This application claims priority under 35 U.S.C. § 119 to the following German Patent Application No. DE 10 2019 132 276.6, filed on Nov. 28, 2019, the entire contents of which are incorporated herein by reference thereto.
The invention refers to a method for clamping of workpieces consisting of ductile material, as well as an embossing device for use in this method as well as a clamping device also for use in this method.
For processing or machining of workpieces in machine tools, particularly for chip-creating machining, the workpieces have to be clamped and held in suitable clamping units. The clamping must be carried out in a manner such that during the machining processes that have to be carried out on the workpiece, also larger forces can be supported without movement of the workpiece in the clamping device or without releasing of the workpiece therefrom. On the other hand, the workpiece must be accessible as far as possible, in order to be able to carry out as many machining processes on the workpiece as possible with one single clamping setting.
For this EP 1 071 542 B1 proposes a method for clamping of workpieces in which regularly spaced depressions are provided on a workpiece in a preparing process step, wherein these depressions do only serve as coupling elements during clamping with a respective clamping device, but are without any function apart therefrom. After this preparing process step the workpieces are placed in chucks that have abutment surfaces at their clamping jaws for friction-fit clamping and that have form-fit elements for form-fit positioning and securing of position that are complimentary to the depressions of the workpiece. Thus the workpiece is clamped in a form-fit as well as friction-fit manner. This clamping method has proved itself in general.
Further a clamping method is known from DE 10 2009 052 334 A1 in which the workpiece is provided with a clamping structure in the proximity of its base surface. Two grooves provided at the flanks of the workpiece form part thereof in which corresponding bar-like projections of two clamping jaws of a chuck engage. The grooves are, for example, introduced by means of a milling process and provide a form-fit connection between the clamping jaws and the workpiece. The wall remaining at the workpiece and limiting the groove must be resistant against bending and breaking, which requires a certain minimum wall thickness of the groove wall. This determines the space requirement of the clamping structure.
When configuring clamping systems, it has to be expected that users desire to machine a range of different workpieces from different materials without being limited to one certain type of workpiece and material. This has to be considered when clamping systems are configured. On one hand the clamping device must reliably hold the workpieces, also if they are subject to high machining forces, wherein on the other hand damaging the workpieces by means of the clamping device has to be avoided, such as unallowed deformations or excavations.
Starting therefrom it is the object of the invention to provide a clamping method with which a wide range of workpieces consisting of different materials can be clamped, wherein the space required by the clamping device on the workpiece shall be as small as possible.
The clamping method according to the invention is based on that in a preparing process step deformations are provided in a defined grid on the workpieces to be clamped, e.g. in the shape of a row of regularly distanced depressions. These depressions (or other deformations) serve as positioning and coupling elements during clamping in a respective clamping device, whereby they do not fulfill any other function on the workpiece apart therefrom. For clamping of the workpieces the clamping jaws comprise clamping surfaces for the friction-fit holding of the workpiece. In addition, the clamping jaws are provided with form-fit elements, preferably at the abutment surfaces that serve to form-fit positioning and securing of the workpiece position. The workpiece is thus clamped in a combined friction-fit and form-fit manner.
According to the invention, the deformations provided on the workpiece are arranged with a center distance of 2.5 mm to 3.5 mm from each other. It has been shown that by means of such a grid an optimum in terms of the holding force and the area required on the workpiece for holding can be obtained. Local stress peaks in the workpiece are reduced to an amount supportable for most materials and a uniform holding force transmission between the clamping jaws and the workpiece is obtained. Excavations, crack formations on the workpiece or other workpiece damages are avoided. A grid dimension of 3 mm (center distance) forms an optimum of the ratio of reachable holding force to required surface area that applies for most of the ductile materials such as plastics, particularly plastically deformable plastics, aluminum, aluminum alloys, as well as other metal alloys and metals.
The depressions are preferably arranged in a row that extends along the bottom edge of the workpiece next to the base surface of the workpiece. Preferably the row is a straight row. The depressions can, however, also be arranged in two or more rows, preferably arranged parallel to each other. The depressions of two rows can be arranged adjacent to one another in pairs or can be alternatively offset from each other. In at least one of the two (or more) rows, preferably in all of the rows, the grid distance is defined to a value in a range from 2.5 mm to 3.5 mm, preferably 3 mm.
Preferably the deformations that have to be provided on the workpiece are depressions that are introduced in the workpiece by plastic deformation by means of an embossing device. Each depression can be created by material displacement by means of an embossing tooth. The depressions are preferably arranged in a straight row and with constant distances to each other. Between the depressions non-depressed or also slightly elevated areas are formed that separate the individual depressions from each other.
The depressions have preferably a rectangular cross-section with rounded corners, wherein the cross-section decreases toward the bottom of the depression. The rectangular depressions have preferably a length in the direction of the row in which they are arranged that is at least as long as the length of the areas between two adjacent depressions respectively that is measured in the same direction.
The material displacement that occurs during creation of the depressions, leads to a flow of the material of the workpiece, whereby below the depression and around the depression a zone of hardened material can be created. Particularly when using metals and metal alloys, this zone can have an increased strength so that it is particularly suitable for support and distribution of forces in the workpiece.
Preferably a distance between the embossing tool and the workpiece is left open between two adjacent embossing teeth in which displaced material can enter. The workpiece surface that is smooth prior to the embossing, e.g. cylindrical or planar, thus obtains the desired deformations, e.g. depressions, during the preparing process step. Thereby wavy or elevated deformations of the workpiece surface can be created between these depressions, due to material displacement. The workpiece surface resulting therefrom that does not only contain depressions for reception of the form-fit elements of the clamping jaw, but in addition is curved multiple times. In other words the formerly smooth workpiece surface can comprise certain regular deformations, particularly in the areas between the depressions or around these depressions after the formation of the depressions.
In the inventive method the clamping surfaces of the clamping jaws are preferably brought in complete contact with the workpiece surface during clamping of the workpiece. In other words the clamping surface of the clamping jaw is pressed with high force on the workpiece surface that was potentially slightly deformed in the preparing working step. In doing so, the workpiece surface can be smoothed in that material displaced out of the workpiece surface is (elastically or plastically) deformed again until—in the ideal condition—the planar clamping surface abuts against the workpiece completely in a two-dimensional manner. This can be combined with a slighter additional plastic deformation of the workpiece, whereby the workpiece is held in the clamping device between the clamping jaws particularly reliably.
The inventive embossing device serves for carrying out of the inventive method. At least one embossing die is part of the embossing device, wherein the embossing die comprises an embossing structure that defines a grid, wherein the grid dimension is in a range of 2.5 mm to 3.5 mm. The embossing die can be a linearly movable die, a roller die or the like. The embossing device comprises a counter support for reception of the workpiece, wherein the counter support is arranged opposite the embossing die. The counter support itself can be configured as embossing die, such that on the workpiece on two opposite sides facing away from each other, the desired positioning and coupling elements can be provided in one single working step.
For embossing the one embossing die or the more embossing dies are pressed against the workpiece, preferably by means of a force generating device. The force generating device is preferably configured to have the embossing die or embossing dies to act on the workpiece with a predefined force. In doing so, the embossing depth is defined by the ductility of the workpiece material. However, in any case damage of the workpiece, due to an excessive force acting on the workpiece, is avoided.
The depressions are created by means of the embossing device preferably while measuring the penetration depth of the embossing teeth. In doing so, it can be ensured that the depressions reach a desired depth during the embossing process, but do not exceed a maximum depth. Mechanical means for limiting the penetration depth, as e.g. abutment teeth provided at the embossing jaws (between the embossing teeth) are not provided. Rather a free space is respectively formed between two embossing teeth, the limitation of which does not get into contact with the workpiece. The penetration depth of the embossing teeth is preferably defined to an amount that is deeper than the tooth height of the holding teeth. In doing so, an uncontrolled workpiece deformation during clamping as well as an excessive wear of the holding teeth is avoided.
The embossing device comprises preferably multiple embossing teeth, the center distance of which corresponds to the grid dimension. Preferably each embossing tooth is provided with at least one, preferably with two or more flanks curved in a concave manner such that the flank angle continuously decreases with the progressive penetration of the embossing tooth during embossing at the penetration location of the workpiece. In this manner similar penetration depths are provided also in different ductile materials such that the workpieces embossed in this manner fit on the clamping device in any case. A small variability of the penetration depth of the embossing teeth can be achieved in case of a large variability of the ductility of the different workpiece materials. In doing so, it is guaranteed that the form-fit elements of the clamping device fit in the depressions provided on the workpiece independent from the used material of the workpiece. This applies at least to a wide range of workpiece materials.
As mentioned, at least slightly different penetration depths of the embossing teeth and thus slightly different cross-sections of the depressions are obtained in different ductile materials. Due to the control or regulation of the embossing force, however, it can be achieved that the embossed depressions always have a depth that is deeper than the tooth height of the holding teeth.
The holding teeth of the clamping jaws are so small that they fit into the smallest depressions that have to be expected in any case. For this reason they can engage with a slightly lateral play in the depressions, if the workpiece is made of a very ductile material and the depressions are rather large. Due to the pressing force that the clamping surfaces of the clamping jaws effect on the workpiece surface and thus on the surrounding area of each depression, however, the depressions can be slightly narrowed again such that the holding teeth finally engage in the depressions without play.
The embossing teeth of the embossing die limit between each other an interstice in which workpiece material can flow during embossing. The interstice preferably comprises limitation or boundary that follows the contour of a cylinder. In addition, the embossing teeth are preferably formed on a bar projection of the embossing die. This ensures that during embossing no planar surface outside the embossing teeth get in contact with the workpiece surface. In doing so, the individual depressions can be surrounded by a more or less large ring-shaped elevation depending on the workpiece ductility. The workpiece surface can freely deform outside of the depressions. This is achieved in that the embossing force acts only and exclusively between the embossing teeth and the workpiece.
The inventive clamping device comprises at least one, preferably multiple clamping jaws, the workpiece clamping surface of which is provided with form-fit elements that are arranged in the predefined grid of the depressions, i.e. comprising a uniform center distance in a range from 2.5 mm to 3.5 mm, preferably 3 mm. The form-fit elements are preferably teeth, the shape of which is similar to the shape of the embossing teeth, wherein the holding teeth are preferably smaller than the embossing teeth. For this reason the dimension and shape of a depression in materials with low ductility can correspond to the shape and dimension of a holding tooth. In high ductile materials the depressions created by the embossing teeth can be indeed also wider and deeper such that the holding teeth are first engaging the depressions with some play. In order to compensate potentially different embossing depth, the holding teeth (or other form-fit elements) are preferably less high than the depressions embossed in the workpiece are deep. When clamping the workpiece, however, a part of the material displaced by the embossing tooth can flow back and finally surround the holding teeth of the clamping device completely and preferably without any gaps. In addition, a two-dimensional contact between the workpiece clamping surface and the workpiece can be achieved. In doing so, the form-fit and the friction-fit are maximized.
Embossing jaws with embossing teeth of a different dimension can be provided for different workpiece materials. In addition or as an alternative, different embossing forces can be used for different workpiece materials. For this the embossing device can be configured such that the embossing force can be adjusted accordingly. In addition or as an alternative, a measurement or monitoring device can be provided that is configured for measuring or monitoring the penetration depth of the embossing teeth in the workpiece. The embossing device can be configured such that it terminates the embossing process, if the desired depth of the depressions is reached. In all presented embodiments the depth of the depressions is preferably in a range of 0.2 mm to 2 mm. Preferably the depth of the embossed depression is larger than the height of the holding tooth by an amount in the range of 0.02 mm to 0.05 mm.
Further details and advantages of the inventive clamping system are apparent from the drawings and the claims. The drawings show:
The subsequent description of the clamping jaw 14 applies for the present and all further embodiments, for the counter support 15 configured as clamping jaw or additional clamping jaws and counter supports accordingly.
The clamping jaw 14 comprises a row of form-fit elements 16 that can have the shape of holding teeth 17 that fit with the depressions 12 in terms of shape, position and dimension. The holding teeth 17 are, e.g. arranged in a straight row that is arranged in a distance to a support surface 18 formed on the clamping jaw 14. The holding teeth can, however, also be arranged in another pattern, e.g. in a zigzag row or in two or more rows. The preferably planar support surface 18 is arranged orthogonal to a clamping surface 19 from which the holding teeth 17 project. The clamping surface 19 is preferably a planar surface. Preferably the holding teeth 17 are configured uniformly.
The depressions 12 as well as the holding teeth 17 are arranged in a corresponding grid R that is symbolically marked on the workpiece 10 in
During clamping of workpiece 10 between the clamping jaws 14, 15 the holding teeth 17 engage in the depressions 12 and the clamping surface 19 gets in contact with the workpiece surface 20 surrounding the depressions 12. Thereby the clamping surface 19 applies a pressure force on the workpiece surface 20. Concurrently the holding teeth 17 are positioned in the depressions 12 without play. In doing so, the workpiece 10 is clamped in a friction-fit and form-fit manner. Due to the low grid dimension of preferably 3 mm, a quasi-continuous form-fit holding of the workpiece 10 with low local force peaks is obtained thereby. Concurrently due to the latching of the holding teeth 17 in the depressions 12, the workpiece position parallel to the clamping jaws 14, 15 is defined.
The embossing die 21 illustrated in
A bar 23 is configured on the embossing die 21 parallel to the support surface 22. The bar 23 is preferably provided with curved or rounded cavities 24. These cavities 24 have preferably a shape corresponding to a cylindrical surface section in each case and limit the embossing teeth 25 between each other, the embossing teeth 25 being arranged in the grid R. In other words the center distances are defined in the preferred grid of 2.5 mm to 3.5 mm and have, for example, a uniform amount of 3 mm.
Apart therefrom, the bar 23 can have parallel flanks or can be wedge-shaped, i.e. extending toward the tips of the embossing teeth 25 in a wedge-shaped manner. In addition the embossing teeth can also be configured in a curved or rounded manner on these flanks.
During an embossing process the embossing dies 21 are preferably moved toward each other in a force-actuated manner, wherein the embossing process is executed preferably in a force-controlled manner, however, at least in a force-limited manner. This means that depth T results from a cooperation of the material ductility of workpiece 10 and the applied embossing force. In doing so, and contrary to distance-controlled embossing processes that have a defined penetration depth, damage of workpiece 10 is avoided. In addition or as an alternative, the penetration depth of the embossing teeth can be measured during the embossing process. The penetration depth is the distance that the embossing jaws travel subsequent to the first contact of the workpiece with the faces of the embossing teeth. The embossing device can be configured to terminate the embossing process as soon as the desired penetration depth is reached and thus the desired depth of the depression is achieved. The depth T of the depression 12 is preferably at least slightly longer than the height of holding teeth 17. The difference can be, e.g. in a range from 0.02 mm to 0.05 mm and can also have a higher or less amount if applicable.
As also apparent from
As shown in
The embossing teeth 25 have preferably two or also four flanks 24a, 24b that are curved in a concave manner, as particularly shown in
As already mentioned, the clamping surface 19 and the workpiece surface 20 are brought into contact during clamping while the holding teeth 17 engage the depressions 12. As apparent from
Due to the predefined grid distance of preferably 3 mm, it is achieved that the influenced zones 26 of the different embossing teeth 25 abut or overlap in the workpiece 10. In doing so, a quasi-continuous clamping of the workpiece 10 is allowed. Tests thereby show that longer as well as shorter grid distances lead to reduced workpiece holding forces.
The horizontal axis (abscissa) shows a grid dimension of the grid R. The grid dimension is a center distance of the embossing teeth 25 and concurrently the center distance of the depressions 12 as well as the center distance of the holding teeth 17. It has been shown that the maximum achievable holding force F related to the area A reaches a maximum with a grid dimension of 3 mm, wherein in the range from 2.5 mm to 3.5 mm still good holding force values can be achieved. The decrease with regard to the maximum holding force has an amount in this area of mostly less than 30%, frequently less than 10%. This applies to nearly all of the at least somehow ductile and thus embossable materials practically used.
Thereby the holding force F is a force that is effective orthogonal to the support surface 18 and thus tends to pull the workpiece 10 that is clamped between the clamping jaws 14, 15 out of the clamping jaws 14, 15 (vertical to the top in
Surprisingly it has shown that the grid distance of 2.5 mm to 3.5 mm is an optimum for a wide range of workpieces and materials such that no determination on specific materials and workpiece geometries is necessary for the presented clamping system. A universal clamping system can be offered having a wide application in practice.
As illustrated in
In addition,
In the inventive clamping method a workpiece 10 is first provided with depressions 12, wherein these depressions are, for example, arranged in one row or in a field having a grid dimension with preferably 3 mm grid distance. The grid dimension is thereby the center distance of the depressions 12. The depth T of the depressions 12 is preferably less than the length of the depressions 12 measured in the direction of the row of the depressions 12. The distances between the depressions 12 preferably correspond approximately to the length of the depressions 12.
Preferably these depressions 12 are formed with embossing tools that comprise embossing teeth 25 with rounded flanks 24a, 24b. Preferably the flanks 24a, 24b are rounded in a concave manner.
The embossing process is preferably carried out such that elevated areas 27 are formed between the depressions 12 that first get into contact with the planar clamping surface 19 of clamping jaws 14, 15 during clamping of the workpiece 10 between the clamping jaws 14, 15. A deformation of these elevated areas 27 during the clamping process increasing the holding force.
The grid distance of 2.5 mm to 3.0 mm has proven to be an optimum for a wide range of usable workpieces and materials.
Number | Date | Country | Kind |
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10 2019 132 276.6 | Nov 2019 | DE | national |