FORM 2
The Patent Act 1970
(39 of 1970)
&
The Patent Rules  2005

COMPLETE SPECIFICATION
(SEE SECTION 10 AND RULE 13)

TITLE OF THE INVENTION

“FIVE AXES NOTCH MILLING MACHINE”

APPLICANTS:

Name : Wendt (India) Limited

Nationality : Indian

Address : 69/70 Sipcot Industrial complex  Hosur 635
126 Tamil Nadu India

The following specification particularly describes and ascertains the nature of this invention and the manner in which it is to be performed:-
TECHNICAL FIELD
[001] The embodiments herein relate to a notch milling machine  and more particularly but not exclusively to a computer numerical controller (CNC) controlled notch milling machine.

BACKGROUND
[002] In the metal working industry  hard material rolls such as tungsten carbide rolls are used to increase the productivity and roll speed. Further  for milling notches on Tungsten carbide rod roll rings conventional notch milling machines are being used. The rolls  after notching operation  are used in the finishing stands of the rolling mill to produce thermo mechanically treated bars. For branding on the thermo mechanically treated bars  it is essential to skip notches on the roll passes. The space achieved through notch skipping operation will be used to engrave the brand name on roll passes through electrical discharge machining (EDM) technology.
[003] At present  the conventional CNC machine that is used for notch milling operation is designed similar to a lathe. Further  in the conventional machine  the work piece is held between headstock and the tail stock center. Further  the milling saddle holds the tool parallel to the groove. It consists of a single induction motor to control both spindle and tool axes through gear train arrangement. The feed and saddle axes are manually controlled through lead screws and hand wheel which makes the limitation on the number of notches and the distance between the notches.
[004] The conventional notch milling machine is configured to carry out continuous notching operation on roll passes by thread forming spiral method and the tool spindle is located vertically. Further  the process of skipping notches as required for branding operation is not possible in the conventional machine. Further  the speed ratio for having the desired pitch and angle are controlled by a set of change gear wheels. In such a machine  the machine set up for every rib type or size is a long time demanding operation in particular for gear handling and installation. Also  the conventional machine is limited by gear train arrangement  which makes the conventional machine inefficient in milling various types of ribs or notches.
[005] Further  the time taken for performing of two separate operations namely  notch milling and branding in two separate machines or through a separate branding attachment to the notch milling machine. Therefore  there is a need for a machine that performs both notching and in-built branding operations in lesser time. Further  the conventional machine for notch milling operation cannot be used in the operations that involves varying notch angle. Furthermore  the conventional machine for notch milling operation is limited to performing operations only in two axes  thereby makes the whole process partially inconsistent or inaccurate.
[006] Further  in the conventional machine for notch milling operations  the work piece is held between the head stock and the tail stock  thereby makes it difficult to hold work piece of varying sizes

OBJECT OF INVENTION
[007] The principal object of this invention is to provide a Computer Numerical Control (CNC) controlled notching machine which is capable of performing continuous notching operation as well as skipping notches as required.
[008] Another object of the invention is to provide a Computer Numerical Control (CNC) controlled notching machine which is capable of performing operations with five different axes all controlled by CNC.
[009] Another object of the invention is to provide a Computer Numerical Control (CNC) controlled notching machine which is capable of performing operations in work pieces of varying sizes and profiles.
[0010] Another object of the invention is to provide a Computer Numerical Control (CNC) controlled notching machine which is capable of performing operations that involves varying notch angle continuously to a minimum of 1 minute and a maximum of 90deg.
[0011] A further object of the invention is to provide a Computer Numerical Control (CNC) controlled notching machine which is capable of performing both notching and in-built branding operations in continuous cycle which reduces the variance and cycle time.
[0012] A further object of the invention is to provide a Computer Numerical Control (CNC) controlled notching machine which is capable of performing notching and branding operations on all metals and carbides.

BRIEF DESCRIPTION OF FIGURES
[0013] This invention is illustrated in the accompanying drawings  throughout which like reference letters indicate corresponding parts in the various figures. The embodiments herein will be better understood from the following description with reference to the drawings  in which:;
[0014] FIG. 1 shows a Computer Numerical Control (CNC) controlled five axes automatic notching machine according to an embodiment of the present invention;
[0015] FIG. 2 depicts an isometric view of an expansion mandrel that could be used with a Computer Numerical Control (CNC) controlled five axes automatic notching machine according to an embodiment of the present invention; and
[0016] FIG. 2a is a line diagram depicting the side view of the expansion mandrel that could be used with a Computer Numerical Control (CNC) controlled five axes automatic notching machine according to an embodiment of the present invention.

DETAILED DESCRIPTION OF EMBODIMENTS
[0017] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly  the examples should not be construed as limiting the scope of the embodiments herein.
[0018] Figure 1 shows a Computer Numerical Control (CNC) controlled five axes automatic notching machine according to an embodiment of the present invention. The notch milling machine 100 according to an embodiment of the present invention includes a work head 102  work spindle 103  an expansion mandrel 104  a milling head with a horizontal milling spindle 106  a branding spindle 108  a branding head 110  a longitudinal table 112 and a cross table 114. Further  a machine base 116 is provided to elevate the notch milling machine 100 to a workable height. In one embodiment  the machine base 116 is provided as an integral element of the notch milling machine 100. The longitudinal table 112 extends longitudinally above the machine base 116 and configured to allow the work head 102 to move along the axes of the longitudinal table 112. Further  in one embodiment  the cross table 114 is provided perpendicular to the longitudinal table 112.
[0019] Further  the expansion mandrel 104 includes a first end 104a and a second end 104b. The first end 104a is connected to a first end 103a of the work spindle 103. Further  the second end 104a includes two or more clamping elements that are configured to hold work piece. In one embodiment  expansion mandrel 104 includes three clamping elements namely  first clamping element 105a  a second element 105b and a third clamping element 105c. Further  the movement of the clamping elements can be controlled independently from one another thereby enables the expansion mandrel 104 to hold work piece of varying sizes. FIG. 2 depicts an isometric view of expansion mandrel 104 that could be used with a Computer Numerical Controls (CNC) with simultaneous interpolation of various axes in a notching machine according to an embodiment of the present invention. In one embodiment  each of the clamping elements is configured to move away from one another thereby creates a space to insert the work piece. Further  each of the clamping elements can be moved independently in the direction towards the work piece in order to hold the work piece of varying sizes. Further  the work spindle 103 is connected to a servo motor or a similar means that is configured to position the work spindle 103 axes precisely. In an embodiment  the work spindle extends in a horizontal direction. Further  the milling head 106 is provided at an axes perpendicular to the axes of the work head 102 and extents vertically. A first end 106a of the milling head 106 includes a milling spindle 107. In one embodiment  the milling spindle 107 is provided as an integral element of the milling head. Further  the milling spindle 107 is configured to hold a milling tool and extends from the milling head 106 towards the expansion mandrel 104. FIG. 2a is a line diagram depicting the side view of the expansion mandrel that could be used with a Computer Numerical Control (CNC) controlled five axes automatic notching machine according to an embodiment of the present invention.
[0020] Further  the milling head 106 enables the milling spindle 107 to move vertically and horizontally along the axes of the milling head 106. Furthermore  the milling spindle 107 is connected to a servo motor or similar means that is configured to provide positioning of the milling spindle 107 axes precisely with a direct coupled feed back arrangement. Further  the branding head 110 is provided with a branding spindle 108. The branding spindle 108 includes a branding tool that is configured to extend towards the expansion mandrel 104. Further  the branding spindle is connected to an AC induction motor which enables rotation of the branding tool. However  it is also within the scope of this invention that the AC induction motor may be replaced by any other motor without deterring the intended function of the notch milling machine 100 as can be deduced from this description.
[0021] Further  five axes of movements namely  work spindle axis B  milling spindle axis A  vertical feed axis Y  horizontal feed axis X and saddle axis Z are connected to a servo motor and controlled through a servo drive connected to a computer numerical controller. A servo drive receives a command signal from a computer numerical control system  amplifies the signal  and transmits electric current to a servo motor in order to produce motion proportional to the command signal. The work spindle axis B is the axis through which the work spindle rotates. In an embodiment  the work spindle is provided along the horizontal direction such that the rotation of the work spindle along the work spindle axis occurs in the horizontal direction. The milling spindle axis A is the axis through which the milling spindle rotates. In an embodiment  the milling spindle extends in an axis perpendicular to the work spindle such that rotation of the milling spindle along the milling spindle axis occurs in the vertical direction. The vertical feed axis Y is the vertical axis through which the milling spindle can be moved. The horizontal feed axis X is the horizontal axis through which the milling spindle can be moved. Further  the saddle axis Z is the horizontal axis along the saddle through which the work spindle can be moved. The fixed gear ratio between spindle and tool of the conventional machine has been dispensed with and can be controlled through the computer numerical controller using its software by interpolating all the five axes which allows optimizing the machine performance  tool life and cycle time for various sizes  profiles and materials. The machine is controlled using the computer numerical controller and the software used for programming the computer numerical controller is through Siemens 840D control systems.
[0022] Further  the continuous notch milling operation is achieved by the synchronized rotation of work spindle 103 and simultaneous movement of vertical feed of the milling tool. Further  the computer numerical controller is configured to adjust a tool probe automatically according to the required notch angle. In one embodiment  the online correction during the automatic operation for the positioning axis and the in-feed axis is enabled with a minimum of 1 Micron step. Further  the computer numerical controller is programmed to achieve skipped notches. Furthermore  the branding spindle 108 includes a branding tool that is configured to rotate. Further  the longitudinal table 112 and cross table 114 is configured to have relative movements  such that it positions the work piece located on the expansion mandrel 104 to the branding tool in order to enable the branding operations. In one embodiment  the branding operation includes the process of engraving the brand name in the work piece. In an embodiment of the present invention  a special screen to improve ease of use for the operator is provided such that the special screen enables the user to feed the required dimension and the sequential program like M-codes and G-Codes are pre-designed behind the screen
[0023] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can  by applying current knowledge  readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept  and  therefore  such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore  while the embodiments herein have been described in terms of preferred embodiments  those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.

CLAIMS
We Claim 
1. A Computer Numerical controller (CNC) controlled notch milling machine  said notch milling machine comprising:
a work spindle defining a work spindle axis (B);
a milling spindle defining a milling spindle axis (A);
a vertical feed defining a vertical feed axis (Y);
a horizontal feed defining a horizontal feed axis (X);
a saddle defining a saddle axis (Z);
at least one motor connected to at least one of said work spindle   said milling spindle  said vertical feed  said horizontal feed and said saddle;
a servo drive connected to said motor; and
a computer numerical controller (CNC) unit 
wherein
said work spindle axis is transverse to said milling spindle axis;
said vertical feed axis is traverse to said horizontal feed axis; and
said computer numerical control  said servo drive and said motor are configured to control a motion of said work spindle along the work spindle axis (B) and the saddle axis (Z)  and said milling spindle along the milling spindle axis (A)  the vertical feed axis (Y) and the horizontal feed axis (X).

2. The notch milling machine as claimed in claim 1  wherein said motor is a servo motor.

3. The notch milling machine as claimed in claim 1  wherein said computer numerical controller (CNC) unit is configured to provide notching and skipped notching operations.

4. The notch milling machine as claimed in claim 1 further includes a branding spindle configured to provide branding operations.

5. The notch milling machine as claimed in claim1 further includes an expansion mandrel having plurality of clamping elements  wherein each of said clamping elements is configured to expand.

6. The notch milling machine as claimed in claim 6  wherein said clamping elements are configured to hold work piece of varying sizes.

7. The notch milling machine as claimed in claim 1  wherein said computer numerical controller (CNC) unit is configured to perform operations that involves varying notch angle.

8. The notch milling machine as claimed in claim 1  wherein said varying notch angle is in the range of 1minute to 90degree.

Dated: 15th May 2012 Signature:
Dr Kalyan Chakravarthy
(Patent Agent)

ABSTRACT
A Computer Numerical controller (CNC) controlled notch milling machine comprising a work spindle defining a work spindle axis (B)  a milling spindle defining a milling spindle axis (A)  a vertical feed defining a vertical feed axis (Y)  a horizontal feed defining a horizontal feed axis (X)  a saddle defining a saddle axis (Z)  at least one motor connected to each of work spindle  milling spindle  vertical feed  horizontal feed and saddle  a servo drive connected to the motors and a computer numerical controller that is configured to control a motion of work spindle along the work spindle axis (B) and the saddle axis (Z)  and milling spindle along the milling spindle axis (A)  the vertical feed axis (Y) and the horizontal feed axis (X).
FIG. 1.