embodiment of the present invention is illustrated in FIGS. 1-5. The boring tool 1 is to be used for performing different types of machining operations, such as for instance internal or external turning, on a rotating workpiece of metallic material. The boring tool 1 comprises a boring bar 2, which is to be fixed to a support structure 3 of a metal cutting machine (very schematically illustrated in FIGS. 9-11) in order to project in a cantilevered manner from this support structure 3. The boring tool 1 also comprises a tool part 4 provided with a cutting element 5, wherein this tool part 4 is carried by the boring bar 2 and mounted to the boring bar at a front end 2a of the boring bar.

[0051] The boring bar 2 comprises an elongated main part 10 configured for attachment to the support structure 3 of the metal cutting machine. This main part 10 has a rear end 10b and an opposite front end 10a. A longitudinal axis 11 of the main part extends between the rear end 10b and the front end 10a of the main part. The main part 10 is preferably tubular and it is to be attached to said support structure 3 at its rear end 10b. In the illustrated embodiment, the main part 10 is cylindrical and has a circular cross-sectional shape. However, the main part 10 may also have any other suitable cross-sectional shape, such as for instance an elliptical or a polygonal cross-sectional shape.

[0052] The boring bar 2 further comprises a front part 12. This front part 12 has a rear end 12b facing the front end 10a of the main part 10 and an opposite front end 12a. A centre axis 13 of the front part extends between the rear end 12b and the front end 12a of the front part. The front end 12a of the front part is arranged to carry the above-mentioned tool part 4. Thus, this tool part 4 is attached to the front part 12 of the boring bar at the front end 12a thereof. As an alternative, the tool part 4 may be integrally formed with the front part 12, which implies that the tool part 4 and the front part 12 are combined into a common component. In the illustrated embodiment, the front part 12 is cylindrical and has a circular cross-sectional shape. However, the front part 12 may also have any other suitable cross-sectional shape, such as for instance an elliptical or a polygonal cross-sectional shape.

[0053] The boring bar 2 also comprises at least one damping module 14 arranged between the front end 10a of the main part 10 and the rear end 12b of the front part 12, wherein this damping module 14 has a rear end 14b facing the main part 10, an opposite front end 14a facing the front part 12 and a centre axis 15 extending between the rear end 14b and the front end 14a of the damping module. In the illustrated embodiment, the boring bar 2 comprises two such damping modules 14 arranged in series with each other between the front end 10a of the main part 10 and the rear end 12b of the front part 12. Thus, these two damping modules 14 are arranged in series with each other in the longitudinal direction of the boring bar 2. The boring bar 2 may as an alternative comprise more than two damping modules 14 arranged in series with each other in the longitudinal direction of the boring bar 2 or one single damping module 14.

[0054] In the illustrated embodiment, the damping modules 14 are cylindrical and have a circular cross-sectional shape. However, the damping modules 14 may also have any other suitable cross-sectional shape, such as for instance an elliptical or a polygonal cross-sectional shape.

[0055] Each one of the damping modules 14 is provided with an electrically controlled vibration actuator 16 for active vibration damping of the boring bar 2, wherein this actuator 16 is arranged in a housing 14c of the associated damping module and configured to generate vibratory forces in order to counteract vibrations induced in the boring bar 2 by cutting forces acting on the cutting element 5 during machining of a rotating workpiece. The vibratory forces generated by the actuators 16 of the damping modules 14 may also be used for intermittently vibrating the cutting element 5 in order to break to pieces larger metal chips cut off from a workpiece by the cutting element 5.

[0056] In the illustrated embodiment, each damping module 14 is provided with one single vibration actuator 16. However, an individual damping module 14 may as an alternative be provided with two or more vibration actuators 16, preferably but not necessarily with the working axes 17 of the two or more actuators 16 angularly offset from each other.

[0057] Each actuator 16 comprises a moveably arranged damping mass 16a configured to generate vibratory forces in parallel or at least substantially in parallel with a working axis 17 of the actuator, wherein the damping mass 16a is moveable in relation to the housing 14c of the associated damping module 14. In the illustrated embodiment, the damping mass 16a is moveable in relation to the housing 14c of the damping module 14 against the action of return springs 16b arranged on opposite sides of the damping mass 16a. The actuators 16 may be of electromagnetic type, wherein the vibratory forces are electromagnetically generated. However, any other suitable type of vibration actuators may also be used.

[0058] The front part 12 is connected to the main part 10 via the damping modules 14. The main part 10, the front part 12 and the damping modules 14 together form an elongated body 6, wherein the main part 10, each individual damping module 14 and the front part 12 constitute separate length sections, i.e. separate segments, of this elongated body 6. Thus, the main part 10, the damping modules 14 and the front part 12 constitute consecutive sections of the elongated body 6 of the boring bar, as seen in the longitudinal direction thereof.

[0059] In the illustrated embodiment, the damping modules 14 abut directly against each other, wherein the rear end 14b of a foremost one of the damping modules abuts against the front end 14a of the other damping module, i.e. the rearmost damping module. As illustrated in FIGS. 1-5, the front part 12 may be arranged with its rear end 12b abutting directly against the front end 14a of the foremost damping module and the rearmost damping module may be arranged with its rear end 14b abutting directly against the front end 10a of the main part 10.

[0060] An external periphery 18 of the main part 10 and an external periphery 19 of each damping module 14 are with advantage flush or substantially flush with each other, as illustrated in FIGS. 1, 2 and 5. Furthermore, an external periphery 20 of the front part 12 is with advantage flush or substantially flush with the external periphery 19 of the foremost damping module 14.

[0061] In the illustrated embodiment, each one of the damping modules 14 is arranged with its centre axis 15 aligned or substantially aligned with the longitudinal axis 11 of the main part 10.

[0062] In order to facilitate maintenance and repair of the boring bar 2, the main part 10, the damping modules 14 and the front part 12 are preferably detachably mounted to each other. In the illustrated embodiment, the damping modules 14 are clamped between the main part 10 and the front part 12 by means of tie rods 22. Each tie rod 22 has a first end 22a fixed to the main part 10 and an opposite second end 22b fixed to the front part 12. Furthermore, each tie rod 22 extends through mutually aligned passages 23 in the damping modules 14. The different parts 10, 12, 14 of the elongated body 6 may as an alternative be mounted to each other in any other suitable manner.

[0063] In the illustrated embodiment, the actuator 16 in each one of the damping modules 14 is accessible through two openings on opposite sides of the damping module, wherein each opening is covered by a detachably mounted cover 24, which forms part of the external periphery 19 of the damping module and which is secured in the associated opening by means of fastening elements 25 in the form of screws. Passages 23 for some of the above-mentioned tie rods 22 may be provided in the covers 24.

[0064] In the illustrated embodiment, cooling fluid is supplied to the tool part 4 through a first feed pipe 26, which extends axially through the main part 10 of the boring bar 2, and at least one second feed pipe 27, which extends between the main part 10 and the front part 12 of the boring bar in parallel with the tie rods 22. In the illustrated example, the boring bar 2 is provided with two such second feed pipes 27. The first feed pipe 26 is fixed to the main part 10 of the boring bar by means of a first end piece 28a fixed to the main part 10 at the front end 10a thereof and a second end piece 28b fixed to the main part 10 at the rear end 10b thereof. Each one of the second feed pipes 27 is connected to the first feed pipe 26 via internal channels in the first end piece 28a. Furthermore, each one of the second feed pipes 27 may be arranged to extend through mutually aligned passages 29 in the damping modules 14.

[0065] The actuator 16 in each one of the damping modules 14 is preferably a single-axis actuator configured to generate vibratory forces in parallel or at least substantially in parallel with one single working axis 17 of the actuator. In the illustrated embodiment, the working axis 17 of each one of the actuators 16 extends in a cross-sectional plane that is perpendicular to the centre axis 15 of the associated damping module 14, wherein the damping modules 14 are arranged with the working axes 17 of their actuators 16 angularly offset from each other. Thus, the actuators 16 of the damping modules 14 are arranged in mutually different rotary positions in the elongated body 6. When the damping modules 14 are two in number, they are preferably arranged with the working axes 17 of the actuators 16 extending perpendicularly to each other, as illustrated in FIGS. 1 and 2.

[0066] In order to make possible an adjustment of the angular position of the working axes 17 of the actuators 16 in relation to the cutting element 5, the front part 12 of the boring bar 2 may be adjustable in its rotary position in relation to the damping modules 14, which implies that the front part 12 is attachable to the foremost damping module 14 in different selectable rotary positions in relation to this damping module. As an alternative to or in combination with such a rotary adjustability of the front part 12 in relation to the damping modules 14, the tool part 4 provided with the cutting element 5 may be adjustable in its rotary position in relation to the front part 12 of the boring bar, which implies that the tool part 4 is attachable to the front part 12 in different selectable rotary positions in relation to the front part. A damping module 14 may also be arranged such that its actuator 16 may be adjustable in its rotary position in relation to a casing of the damping module. When the damping modules 14 are two or more in number, they may be arranged such that their respective rotary positions may be adjustable in relation to each other.

[0067] The cutting element 5 fixed to the tool part 4 may be a positive cutting element, as illustrated in FIGS. 7a-7c, or a negative cutting element, as illustrated in FIGS. 8a-8c. The cutting element 5 comprises an upper rake side 30, a bottom side 31 extending in parallel or substantially in parallel with the rake side 30 and a peripheral relief surface 32 extending between the rake side 30 and the bottom side 31. A cutting edge 33 is formed at an intersection between the rake side 30 and the relief surface 32. In the illustrated examples, the cutting edge 33 extends all around the rake side 30 along the periphery thereof. In case of a positive cutting element 5, the relief surface 32 extends at an acute angle α to the rake side 30, as illustrated in FIG. 7c. In case of a negative cutting element 5, the relief surface 32 extends at a right angle to the rake side 30, as illustrated in FIG. 8c.

[0068] A hole 34 extends across the cutting element 5 between the rake side 30 and the bottom side 31. The cutting element 5 is configured to be releasably mounted to the tool part 4 with the bottom side 31 of the cutting element 5 resting against a support surface 35 (see FIG. 6a) on a seat provided for the cutting element in the tool part 4. The cutting element 5 is fixed to said seat in the tool part 4 by means of a fastening element 36 in the form of a screw (see FIG. 5), which extends through the hole 34 in the cutting element 5 and is engaged in a threaded hole in the support surface 35 on the seat.

[0069] In the illustrated examples, the cutting element 5 comprises two cutting corners 37 located opposite each other on opposite sides of the cutting element. The cutting element 5 is to be fixed to the tool part 4 with one of the cutting corners 37 facing outwards away from the longitudinal axis 7 of the boring bar 2, wherein the cutting element 5 is intended to make contact with a rotating workpiece via this outwardly facing cutting corner 37. During machining of a rotating workpiece, the boring tool 1 is normally so positioned in relation to the workpiece that the above-mentioned tangential force Ft on the cutting element 5 will be directed at an angle θ of approximately 6° to the relief surface 32, as illustrated in FIGS. 7c and 8c.

[0070] A straight and imaginary reference line L (see FIGS. 6a and 6b) is defined in a cross-sectional plane that is perpendicular to the longitudinal axis 7 of the boring bar 2 and that intersects the cutting edge 33 in a radially outermost point 39, wherein this reference line L intersects the cutting edge 33 in the radially outermost point 39 and extends in this cross-sectional plane at an angle β of 6° to the relief surface 32 on the outside of the cutting element 5, i.e. with this angle β measured on the outside of the cutting element 5. Thus, when a positive cutting element 5 of the type illustrated in FIGS. 7a-7c with a relief angle of 6° is fixed to the tool part 4, the reference line L may extend perpendicularly to the rake side 30 of the cutting element, as illustrated in FIGS. 6a and 6b.

[0071] The actuator 16 in the damping module 14 closest to the front part 12 of the boring bar 2 is with advantage arranged in such a rotary position in the boring bar 2 that its working axis 17, when seen in the above-mentioned cross-sectional plane, forms an angle of 90°±10° to said reference line L (as illustrated in FIG. 6a), preferably an angle of 90°+5°, and more preferably an angle of 90°±1°. In this case, the working axis 17 of this actuator is arranged substantially in parallel with the radial force Fr on the cutting element 5. With such an arrangement of the actuator 16 in the damping module 14 closest to the front part 12 of the boring bar, this actuator will be optimized for counteracting the vibrations caused by the radial force Fr on the cutting element 5.

[0072] According to a favourable alternative, the actuator 16 in the damping module 14 closest to the front part 12 of the boring bar 2 is arranged in such a rotary position in the boring bar 2 that its working axis 17, when seen in the above-mentioned cross-sectional plane, forms an angle of 0°±10° to said reference line L (as illustrated in FIG. 6b), preferably an angle of 0°+5°, and more preferably an angle of 0°±1°. In this case, the working axis 17 of this actuator is arranged substantially in parallel with the tangential force Ft on the cutting element 5. With such an arrangement of the actuator 16 in the damping module 14 closest to the front part 12 of the boring bar, this actuator will be optimized for counteracting the vibrations caused by the tangential force Ft on the cutting element 5.

[0073] Different embodiments of a boring arrangement 40 comprising a boring bar 2 of the type described above are very schematically illustrated in FIGS. 9-11. The boring arrangement 40 further comprises an electronic control unit 41, which is configured to control the supply of electric current to the actuators 16 in the damping modules 14 of the boring bar 2 in order to control the generation of vibratory forces in the damping modules. The electric current is supplied to the actuators 16 from a power source, which may be an external power source 42, as illustrated in FIG. 9, or a power supply unit 42′ mounted to the boring bar 2, as illustrated in FIG. 11, or to the support structure 3 or any other part of the metal cutting machine, as illustrated in FIG. 10. The power supply unit 42′ comprises at least one energy storage member, for instance in the form of a battery, for storing electric energy. The electronic control unit 41 may be mounted to the front part 12 of the boring bar 2, as illustrated in FIGS. 10 and 11, or to any other part of the boring bar. As a further alternative, the electronic control unit 41 may be mounted to the support structure 3 or any other part of the metal cutting machine, as illustrated in FIG. 9.

[0074] The boring arrangement 40 further comprises at least one vibration sensor 43, for instance in the form of an accelerometer, which is configured to generate measuring signals related to the vibration of the boring bar 2 and to send the measuring signals to the electronic control unit 41 through a wireless connection or a cable connection. Said at least one vibration sensor 43 is preferably mounted to the front part 12 of the boring bar or to the tool part 4, but it may as an alternative be mounted to any other suitable part of the boring bar 2.

[0075] The electronic control unit 41 is configured to receive the measuring signals from the at least one vibration sensor 43 and to control the supply of electric current to the actuators 16 in the damping modules 14 in dependence on these measuring signals in order to control the generation of vibratory forces in each damping module 14 in dependence on these measuring signals and thereby counteract the vibrations induced in the boring bar 2 by the cutting forces Fr, Ft acting on the cutting element 5 during machining of a workpiece.

[0076] The invention is of course not in any way restricted to the embodiments described above. On the contrary, many possibilities to modifications thereof will be apparent to a person with ordinary skill in the art without departing from the basic idea of the invention such as defined in the appended claims. For example, it is possible to arrange the actuator in the associated damping module such that the working axis of the actuator is parallel to or coincides with the centre axis of the damping module, which implies that the actuator is arranged with its working axis in parallel to or alignment with the longitudinal axis of the elongated body. It is also possible to integrate a two-axes actuator in one damping module in order to obtain damping both in radial and tangential direction of the boring bar by using only one damping module.