Manufacturing Laboratories, Inc.

Mikron Smart Machine Discussion

Manufacturing Laboratories, Inc.

MLI’s Activities (Past and Current)

Operating full-time since 1989 as a provider of high-performance machine technology specializing in machining vibrations.

Previously designed and built special one-of-a-kind machine tools and accessories.

Currently member of: NCMS (National Center for Manufacturing Systems), Ann Arbor, Mi NCDMM (National Center for Machining and Mfg.), Latrobe, PA AMRC (Advance Mfg. Research Center) Sheffield, U.K.

Provides consulting on both machining and machine/spindle design.

Develops/facilitates strategies and techniques for High Performance machining.

Markets dynamic analysis and optimization products for the shop floor since 1996.

Manufacturing Laboratories, Inc.

What’s MLI Goals

In the field of high-performance machining create acceptance of the affect of dynamics (frequency behavior) in the cutting process.

Provide equipment that measures dynamic influences on the machining process and allows customer to control and manipulate dynamic affects.

Provide “on-machine” process monitoring and control equipment for dynamic effects.

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MLI’s Product Mix

MetalMAX™ is our main product. A predictive analytical

package to determine optimum dynamic operating conditions without machining and track this information for use in NC programming.

Validation and diagnostic functionality delivered by Harmonizer®

Harmonizer® separately marketed machine monitoring and control packages for detection and control of adverse vibrations.

Manufacturing Laboratories, Inc.

MetalMAX: What’s Needed?

Modal analysis kit specifically configured and designed for measurement of machine tools. Frequency/modal

Analysis. Sensors. Well established cutting

theory. All combined in user

friendly software. Setup man or engineer

with progressive attitude. (does not require a “vibration expert”).

MLI’s MetalMAX™ kit with computer.

Manufacturing Laboratories, Inc.

A Typical Measurement Setup

Schematic of Measurement Setupfor “Bump”, “Ping” or “Modal” test.

4

3

2

1EXCITATION

(HAMMER)

RESPONSE

(ACCEL)

Sensor Interface Module

PC

Accelerometer

STRIKE

Hammer

Power Cable

Sensor Cable

Machine tooland Spindle

*Can also measure work piece ina similar fashion and combine behavior

with cutting tool measurement.

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Stability Plot20 mm 3-fluted Tool in 30 kW 24 krpm Spindle

ProcessDampingRegion

Unstable

Torque Limit

ChatterFrequencies

Stable

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Purpose?Machine the Part the First Time…

Air frame tray, unsupported tab approx. 50-mm high by 1.5-mm thick.

Guessing? Knowing

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Check Results

Monitor cutting operation

Determine if it is stable, chattering or resonating.

Make fine adjustments if needed.

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Record Results

Record data for later comparison or analysis.

Track behavior as function of cutting tool, machine, work piece.

Provide means to inform NC programmers, tool room, etc. of dynamic limitations.

Manufacturing Laboratories, Inc.

MetalMAX Provides

Modal Analysis of cutter and work-piece.Prediction of stable depths of cut and

spindle speeds.Refinement of process parameters for

optimal dynamic cutting accuracy.Monitoring and adjustment (if needed) of

cutting process.Recording of results in database for later

use.

Manufacturing Laboratories, Inc.

Vibration Monitoring

Harmonizer utilizes Broad banded frequency analysis. Audio detection of machining vibration. Identification of chatter and “suspected” resonant conditions Deterministic process parameter (speed and feed)

corrections to minimize vibration. Harmonizer implementations include:

Handheld vibration monitor Most basic and lowest performing.

Web Based Occasional use, as needed, requires TCP/IP connection. Can

also implement web-based monitoring. General computer software

Full functioning vibration analyzer with chatter control features. NC Integrated

NC control linking with adaptive capacity.

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Spectral Analysiswith identified

chatter frequencies

Vibrationsignal

Must know: Max. Allowable

speed Spindle Speed Number of teeth Nothing else

Technique Identifies Chatter Recommends new

spindle speed.

Detecting Chatter

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Chatter Eliminated

Can either increase cutting depths (ap or ae) or feed rate.

Eliminating Chatter

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First Part Machined Correctly!

0.5 mm wall and floor thickness, 1 mm diameter pins, walls and pins 30 mm high.

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Example: Increased Power and Increased Quality at lower speed

Spindle Speed: 20,000 RPM

Axial Depth of Cut 25 mm

Radial width of cut 0.25 mm

Cut Power 0.3 kW

BAD SURFACE

Aluminum

> 475% increase in

Power and MRR

Spindle Speed: 16,580 RPM

Axial Depth of Cut 25 mm

Radial width of cut 1.8 mm

Cut Power 1.75 kW

GREAT SURFACE!!!Same behavior

in other materials

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Possible Inclusion of Harmonizer® into Mikron Smart Machine APS Non-intrusive additional sensor (microphone),

audio (displacement) detection. Can utilize current vibration sensor(s),

accelerometer, etc. Provides broad banded frequency analysis of

cutting condition. Detects the presence of chatter and resonance. Besides enhancing APS’s machining

monitoring/warning/diagnostic capabilities, Harmonizer can also provide deterministic process parameter corrections.

Manufacturing Laboratories, Inc.

Areas for Cooperative Work

Add Harmonizer technology to Mikron APS Product High Frequency Chatter and Resonant Detection. On machine suggested speed and feed corrections. Part try-out corrections (controller linkage). Automated tool testing and optimization (control links with

NC programs). Application Engineering and Field Service Support with

MetalMAX product. Train and equip field service with dynamic solution package. Added diagnostic and service capabilities.

Product representation through Mikron Distributors/sales offices. Help setup as part of a services division the capability to

deliver dynamic analysis services. Provide support resources for MLI sales.

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Packages for Machining Vibration Prediction and Control

Machining simulations

Prediction and Monitoringof the Cutting Process

Machining Vibration Solutions

DrillSim*

Recording and tracking information for use by NC Programmers