M.A.L. Products

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23年 4月 22日

©University of British Columbia - Manufacturing Automation Laboratory

M.A.L. Products

HIGH PERFROMANCE MACHINING TECHNOLOGY

MAL Manufacturing Automation Laboratories Inc

Vancouver, B.C., CANADA

http://www.malinc.com

23年 4月 22日

Products

MAL Inc. has two lines of Products to boost productivity of machining operations

• ShopPro – Practical, easy to learn and use, integrated tap testing, chatter avoidance and diagnostics software for milling

• CUTPRO – Advanced Simulation and Testing Software tool box to design, optimize, measure and diagnose machining operations, cutters and machine tools.

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Instrumentation

ShopPro/CUTPRO Instrumentation Set

1. Labtop computer

2. National Instruments NI9233 USB Measurement Box

3. Impact hammer and accelerometer

4. Microphone

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ShopPro Steps

3 Simple Steps in Using ShopPro

1. Enter material type and basic cutter geometry

2. Tap test the cutter on the machine or define dynamic parameters

3. Chatter stability lobes (vibration free speeds and depth of cuts), torque, power and material removal rates will be displayed instantly.

The noise from the machine can be recorded, and ShopPro provides automated diagnosis and advice.

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ShopPro

Step 2 - Tap Test the tool to obtain machine stiffness

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ShopPro

Step 3- Machine Sweet Spots (depth of cut, spindle speed) are displayed with Torque, Power and MRR

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CUTPRO Modules

CUTPRO Machining Software Modules• MALTF – Advanced Tap Testing System• MALDAQ – Multi Channel Data Collection • MODAL – Modal Analysis with machine data base and tool

tuning modules• MILLING – Advanced cutter design, optimization and

simulation system for milling • TURNING, DRILLING and BORING Modules • SpindlePro – Finite Element Modeling and Analysis of

Spindle Drives• Virtual CNC – A complete 5 axis modular CNC system

design with drive design, sensors, amplifiers, friction, trajectory generation, interpolation and control modules

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CUTPRO :Parametric Tool Definition in APT

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Helical flute is wrapped around the solid end mill.

geometry.arbitrary with millend solidany for power torque,

forces, total thefindcan weup, themsumming and in each

projectingBy edge. cuttinghelical on the point each on act ,, forces alDifferenti

PdFdFdF art

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CUTPRO: Prediction of milling forces from tool geometry and orthogonal

cutting material data.

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Cutter:Taper helical ball end mill, rake angle=10°, relief angle=10°, D=6.0, R=3.0, Rr =0, Rz =3.0, h=38.0, lead=105.0mm, a=0°, b=4.0°, Nf =1Cutting Mode: Slot cutting Cutting Coefficients: Orthogonal cutting coefficients for Ti6Al4Vby using orthogonal to oblique transformation

CUTPRO: Tapered Helical Ball End Milling (Jet Engine Machining)

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CUTPRO: Inserted Helical End Mill

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CUTPRO: Prediction of Serrated Cutter Forces

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Source of Vibrations in Machine Tools

FlexSource.ai

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CUTPRO : Vibration Model of Milling System

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REGENERATION MECHANISM

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FRF file

CMPfiles

Modal Analysis ModuleMilling Module

TF measurement MALTF

Stability LobesProcess simulation and

chatter stability lobe prediction in CUTPRO

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Increase the material removal rate by 500% and avoid poor

surface finish and tool/spindle damage

n=15400 [rpm], DOC=4.0 [mm] N=17000 [rpm], DOC=4.5 [mm]

Milling Mode: SlottingMachine tool: Mori Seiki SH403Tool:Jabro,16.0 [mm], 2-fluted cylindrical endmill

Feed rate: 0.1 [mm/tooth]

2884 [Hz]Chatter frequency

567 [Hz]Tooth passingfrequency

Surface finish Surface finish

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Slot milling of Al7050 with 2 Fluted, 16mm diameter end mill.

N=17,000 [rev/min],

depth of cut = 4.5 [mm]

NO CHATTER

N=15,400 [rev/min],

depth of cut = 4.0 [mm]

CHATTER

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Sound - Metal Cutting

Time [s]0 0.5 1 1.5 2 2.5 3

100000

120000

140000

160000

180000

Power Spectrum - Metal Cutting

f - Frequency [Hz]0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000

100000

120000

140000

160000

180000

ShopPro: Detection of Chatter with a microphone

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Sound - Metal Cutting

Time [s]0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8

-1400-1200-1000-800-600

-400-200

400600

80010001200

Power Spectrum - Metal Cutting

f - Frequency [Hz]0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000

Stability Lobes

Spindle Speed [rev/ min]5000 10000 15000 20000 25000 30000

4.5Chatter Zone

Stable Zone

Power / Torque

Spindle Speed [rev/ min]5000 10000 15000 20000 25000 30000

4.5__ _ Power__ _ Torque

Chatter is avoided by selecting proper speed recommended by ShopPro

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High Speed Milling of Spiral

Material: AL 7050-T7451, 100x100x50 [mm]Tool: Jabro 16 [mm] diameter, 50 [mm] length Number of flutes:2Roughing 17400 [rpm] Depth of cut: 7mm slotting Chip load: 0.2 mmFinishing: 20,000 [rpm] Depth of cut: 1mm, Width of cut:10 mm, Chip load:0.25 mmThickness of the wall: 0.15 [mm] Height of the wall: 35 [mm]Feed rate: 0.25 [mm/tooth] Machine tool: Mori Seiki SH403Cycle time:9 min 20 sec.

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Impeller Milling UBC + P&WC NSERC Chair

BEFORE AFTER

Surface roughness improved by 8.4 fold

• Cycle Time Reduction: 62%• Cycle Time Reduction: 62%

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10600 17600

4.5 [mm]

Force in X and Y directions

Surface finish

Example - 2

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Types of cutters in CUTPRO

-Milling Module

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