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transcript
© WZL/Fraunhofer IPT
Virtual Machine Tool
Lecture 1:
Introduction to Machine Tool Design
Assistant lecturer:MSc. Dipl.-Ing. Yury Trofimovtel. 0241 / 80-27729wing 53b, room 415be-mail: y.trofimov@wzl.rwth-aachen.de
Seite 1© WZL/Fraunhofer IPT
Machine Tool Industry in German Economy
Drive systems and componentsMachine ToolsPrecision ToolsBulk Material HandlingGeneral Ventilation TechnologyFood- and Packaging MachinesPrinting- and Paper TechnologyOther Machine ToolsConstruction and Building Material MachinesFittingsRubber and Plastic Material MachinesTextile MachinesAgriculture MachinesLiquid PumpsPower Systems, Engines and SystemsRobotics and AutomationApparatus DesignFluid Engineering (without Hydraulic Pumps)Compressor and Vacuum PumpsWoodworking and Woodpressing MachinesEscalator and Elevator TechnologyMining MachinesIndustrial Furnaces, BurnersIron and Steel Works and Rolling MachinesTest MachinesBalancesMachines for Clothing and Leather WorkingFoundry MachinesFire Brigade ToolsWelding Technology (without Electrical)Safes
Field Employees (x 1000) Production (x Mill. Euro)
0,31,61,1
2,95,7
5,19,81010,7
13,510,2
21,820,6
25,630,030,0
58,328,327,021,2
31,541,9
49,014,5
50,058,759,359,5
73,766,4
82,5
49,5149481593
1.053855
1.5711.9391.983
3.4151.964
3.6564.126
5.1305.580
4.5828.513
5.7347.996
3.7925.240
7.79310.71710.377
9.21910.558
11.53913.417
9.38912.603
15.463
Stand: 2010
Seite 2© WZL/Fraunhofer IPT
Historical Development of the Achievable Machine Ac curacy
Measuring device
CoinLimit theories
Optical measuring deviceElect. measuring device
Processing accuracy2004
1750 1800 1850 1900 1950 2000 year10-6
10-5
10-4
10-3
10-2
10-1
10 0
10 1
mm
Ach
ieva
ble
mac
hini
ng p
reci
sion
Invention and historical events:18
18 M
illin
g m
achi
ne to
ols
1832
Rol
l grin
ding
mac
hine
tool
1866
Dyn
amo
mac
hine
(S
iem
ens)
1876
Fou
r cy
cle
engi
ne18
89 T
hree
pha
se m
otor
1907
Ass
embl
y lin
e
1960
Las
er
1923
Tra
nsfe
r st
reet
1900
Tay
lor
rapi
d w
orki
ng s
teel
1942
Pro
gram
circ
uit
at th
e T
M
1850
Beg
inni
ng o
f res
earc
h re
late
d to
cut
ting
(Ger
man
y)
1872
Intr
oduc
tion
of th
e M
eter
in G
erm
any
1756
Cyl
inde
r an
d dr
illin
g m
achi
ne
1769
ste
am e
ngin
e
1794
Tur
ning
lath
for
met
als
with
supp
ort
1814
Pla
nnin
g m
achi
ne to
ols
1953
NC
-Lat
he
Dial indicators
Dril
ling
mac
hine
s
Mill
ing
mac
hine
s
Tur
ning
lath
es
Grin
ding
mac
hine
s
Pre
cisi
on m
achi
nes
Hon
ing
mac
hine
sLa
ppin
g m
achi
nes
Pol
ishi
ng m
achi
nes
Ultr
a pr
ecis
ion
mac
hine
tool
s, e
lect
roch
emic
al p
roce
sses
Standard-Machine
tools
Standardfinishing machine
tools
1994
Mac
hine
tool
s w
ith
Par
alle
l kin
emat
ic s
truc
ture
Stand: 2010
Seite 3© WZL/Fraunhofer IPT
Development in the Design of Lathes
1797 1906 1925
1966 1978 1996
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Classification of Machine Tools (DIN 69651)Manufacturing systems
Wood working Metal working Working of other metals
MT for forming MT for separating MT for submitting MT for different systems
Multi-machinesystems
PressHammerRolling machinesBending machinesDrawing machinesMachines for the forming with-media -energy
Machine tools by DIN 69651
Manufacture plants for shaping
Separating MT
ShearingPress cutting
Turning latheDrilling machinesMilling machinesPlanning machinesBroaching machinesSawing machinesFile machinesBrushing machinesChisel machines
Chipping MTgeom. defined cutter
Grinding machinesBelt grinding machinesLift grinding machineHoning machinesLapping machinesBeam cutting machinesSlide cutting machinesPolishing machines
Chipping MTgeom. undefined cutter
Production processes by DIN 8580
Metal removing MT
EDM machinesLaser cutting machines
ECM machinesFlame cutting machines
Manufacture plants for forming
Manufacture plants for separating
Manufacture plants for submitting
Manufacture plants for
coating
Manufacture for changing of
material properties
Seite 5© WZL/Fraunhofer IPT
Classification of Manufacturing Systems based on Degree of Automation
FunctionTerms of the Manufacturing
system
Automated flow of work piece and tool for the entire manufacturing system
Manufacturing system Flexible line, transfer line
Machine
Sin
gle
mac
hine
sAutomated exchange of work piece with work piece storage
Automated tool exchange with tool storage
Cell
Centre
NC-MachineAutomated control of machining sequences
Generation of cuttingand feed motion
Generation of processforces
Seite 6© WZL/Fraunhofer IPT
Components and Characteristics of a Machining Centr emain- and secondary drives-servo motors
-wide speed range-high driving power
-transmissions of dynamical high quality
-high positioning velocity and positioning accuracy-zero-backlash feed drives withposition control
Constructional characteristics
-rigid spindle-bearing-system-rigid machine bed-thermo-symmetrical structure-good chip and coolant flow-constant spindle offload-supported moving loads
Tools
-automatic tool change-tool storage-substitute tool-strategy-automatic cutting edge adjustment-automatic tool life acquisition
Diagnostic systems
-Sensors for monitoring tool wearand tool breakage
Control
-control panel with display screenand alphanumeric keyboard
-punched-tape reader-Diskettenlaufwerke-DNC-port-production data aquisition (BDE)
Integrated quality control
-automatic workpiece measurement
Closed Workspace
Workpiece change
-automatic workpiece change-automatic clamping devices or
palettes-automatic chuck change-short workpiece change period
High machine availability
-reliable machine components-fail-safe machine control-short repair periods
Transportable unit
Seite 7© WZL/Fraunhofer IPT
Machining with Geometrically Defined Cutting Edges
Source: DIN 8580 (2003)
metalforming
separation joining coatingchanging of material properties
primary shaping
metaldividing
machiningwith
definedcuttingedge
geometry
machining with
undefinedcutting edge
geometry
erosion breakingup cleaning
drillingsinkingrubbing
milling planingshaping
broaching sawing filing
rasping
machiningwith
brushesswapingturning
Seite 8© WZL/Fraunhofer IPT
Machining with Geometrically Defined Cutting Edges
Cutting forces
Contact conditions
Characteristics of cutting Turning - Chip formation - Ty pes of turning
Workpiece
Tool
cm
cc hbkF −∗∗= 1
11.
fmcf hbkF −= 1
11 **.
pm
pp hbkF −= 1
11 **.
Kienzle-formula
cutting force
feed force
passive force
ki1.1 : specific cutting forces1-m : cutting force inclination value
κsinpa
b =
κsin*fh =
ap:depth of cutf:feed rateb:width of cuth:thickness of cutκ:tool cutting edge anglevc:cutting velocity
Longitudinalturning
Facing Form turning
WorkpieceWorkpiece
Workpiece
ToolTool Tool
Seite 9© WZL/Fraunhofer IPT
Structural Shapes and Auxiliary Fixtures of Lathes
relative positionbetween tooland Workpiece
shapes of machine beds
compound sliderest designs for
tool carrier
auxiliaryattachments
spindle in parallelwith the foundation
spindle perpendicularto the foundation
flat-bed inclined bed front-bed
columnvertical-spindle-bed
flat-bed
inclined-bed
front-bed
vertikal-spindle
lathe tool holder flat-table revolver
starrevolver
crown-revolver
barrel-revolver
tailstock back (movable) rest workpiece clamping
Seite 10© WZL/Fraunhofer IPT
Overview of Structural Shapes of Lathes
Flat-bed lathe Inclined-bed lathe Front-bed lathe
Single-column vertical lathe Double-column vertical lathe vertical lathe
Cross-slide
Longitudinal slide Bed
Tailstock
Spindle Cross slide Tailstock Headstock,left
Cross slide,left
Headstock,right
Bed
Longitudinal slide,left
Traverse supportleft Turret slide
Traverse
Column
Side supportslide
Side supportBed
Face plate
Rail head
Traverse
Column, right
Traverse support, left
Face plate
BedSide support
Side supportslide
Traverse
Traverse support right
X-slideMain spindle
Workpiece supply
Star turret
Bed
Headstock
Longitudinal slide
Rail head
Traverse sup. right
Seite 11© WZL/Fraunhofer IPT
Lathe Gildemeister TWIN 500 – View without Guards
spindle 1drive ofrevolver
tool-revolver spindle 2
cooling lubricant-supply
milling spindle tool changer
Seite 12© WZL/Fraunhofer IPT
Milling Operations
Surface milling Circular milling Thread milling Hobbing Profile milling
face-peripheral milling
face-peripheralmilling
face milling
peripheral milling
internal cylindricalmilling
cylidrical milling with internal geared tool
worm milling
short-thread milling
long-thread milling
whirl thread
hobbing longitudinal profile milling
cylindrical profilemilling
external cylindricalmilling
profile millingwith chain
Seite 13© WZL/Fraunhofer IPT
Structural Shapes of Horizontal Drilling and Milling M achines
Num
ber
of a
xes
in to
ol h
olde
r
thre
etw
oon
e
Y
X'
Z'
Y
X Z'
Z Y
X
Cross-table construction
Frame column construction
Cross-bed construction
Z
Y' X'
YZ
X'
Y
Z
X
Knee-type columnconstruction
Knee-type bedconstruction
Moving column construction
Y Z
X
Z Y'
X
Drilling machine construction
Cross-bed construction
X - tool sidedX' - workpiece sided
Seite 14© WZL/Fraunhofer IPT
Structural Shapes of Vertical Drilling and Milling Mach ines
Num
ber
of a
xes
in to
ol h
olde
r
thre
etw
oon
e
Cross table construction
Y'
X'
Z
ZY
WX
Portalgantry-construction
X'
YZ
Portal table construction
Console columnconstruction
Moving column construction
ZY
WX'
Z
Y
X
Portaltable construction
Y
Z' X'
Y
Z'
Console bedconstruction
X
X - tool sideX' - workpiece side
Seite 15© WZL/Fraunhofer IPT
Example Machine Tools – Standard Milling Machines
Source: StarragHeckert GmbH, Chiron Werke GmbH & Co. KG
Seite 16© WZL/Fraunhofer IPT
Example Machine Tool – Gantry Design
XZ
Yhorizontal support
x-drives and guideways
milling head workpiece
z-ram
Quelle: Waldrich Siegen Werkzeugmaschinen GmbH
Seite 17© WZL/Fraunhofer IPT
Machining Centre in Hexapod Design with Horizontal Sp indle
Length-variable strut
Actuatur drive and belt transmissionwith ball screw spindle
Water-cooled machine frame
Spindle platform
Workpiececlamping table
Source: WZLSource: Ingersoll Machine Tools Inc.
Seite 18© WZL/Fraunhofer IPT
Bipod Machine Concept with Coupler Mechanism
Weightcounter balance
Telescopicstruts withdirect linearscale
Couplermechanism
z-pinole withmotorspindle
ZX
Y
Coupler mechanism
Seite 19© WZL/Fraunhofer IPT
Grinding Machines
profile grinding machine form grinding machine tool grinding machinespecial purpose grinding machine
external surface grinding
work piecegrinding wheel
work piece grindingwheel
cramshaft grinding
feed motion, back and forth feed motion, continuousfeed motion, stepwise
infeed motion, stepwise
cylindrical grinding machine surface grinding machine gear grinding machinescrew grinding machine
external screw grindingwork piece
grinding wheel
cylindrical traverse grinding
grinding wheelgrinding wheel
discontinuous external gear grinding
workpiece
profile plunge grinding
work piece
grinding wheel
workpiece
cutting tool grindingform grinding
workpiece
grinding wheel
work piece
grinding wheel
Seite 20© WZL/Fraunhofer IPT
Surface Grinding Machine
Source: Blohm
X
Z
Y
machine bed
workpiece
magneticclamping plate
feed drive motor
ball screw drivegrinding wheel
guiding system
Seite 21© WZL/Fraunhofer IPT
Gear Manufacturing: Generating Methods
vc Schnittgeschwindigkeitfa Axialvorschubfr Radialvorschubft Tangentialvorschubfw Wälzvorschub
vc
fw
ft
fr
fa
fw
fr fw
fw vc
fw
fr
Planing Hobbing Shaping
vc cutting velocityfa axial feedfr radial feedft tangential feedfw generation motion
Seite 22© WZL/Fraunhofer IPT
Design of a Gear Shaping Machine
Z3
Z2
C1
C2
B4
X C3
Z1 Gegenhalter
X: radial feedY: Tangential offsetZ1: Height of strokeZ2: Length of strokeZ3: Stroke motionB3: Spindle inclinationB4: Move out strokeC1: Rotation workpieceC2: Rotation toolC3: Automatic workload
C2
X
B3
B4
Y
C1
Z2Z1
Z3
steady
Seite 23© WZL/Fraunhofer IPT
Robot with Hydraulic Mass Compensation Source: Kuka Robotics
Handachsenantriebeals Ausgleichsmasse
Zusatzmasse alsOption für 150 kg
Rückstellkraft F
Hydraulikmedium
Stickstoff-druckspeicher
Membran
Hydraulik-zylinder
A
B
Karussel
Ständer
Schwinge
Arm Handgelenk
D E
P
C
- Nutzmasse:- Reichweite:- Wiederholgenauigkeit:- Max. Geschwindigkeit:
150,0 kg2,4 m
+/-0,2 mm100,0 °/s
LeistungsdatenPerformance DataRated load: 150.00 kg
Range: 2.4 m
Repeatability: +/- 0.2 mm
Maximum speed: 100.0 deg/s
Hand axes unit
Additional mass
Restoring force
Hydraulic medium
Nitrogen accumulator
Hydraulic cylinderStand
Carrousel
Crank
Arm
Membrane
Hand axes drives / mass compensation
Source: Kuka Robotics
Seite 24© WZL/Fraunhofer IPT
Tool Changer in Machine ToolsTool changer with single-arm gripper
(source: Maho)Tool changer with double-arm gripper
(source: Deckel)
Tool changing processwith horizontal Spindle
Tool changing processwith vertikal spindle
Seite 25© WZL/Fraunhofer IPT
Characteristics of Machine Tools
Accuracy
Reliability
Environmental behaviour
!
No load With load
Accuracy Environmental behaviour Reliability
Capability
Static stiffness
Dynamic stiffness
Thermal deforma
-tion
Drives & NC-
controldynamics
Noise
Vibrations
Process materials
Industrial safety
Ergonomics
Errors in- Fabrication- Assembly- Control
Source: DMG
- Availability
- Failure rate
- Restorability
Seite 26© WZL/Fraunhofer IPT
Methodical Design Sequence (according to VDI-Guideline s 2222)
Planing
-Selection of the task-Product finding
Conceptual design
-classification of the totalfunctions
-Search for solutionprinciples Draw up
-Realization of theprincipal solutions
-Roughdimensioning Elaboration
-Complete elaboration(engineering data)
-Examination
specification
total design conceptrequirements specification
layout
Seite 27© WZL/Fraunhofer IPT
Integration of CAD Design and Calculation Tools
standard partdata base
Optimization offrame or standard
components
Detection of aframe or standardcomponent as a
weak point
Spindle design Guidecalculation
CAD-rough modell
FE-model
Construction ofstructure components
MKS-modell