Machining Centers and Machine Tool Structures

Presented by
NITESH P. WANKHADE (12MCD1003) M.TECH (CAD-CAM)

Introduction

Computers improved the capabilities of machine tools Have the capability of rapidly producing extremely complex part geometries

Machining Centers

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Brief review: Possibilities exist in net-shape or near-net shape production Some form of machining is required and is more economical to finish machine parts to their final shapes

Machining Centers
The Concept of Machining Centers Machining parts can be highly automated to increase productivity Transfer lines are used in high-volume or mass production, consist of several specific machine tools arranged in a logical sequence Workpiece is moved from station to station, with a specific machining operation performed at each station A machining center is an advanced computercontrolled machine tool that perform machining operations without removing

Machining Centers

Machining Centers
Components of a Machining Center The workpiece in a machining center is placed on a pallet, or module Can be moved and swiveled in various directions New pallet is brought in by an automatic pallet changer A machining center is equipped with a programmable automatic tool changer (ATC)

Machining Centers
Components of a Machining Center The tool-exchange arm swings around to pick up a particular tool and places it in the spindle Tool-checking and/or part-checking station would feeds information to the machine control system Touch probes select the tool settings and inspect parts being machined

Machining Centers: Types of Machining Centers

Vertical-spindle Machining Centers Performing various machining operations on parts with deep cavities, as in mold and die making Horizontal-spindle Machining Centers Suitable for large and tall work pieces that require machining on a number of their surfaces

Machining Centers: Characteristics and Capabilities of Machining Centers

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Major characteristics of machining centres: Handles a wide variety of part sizes and shapes efficiently Versatile and quick changeover Time required is reduced Detection of tool breakage and wear Inspection of machined work Compact and highly automated

Machining Centers: Selection of Machining Centers

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Selection of type and size of machining centers depends on: Type of products, their size, and their shape complexity Type of machining operations to be performed and the type and number of cutting tools required Dimensional accuracy required Production rate required

Machining Centers: Selection of Machining Centers

EXAMPLE 25.1 Machining Outer Bearing Races on a Turning Center Machining of outer bearing races

Machining Centers: Reconfigurable Machines and Systems

There is a need for the flexibility of manufacturing which involve concept of reconfigurable machines, consisting of various modules 3 axis machining center can perform different machining operations while accommodating various workpiece sizes and part geometries

Machining Centers: Reconfigurable Machines and Systems

A five-axis machine can be reconfigured by assembling different modules

Machine-tool Structures: Materials

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A list of materials suitable for machine-tool structures: Gray cast iron Welded steel Ceramic Composites Graniteepoxy composites Polymer concrete

Machine-tool Structures: Machine-tool Design Considerations

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Important considerations in machine tools: Design, materials, and construction Spindle materials and construction Thermal distortion of machine components Error compensation and the control of moving components along slideways

Machine-tool Structures: Machine-tool Design Considerations

Stiffness It is a function of the: 1. Elastic modulus of the materials used 2. Geometry of the structural components Enhanced by using diagonally arranged interior ribs Thermal Distortion 2 sources of heat in machine tools: 1. Internal sources 2. External sources

Machine-tool Structures: Machine-tool Design Considerations

Assembly Techniques for Machine-tool Components Traditionally components have been assembled using threaded fasteners and welding Advanced assembly techniques include integral casting and resin bonding Guideways Plain cast-iron ways in machines require much care to achieve the required precision and service life

Machine-tool Structures: Machine-tool Design Considerations

Linear Motor Drives A linear motor is a typical rotary electric motor that has been rolled out (opened) flat Sliding surfaces in drives are separated by an air gap and have very low friction Some advantages: 1. Simplicity and minimal maintenance 2. Smooth operation, better positioning accuracy, and repeatability 3. Wide range of linear speeds 4. Moving components encounter no wear

High-speed Machining

Spindle designs for high speeds require high stiffness and accuracy Due to inertia effects during the acceleration and decelaration of machine-tool components, there is a use of lightweight materials consideration High-speed machining should take cutting time as a cosideration High-speed machining is economical for certain specific applications As cutting speed increases, more heat is generated, while the tool and workpiece should remain close to ambient temperature

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