UDK 621.951.4:531.7 M. ZLOKOLICA, B, SOVILJ, PT. CAVIC, M. KOSTIC, D.

BRAAN

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Kinematic of Tools for Polygonal Holes r Production in the Real Condition*

n T

:E O E

a IJ.J cc

LU

Polygonal holes can be made in many different ways. Using rotational tool for boring the polygonal holes is a very efficient way of doing it. Since, in this cese, the applied tool is of i ,rry complex movement, the variable speed of a btade of the tool must be found for the given constant angle velocity. The aim of this paper is to determine the speed of the tool's blade used for polygonal hole production. The given task will be solved using alternattve mechanism ancl applyting centrodes. Euler-Savary equation will be used for defining the path of the tool's blade at the rcp points, while processing the polygonal holes. After theoretical description of the kinematics problem the cutting speed will be defined too in real conditions. The proposed proced.ttre wes applied on a concrete case of polygonal hole processing with the aim of defining the velocity of tool's blade as well as of geometry of polygonal contour. The procedure is a very simple one and ct very accurate one giving the precise solutions in an analytical and a graphical presentation. Keywords: kinematics, polygonal holes, cutting speed

1. INTRODUCTION Besides the possible way of polygonal holes productionby grating or pulling through they could alsobe madeby boring. During boring of theseholes tool geometryand the polygonalhole itself must be synchronrzed, which meansthat the hole contourcan be wind on severalconsecutive tool positions.The tool is guided during work accordingto stereotype with the shape same as the hole to be produced. Besidesrotationalmovementtool has also a vertical movementduring work. At one observed momentof time excluding vertical movement tool is moving with anglespeed<oguided insidecontourstereotype. Because of complex movement of tool it is interestingto analyze the changeof speedof cutting biadeduring working cycle.

It is enough to notice, in the observedtime, two points of tool blade whose path correspondsto stereotype contourfor tool leading.It is shown in the Fig.l that the path of point A and B are overlapped with contour and II. In that case the direction of speedVe and Vs zrreoverlappedwith contoursand II. Now the direction of speed for point C is determined in the relation to existing pole P determinedvia turnover speed direction of Va and Vs. The same solution can be achieved by using (changeable) alternative mechanismshown in Fig 2. Being acquaintednow with mechanism shown in Fig.Z the movement can be brought to rolling of moveablecentrodeover fixed one (fig.3 ) by using construction of fixed centrode presented by constructionof moveablecentrode.

2. KINEIITATICAL DESCRIPTION OF THB POLYGONALHOLESBORING

Let us take one sector from single most general s hape o f p o ly gonal hole gi v e n i n F i g u re l .

Prof. dr Miodrag Zlokolica, Prof. dr Bogdan Sovilj, Ass.Maja Cavit, Ass. Milan Kostic. David Braun Faculty of TechnicalSciences, Universityof Novi Sad

Fig.I. Contour of polygonal hole

* The paper was published at The First Mediterranean Conference on Tribology in Israel.

Tribologyin indusr4y, Volume 22,No. 3&4, 2000.

53

Positionvector of point L is given by the expresslon ir=7r+Fr. First derivationof vector position VL by time gives velocity of point L. d7, dt -- I +16,Vn)Vr= * "dtdt-z-

-ioGr.-ro)-le0L-yi
Where:
Fig. 2. Alternative mechanism

(1)

7r,7, - vector position of current pole P and L in coordinatesystemOxy and P(r1 d =0 -angularvelocity of tool, *'r = Vp =0, V, -speed of currentspeed pole
lrr

tlt

systemOxyz. | ,j,E - unit vectorsof fixed coordinate (1) of Using equation the way of determination speed of one arbitrarytool point for boring is given, while the speed of all of the rest interesting points is determinedin the sameway. Fig.3. Constructionof centrode to Beside kinematicsit is necessary analyzethe path of tool blade point in one determinedperiod, because the polygonal hole can not be made with sharp but with roundedcrowns. The path of some arbitrary point L and semi diameter of curve at the determined period is achieved by analyzing the movement of the pair of centrodes given in Fig. 5. equationthe radius of curve p From the Euler-Savary in the observed point L of the curve k-k can be presentedin the form: ) (2) p=--*
q - d.cosd

Fig. 4. Kinematics of centrode

d - diameterof the circle of the tangential acceleration. - angle betweendirection of normal on the o centrodeCp and CN in the conjunctionpoint P and line PL . Fig. 5. Position of centrode Fixed centrode is presented with CN curve, and moveable with Cp curve with current observed in conjugation the currentPz pole. The movementof moveable centrode Cp is done with known angle speed 0J. Let us analyze now the movement of movablecentrodeshown in Fig. 4, with the aim to determrnethe cutting speed of the points which presentthe tool blade. Moveable coordinatesystem P\q is linked to moveablecentrodeCp, while fixed CN. systemOxy is lined to fixed centrode coordinate In this way radius of the path of any point of tool blade can be determined. If we know the trajectoryof a single point r(s) at the top point holes then the radius of a curve can be (3): obtainedon the basisof the expression p(s) = F!-+-l

lrcrll'

x r (s)l l/(s)

(3)

of Where s is a parameter the trajectorypoint of the tool. In our case top point of a tool has the following

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Tribology in industry,Volume22, No. 3&4' 2000.

coordinates ^(e,fl,ffi) Y^(e,n,m).On the basis of X , that we have the vector position i^(e,n,m)=X^(0,n,*)i+Y^(0,n,m)j in a fixed system (xOy). Radius of a path curve in the function of parameter(0) is given by the expression (4):
p ( 0 , t t , t n )=

tool blade point. The presentation the solving of of problemwith the help of centrodewill be given this by the exampleof squarehole. The shapeof tool for boring of squarehole is given in Fig. 6d.

li^r',',^)l
li^rr,n,m)xi^(e,r,Dl

n, - ^ n, .y l* ^ tt, n,m) t ^ {e, m) ii. (0, m) ^ (0,n,fil

tl

(4)

If the top of the tool entersthe hole then the radius of the curve decreases, and the radius of the curve on the exit path increases. the basisof that minimum On radius appears at the positions ( 9 0 . ' n= 0 , 2 '0 9, 4 0 g. . . 2 n ' 0 9) . The obtained radius represents non-dimensional value. The real radius is obtained via formula
p(0,rt,ftt),,o= a. p(0,n,nt) . t

r (a
^\

c)

-f
o
/
B-->
,.y

d)

v.

Knowing the positionof any of the top points in the functionof rotatingangle of the tool, the velocity of the top points can be easily obtainedthrough general kinematicrelation:
i ^ ( e , n , m ) = 7 ^ ( 0, n , m ) = = X . ( 0 , n , m ) .i + Y^ ( e , n , m ) .i

(5)

When defining the regime of the processing have we to know the intensitvof vectorvelocitvas: . . ,., . v ^ ( 0 , n , m= , l x ^ ( 0 , r , m ) 2 Y ^ ( 0 , n , m ) 2 m / r a d ) ( 6 ) ) + 1 In that way we obtainthe velocityof the top pointsof the tool dependingon rotating angle of the tool. Since all length measures are non-dimensional comparing the sizeof the hole contour(a), the real to b l a d es p e e ds o b t a i n e d s : v ( 0 , n , f f i ) , ,-oa . v ( 0 , n , m.) i t a During boring the tool is rotating with a constant angle velocity (A), so we can introduce the shift 0 ( t ) - 9 . y . O n t h e b a s i so f t h a t w e c a n o b t a i n t h e velocitydepending the time as: on
v^(t,n,m)=0 -

Fig. 6 Kinematicsschemeof alternativemechanisms Fig. 6a,b,cand squareshole with tool, Fig.6d.,and velocityof blade of tool VA- Ve(Sil Fig.6e. Dimensions of tool are synchronized with the dimensionsof the square holes as shown in F'i-9. 6a,b,c.The tool during boring is led over the square hole of dimension(a), and is turned by angle speed 0=(D. The speedof blade cutting of the tool A, B and C will be determined using already determined way, given in the introduction. for Alternativemechanisms one fourth of tool turn are given in Fig. 6a,b,c. On (4) the basisof the generalexpression the speedfor points A,B and C are:

-16,(vA v^ -i')l;
A

iu =@,(iu -ir));
(8)

= 6 . ,^(o,n,m) (rrls)

(7)

t'/C V

-i')l -10,(vc

lA,vB,ic - vectorspositionof pointsA , B , C a n d P 'v' 3. EXAMPLE Using the centrodeswe can find the velocity of points and after that by using Euler-Savaryequation can be found as weil as the radius of part curve of Using expression(4), Fig. 4 the survey of speed c&Il changefor point A from ,4.'-4.,6 be given in Fig. of The surveyof the currentpositionof centrode 6e.

Volume22, No. 3&4, 2000. Tribology in industryr,

55

curvek-k and positionof point As in which radiusp3 of the curve k-k is searched is given in the Fig.5 for (2). and equation

p^=--!

q+d.cosa

(e)
p ( 0 , 4), 3

According to that the current pole of acceleration Pag is achieved in the cross section of direction of acceleration for point Bs and Cs. We can say that the diameter of circle of tansential acceleration is d -

4P"r'
On basis of the expression(7) the velocity of tool bladesduring single moving period is calculatedand is shown in Fig 1. for each top-headof a triangle s h a p e do o l ( m - 1 , 2 , 3 ) . t Maximal and mrnimal (non-dimensional) blade velocity during drilling of a square hole is !',"*=0.861'?,' v"',"-0.366'a . Velocity obtained in this way hasdimension(+)
rad

0.05

0.05

e
Fig. 8. Radius of curve at top point of the hole

h;:l^!![
l l

where A is the edge of the squarehole. On basis of (4) the expression the radius of curve path of the tool blade at the top points of the squarehole (n=4), as well as of the triangle shapedtool (m was calculated m = 3) were calculated, and its changewas shown in the Fig. 8. Minimal radius of the curve hole contour is obtained at the top points of the hole (Fig. 8). Minimal radius holes is of square =0.098.a for a = 50 ITun,we have p^ (e -0,4,3) '50 p ^^ = 0,098 = 4,5mm.In Fig.9 we havereal shape hole. of the squares

Fig. 9. Real shapeof the squareshole

4. CONCLUSION Proposedway of solving the problem is very quick analyticaland graphicalsolution and simple.Besides quick and accurate results concerning the it gives velocity, and also concerning the geometry of the hole.

y'" y"
vt0,N.lt

REFERENCES |l.)Suh C. H. & Radclffi C. W., Kinematics & Mechanisms Design, John Wiley & Sons, Inc., New York, 1978. l2.l Zlokolica, M., Kinematics of Tools for Journal Tehnika Polygonal Drilling, Masinstvo, Beograd, year XXIV- I9l5, No. 6, p . p .1 5 - 1 8 . M., About the blade cutting speedof 13.lZlokolica, the tools for polygonal hole processing, V Flexible Technologies, lnternational Conferencepp.163-169. Proceeding Novi Sad,1994, II,

0.25

: .
0

0.52

r.05

t.57

2.09

e
Fig. 7. Change of tool cutting velocity

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Volume22,No. 3&4, 2000. in Tribology industry,