Vortical Duplication Machining

a method of fabricating articles with the removal of material, in which the three-dimensional shape of a tool is copied on the work-piece. This is accomplished by the reciprocating motion of the tool or the workpiece (see Figure 1) along a curved trajectory whose radius is equal to the eccentricity λ of the shaft. The oscillations occur in a plane perpendicular to the direction in which the tool approaches the workpiece.

Mechanical, electrophysical, and electrochemical vortical duplication processes exist. In the mechanical method the cutting surface of the tool has incisions or is covered with abrasive material; the workpiece is shaped by removing chips. In electroerosion machining the tool acts as one of the electrodes. The introduction of an abrasive suspension between the workpiece and the tool, or the connection of the tool as a cathode to a current source for electrochemical

Figure 1. Schematic kinematic diagram of vortical duplication machining with circular translatory motion; d is the direction of motion of the workpiece

dimensional machining, is also possible. In this case the machining allowance is removed by burning it off (flashing off) with a spark.

Vortical duplication machining is used in the fabrication of products of complex shape from materials that are easily worked by cutting (graphite, wood, and stone), for the abrasive finishing of metal parts, and for correcting the dimensions of products obtained by casting or stamping; surface quality is improved in the electrophysical and electrochemical methods.

Vortical duplication machining is performed on special machines or by electroerosion, electropulse, and vertical milling machines on which an attachment for circular translatory motion has been mounted.

Vortical duplication machining was proposed in 1960 by researchers at the Experimental Scientific Research Institute of Metal-cutting Machines and has become widespread both in the USSR and abroad.