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Automated Machining

Automated Machining. Manufacturing Processes. Outline. Machining Centers Equipment Tool Changers Centering and Clamping Selection of Equipment Selection of Tooling Machine Performance Monitoring Manufacturing Cells Manufacturing Economics. Machining Centers. Machining Center

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Automated Machining

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  1. AutomatedMachining Manufacturing Processes

  2. Outline • Machining Centers • Equipment • Tool Changers • Centering and Clamping • Selection of Equipment • Selection of Tooling • Machine Performance Monitoring • Manufacturing Cells • Manufacturing Economics

  3. Machining Centers Machining Center A computer-controlled machine tool capable of many types of cutting operations on multiple surfaces and directions on a workpiece

  4. Manufacturing Centers Z Y X 3-Axis Operation φ 4-Axis Operation φ θ 5-Axis Operation

  5. Components of aMachining Center

  6. Example of aMachining Center

  7. Example of aMachining Center

  8. Example of a Machining Center Example of a 5-axis CNC machine (the tool pivots instead of the workpiece)

  9. Example of a Vertical Machining Center

  10. Example of a Horizontal Machining Center

  11. Examples ofManufactured Parts

  12. Automated Robotic Loading

  13. Automated Robotic Loading

  14. Equipment Pallets The workpiece is placed on a pallet (module) which can be oriented in different directions by the machine Automatic Pallet Changers When the workpiece is finished, automatic pallet changers remove it and replace it with another workpiece

  15. Pallets Example of a part mounted on a pallet Courtesy Toth Industries

  16. Pallet Changers

  17. Equipment Automatic Tool Changer Can switch between up to 200 tools stored in a magazine, drum, or chain Tool Exchange Arm Picks up particular tools with attached toolholders

  18. Tool ChangerTypes Automatic (Sequential) Spindle Turns one increment in one direction for each tool change; tools must be placed in the spindle in the order they are used Indexable (Random Access) Spindle Turns either direction to make a specific tool accessible; tools can be placed in any order as long as the computer knows their positions

  19. Tool ChangerTypes 2 3 1 4 6 5 Sequential Spindle 8 1 4 6 2 5 3 7 Random Access Spindle

  20. Tool Changer Spindle

  21. Tool Changer Spindle Tool changer spindle capable of holding 60 tools Courtesy of Toth Industries

  22. Tool Changer Arm

  23. Tool Changer Arm

  24. Tool Changer Arm

  25. Tool Changer –Live Spindle

  26. Types ofManufacturing Cutting From Bulk Material Starting with a readily available shape (rods, ingots etc.) and machining the part from this Cutting From Near Net Shape Starting with a pre-formed (often cast) piece with the general shape of the part and removing little material

  27. Centering andClamping Pre-cast designs should be made so that the machines can clamp and orient them quickly and accurately Parts to be lathed should have radially symmetrical outer surfaces and pre-cast holes to mark the center; they should also have a center of mass on the center line to prevent vibration

  28. Orienting andClamping Pre-cast parts should have at least three distinct features that the computer can recognize and use to orient the part notches holes

  29. Centering andClamping Pre-cast parts should have flat parallel surfaces for clamping or cylindrical surfaces for chucking Areas to be clamped or chucked can be ground flat after casting to improve grip

  30. Selection ofEquipment Various types of parts may require various machining centers Parts with numerous cylindrical surfaces (or other radially symmetrical surfaces) should be mounted on a machine center capable of turning Specialized machine centers are available for high-speed machining and for ultraprecision cutting

  31. Selection ofEquipment Example: Pump Cover Starting with the rough casting, drill and ream the center hole, then cut the internal notch with a milling cutter. Mount the piece on a mandrel and use turning operations to cut the faces and outer edge. Mill the external notch and drill and ream the smaller holes in the plate.

  32. Selectionof Tooling The proper selection of tools depends on the workpiece material, size and shape of holes, radii of the corners of milling pockets, and various other parameters The selection of tools affects the cost and time of the operation

  33. Machine PerformanceMonitoring

  34. Machine PerformanceMonitoring Y Y’ Part Orientation X’ X Cutting Performance

  35. Machine PerformanceMonitoring Tool/Part-Checking Station Measures workpieces and tools so that the computer can compensate for variations and tool wear Touch Probes Pressed against a workpiece or tool to measure its exact size and position

  36. Touch Probes

  37. Measurement andAdjustment Advanced machining software can use data from probes to adjust its coordinate system, ensuring that critical distances remain within tolerances even in deformed workpieces critical distances Holes to be drilled (initial) Holes to be drilled (adjusted)

  38. Touch Probes tool holder probe part Using a touch probe to measure a part Courtesy Toth Industries

  39. Touch Probes A machining center, being used to measure and determine the orientation of a part Courtesy of Toth Industries

  40. Touch Probes tool changer arm probe part A machining center, being used to measure and determine the orientation of a part Courtesy of Toth Industries

  41. Touch Probes To determine the orientation of the part, the machine measures the two large holes and calculates their centers. A line constructed between the centers serves as a base for the computer’s coordinate system. Courtesy of Toth Industries

  42. Machine PerformanceMonitoring Tool Failure Detection: • Time When the total cutting time of the tool exceeds the pre-programmed tool life, the tool is replaced • Horsepower Dull tools draw more power; if the power exceeds pre-programmed limits, the tool is replaced

  43. Machine PerformanceMonitoring Tool Failure Detection: • Acoustic Emissions Cutting tools produce ultrasonic vibrations and weakened ones produce up to five times the normal amplitude; when it rapidly increases, the tool is immediately replaced

  44. Machine PerformanceMonitoring Tool Failure Detection: • Feed Force Records the feed force of sharp tools; if the force increase exceeds a predetermined percentage, the tool is replaced; if the force suddenly rises, the tool has broken and is replaced immediately

  45. ManufacturingCells

  46. ManufacturingCells

  47. ManufacturingCells

  48. Manufacturing Cells –Examples Courtesy of Toth Industries

  49. ManufacturingEconomics Cost: If the cutting speed is too low, the cost of cutting increases because of increased power consumption If the cutting speed is too high, the cost of tool replacement increases because tools wear out faster

  50. ManufacturingEconomics Time: If the cutting speed is too low, the cutting time increases If the cutting speed is too high, the tool replacement time increases

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