Micromachining system and method

A system for short run production of small precision parts, comprising:

• spindle means movable along a first horizontal axis in response to first axis signal commands, the spindle means including collet means for holding stock to be machined;
• tool means movable along a second horizontal axis orthogonal to the first axis in response to second axis signal commands, the tool means including a number of tools disposed along the second axis facing the spindle means;
• the operative positions of the spindle means and the tool means being known relative to the first and second axes, and the first and second axes intersecting at a reference point;
• data processing means including means for storing data as to the operative positions of the spindle means and the tool means, means for storing a series of function commands for different operations on stock to be machined, and means for generating first and second axis commands for the spindle means and tool means respectively;
• and
• viewing means providing a magnified image disposed to view the region of intersection of the first and second axes, and wherein the system includes means for storing the positions of the stock and tool means relative to the intersection for different functions, whereby the stock and tool means can be precisely positioned without cumulative errors being introduced.

A system for screw machine-type manufacture of small parts comprising:

• a planar machine bed;
• first carriage means movable along the bed in a Y axis direction in response to Y axis commands;
• second carriage means including spindle/collet means for holding a part to be machined, the second carriage means being movable relative to the bed along an X axis direction, in response to X axis commands;
• a plurality of tool means mounted on the first carriage means, each of the tool means having a known operative position in X and Y;
• viewing means providing a magnified image disposed to view the region of intersection of the X and Y axes, and wherein the system includes means for storing the positions of the stock and tool means relative to the intersection for different functions, whereby the stock and tool means can be precisely positioned without cumulative errors being introduced;
• and
• data processor means including data storage means, signal input means and comprising:
• (a) means storing sequences of commands for different tool operations,
• (b) means storing reference data identifying the X, Y positions of the operative portions of tools on the first carriage,
• (c) means responsive to the signal input means for modifying dimensions in the sequences of commands, and
• (d) means responsive to the stored sequences of commands and the X, Y positions of the tool operative portions for generating digital signal commands for the first and second carriage means.

A system for screw machine-type manufacture of small parts comprising:

• a planar machine bed;
• first carriage means movable along the bed in a Y axis direction in response to Y axis commands;
• second carriage means including spindle/collet means for holding a part to be machined, the second carriage means being movable relative to the bed along an X axis direction, in response to X axis commands;
• a plurality of tool means mounted on the first carriage means, each of the tool means having a known operative position in X and Y;
• data processor means including data storage means, signal input means and comprising:
• (a) means storing sequences of commands for different tool operations,
• (b) means storing reference data identifying the X, Y positions of the operative portions of tools on the first carriage,
• (c) means responsive to the signal input means for modifying dimensions in the sequences of commands,
• (d) means responsive to the stored sequences of commands and the X, Y positions of the tool operative portions for generating digital signal commands for the first and second carriage means
• (e) means for providing sequences of positioning commands to control the first and second carriage means concurrently so as to provide a sequence of different machining operations at the X, Y intersection from data entry alone and without modification of the tool positions;
• and
• wherein the spindle/collet means includes means for feeding stock therethrough and means for driving the spindle to fixed angular positions, and wherein the tool holder means include means for removable attachment to the first carriage means.

A system for screw machine-type manufacture of small parts comprising:

• a planar machine bed;
• first carriage means movable along the bed in a Y axis direction in response to Y axis commands;
• second carriage means including spindle/collet means for holding a part to be machined, the second carriage means being movable relative to the bed along an X axis direction, in response to X axis commands;
• a plurality of tool means mounted on the first carriage means, each of the tool means having a known operative position in X and Y;
• data processor means including data storage means, signal input means and comprising:
• (a) means storing sequences of commands for different tool operations,
• (b) means storing reference data identifying the X, Y positions of the operative portions of tools on the first carriage,
• (c) means responsive to the signal input means for modifying dimensions in the sequences of commands,
• (d) means responsive to the stored sequences of commands and the X, Y positions of the tool operative portions for generating digital signal commands for the first and second carriage means
• (e) means for providing sequences of positioning commands to control the first and second carriage means concurrently so as to provide a sequence of different machining operations at the X, Y intersection from data entry alone and without modification of the tool positions;
• viewing means positioned to be directed at the X, Y intersection and including means providing a magnified video image, and video display means proximate the bed for displaying the magnified image of the X, Y intersection;
• means coupled to the processor means for generating Y and X axis digital commands to adjust the relative position of said first and second carriage means to modify the relative positions of the tools adjacent the X, Y intersection to the spindle/collet and stock therein;
• and
• wherein the means for adjusting comprises joystick means and the data processor means includes means for generating X and Y axis digital commands that are responsive to the movement of the joystick means.

A mechanism for performing multiple machining operations on small bar stock comprising:

• a bed having an upper surface defining an X, Y plane;
• a first carriage movable along the bed in a Y axis direction;
• a plurality of separate tool holder means replaceably coupled to the first carriage at different positions along the Y axis and each including tools mounted on each tool holder means, within a zone spanning a range in the X axis and extending along the Y axis;
• spindle/collet means including a second carriage movable along the bed in the X axis direction, the X axis and Y axis directions forming a reference X, Y intersection lying in a given horizontal plane above the bed, the spindle/collet means including means for gripping and releasing bar stock to be machined;
• viewing means providing a magnified image disposed to view the region of intersection of the X and Y axes, and wherein the system includes means for storing the positions of the stock and tool means relative to the intersection for different functions, whereby the stock and tool means can be precisely positioned without cumulative errors being introduced;
• and
• means for controlling movements of the first and second carriages in the X and Y axis direction in arbitrary fashion to effect a sequence of machining operations using different tools on the bar stock.

A machine tool system for performing a multiplicity of serial operations on round bar stock comprising:

• a platform having a flat, horizontal superior surface;
• base means mounted on the platform;
• a pair of X axis guide rails mounted on the base means along a horizontal X reference axis, the guide rails being spaced apart transverse to the X axis direction, each of the guide rails having side guide grooves therein;
• a spindle frame assembly disposed above the base means, the spindle frame assembly including a pair of linear ball bearing guide rail followers on the lower side thereof, each slidably engaging a different one of the guide rails and including means registering in the side guide grooves therein, the spindle frame assembly also including a vertical plate transverse to the X axis and a spindle holder member adjacent a Y axis along one side thereof and spaced apart from the vertical plate along the X axis;
• a pair of spindle means mounted in spaced apart relation along the Y axis in the spindle holder member to rotate along horizontal axes parallel to the X axis and spaced apart along the Y axis, the spindle means including collet means and means to advance bar stock therethrough along the X axis direction to intersect the Y axis;
• spindle drive motor means mounted on the vertical plate on the side opposite the Y axis;
• belt drive means coupled to the spindle drive motor means and mounted between the vertical plate and the spindle holder member for selectively driving the spindle means from the spindle drive motor means;
• first stepping motor means mounted in fixed relation to the base means and opposite from the Y axis, the first stepping motor means rotating about an axis parallel to the X axis;
• first ball screw drive means coupled to the first stepping motor means and disposed along the axis thereof;
• follower means on the spindle frame assembly engaging the first ball screw drive means for moving said assembly along the X axis in response to actuation of said first stepping motor means;
• a tool support bar disposed adjacent and parallel to the Y axis, said bar including a dovetail section with horizontal superior surface and horizontal lower surface;
• a first horizontal Y axis guide rail attached to the underside of the support bar at the lower surface thereof and extending along an axis parallel to the Y axis;
• a second horizontal Y axis guide rail mounted on the base means parallel to the Y axis and spaced apart from the first guide rail further from the Y axis, each of the first and second Y axis guide rails having side grooves therein;
• first Y axis linear ball bearing means mounted on the base means and slidably engaged to the first Y axis guide rail an the side grooves therein;
• second Y axis linear ball bearing means coupled to the tool support bar and slidably engaged to the second Y axis guide rail and the side grooves therein;
• second stepping motor means mounted in fixed relation to the base means to rotate about a Y axis spaced apart from the Y reference axis on the opposite side from the tool support bar;
• second ball screw drive means coupled to the second stepping motor means and extending along its axis;
• means engaging the second ball screw drive means and coupled to the tool support bar for moving the tool support bar along the Y axis direction in response to actuation of the second motor means;
• a plurality of tool holder means disposed along the upper surface of the tool support bar and including dovetail apertures precisely engaging the dovetail section of the tool support bar, the tool holder means each including means for detachably securing the tool holder to the tool support bar at a selected Y axis position thereon;
• and
• a plurality of tools for machining operations, each mounted on a different tool holder means in a direction facing the Y reference axis.

A system for driving at least one spindle/collet mechanism rotatable about a given axis comprising:

• a first drive motor;
• a drive capstan coupled to the first drive motor;
• belt means coupling the first drive motor capstan to the spindle/collet system;
• a stepper motor disposed adjacent to the belt;
• drive capstan means coupled to the stepper motor and in proximate relation to the belt;
• and means for shifting the position of the stepper motor capstan so that the stepper motor capstan engages the belt, whereby the spindle/collet drive can be alternatively incremented by the stepper motor as well as being driven by the first drive motor.