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MACHINE TOOL RESEARCH CENTER

MACHINE TOOL RESEARCH CENTER. University of Florida Department of Mechanical and Aerospace Engineering. 55 Faculty 2 degree programs 980 undergrad students 275 full-time graduate students ~150 BS degrees per year ~15 PhD degrees per year ~55 MS Degrees per year

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MACHINE TOOL RESEARCH CENTER

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  1. MACHINE TOOL RESEARCH CENTER University of Florida Department of Mechanical and Aerospace Engineering • 55 Faculty • 2 degree programs • 980 undergrad students • 275 full-time graduate students • ~150 BS degrees per year • ~15 PhD degrees per year • ~55 MS Degrees per year • ~ $13M sponsored research per year

  2. University of Florida Machine Tool Research Center • Founded in 1984 by Dr. George Tlusty • 24 PhDs graduated • 55 MS graduated • Over $8 million in externally sponsored • research from government and private industry • Over 2300 ft2 lab space • State of the art machine tools, metrology • equipment, instrumentation MACHINE TOOL RESEARCH CENTER

  3. HSM-1 • 5 axis • 2 g acceleration • 1200 ipm axis speed • 35,000 rpm, 35 kW spindle • HSM-2 • 3 axis • 1 g acceleration • Hydrostatic guideways • Linear motor drives on Y • Hydrostatic leadscrew on X MTRC Facilities MACHINE TOOL RESEARCH CENTER

  4. Ingersoll HVM 600A • Linear motor drives • 3150 ipm feedrates • 1g accelerations • 20,000 rpm, 50HP hydrostatic • spindle, HSK 63a • Installed Fall ‘02 MTRC Facilities MACHINE TOOL RESEARCH CENTER

  5. MTRC Facilities • Instrumentation • Dynamic analyzer • Laser vibrometer • Heidenhain grid • plate • Laser • interferometers • Laser ball bar • Dynamometer • Cap gages • Hexapod CMM • 5-DOF • Laser interferometer • feedback • Self-calibrating • Brown & Sharpe CMM • Direct computer control • 20” cube workspace MACHINE TOOL RESEARCH CENTER

  6. MTRC Faculty • John Ziegert – design of precision machines, precision metrology, tools for HSM • John Schueller – difficult to machine materials, automatic controls • Tony Schmitz – machining dynamics, machine tool metrology, process modeling • Brian Mann – non-linear dynamics, machining dynamics, process modeling • Greg Sawyer – tribology, tool wear

  7. MTRC Research Accomplishments • Chatter modeling and development of fast, simple methods for determining optimal spindle speeds and cutting parameters. • Design, analysis, and testing of high speed spindles. • Development of methods for producing parts with thin walls/floors using HSM techniques, enabling monolithic aircraft components. • Design and construction of the world’s fastest 3 axis milling machine (in 1994), with 32”x32”x20” travels, 1200 ipm feedrates, 2g accelerations, and 35,000 rpm spindle. • Development of a HSM testbed to evaluate axis drive components and control strategies. • Development of the Laser Ball Bar system for rapid metrology of all axes of a machine tool in a single setup. MACHINE TOOL RESEARCH CENTER

  8. MTRC Research Accomplishments • Development of a novel hexapod coordinate measuring machine • with self-calibration capabilities. • Development of a specialized 1D measuring machine for NIST • calibration of ballbars. • 9. Application of HSM to: • - aluminum and magnesium (Boeing, McDonnell Douglas, Bell) • - titanium (Bell) • - stainless steel (Sandia) • hardened die steel (Motorola, Cincinnati Milacron) • 10. Analytic methods to predict tool point FRF’s for varying overhangs. MACHINE TOOL RESEARCH CENTER

  9. MTRC Current Research Interests • Application of Receptance Coupling Substructure Analysis to HSM. • Surface Location Error in high speed milling. • Development of novel milling cutters for HSM with internal damping mechanism for improved stability. • Tunable tool holder for enhanced boring bar stability. • Effect of changing spindle dynamic response with speed on chatter stability. • Continuously renewable solid lubricant tool coatings. • Development of ultra-high speed micro-milling spindle. • Investigation of reduced fatigue life in high-speed machined titanium components. • Micro-molding of metallic glasses. MACHINE TOOL RESEARCH CENTER

  10. MACHINE TOOL RESEARCH CENTER MTRC Research Sponsors/Partners National Science Foundation Motorola US Air Force 3M Office of Naval Research General Electric Lawrence Livermore National Lab McDonnell-Douglas Sandia National Lab Brown & Sharpe NIST Bell Helicopter Oak Ridge National Lab Y-12 General Motors Boeing Cincinnati Milacron Alcoa

  11. MTRC Graduates Sandia National Lab Cummins Diesel NIST Harris Corporation Ingersoll Proctor & Gamble Moore Nanotechnology Bourne & Koch Machine Kodak Hewlett-Packard Ford UNC-Charlotte Lawrence Livermore National Lab KLA-Tencor MACHINE TOOL RESEARCH CENTER

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