virtual machine tool - rwth aachen · pdf filevirtual machine tool lecture 1: introduction to...

© 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: [email protected]

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


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


Development in the Design of Lathes

1797 1906 1925

1966 1978 1996


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


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


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


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


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


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


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


Lathe Gildemeister TWIN 500 – View without Guards

spindle 1drive ofrevolver

tool-revolver spindle 2

cooling lubricant-supply

milling spindle tool changer


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


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


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


Example Machine Tools – Standard Milling Machines

Source: StarragHeckert GmbH, Chiron Werke GmbH & Co. KG


Example Machine Tool – Gantry Design

XZ

Yhorizontal support

x-drives and guideways

milling head workpiece

z-ram

Quelle: Waldrich Siegen Werkzeugmaschinen GmbH


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.


Bipod Machine Concept with Coupler Mechanism

Weightcounter balance

Telescopicstruts withdirect linearscale

Couplermechanism

z-pinole withmotorspindle

ZX

Y

Coupler mechanism


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


Surface Grinding Machine

Source: Blohm

X

Z

Y

machine bed

workpiece

magneticclamping plate

feed drive motor

ball screw drivegrinding wheel

guiding system


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


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


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


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


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


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


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

virtual machine tool - rwth aachen · pdf filevirtual machine tool lecture 1: introduction to...

Documents