Solutions for Sustainable Machining

2016 ◽  
Vol 139 (5) ◽  
Author(s):  
Eckart Uhlmann ◽  
Bernd Peukert ◽  
Simon Thom ◽  
Lukas Prasol ◽  
Paul Fürstmann ◽  
...  
Keyword(s):  
Machine Tool ◽  
Environmental Analysis ◽  
Machine Tools ◽  
Cutting Tool ◽  
Milling Machine ◽  
Dry Machining ◽  
Sustainable Machining ◽  
Sustainable Systems ◽  
Manufacturing Environments ◽  
Ieee International Symposium

The manufacturing industry contributes over 19% to the world's greenhouse gas emissions (U.S. Energy Information Administration, 2008, “Rep: Annual Energy Review 2008,” Report No. DOE/EIA-0384; Diaz et al., 2010, “Environmental Analysis of Milling Machine Tool Use in Various Manufacturing Environments,” 2010 IEEE International Symposium on Sustainable Systems and Technology.) and 31% of the total energy consumed annually in the U.S. (Herzog, T., 2005, “World Greenhouse Gas Emissions in 2005,” World Resources Institute, Washington, DC 2; Diaz et al., 2010, “Environmental Analysis of Milling Machine Tool Use in Various Manufacturing Environments,” 2010 IEEE International Symposium on Sustainable Systems and Technology.). There is therefore an increasing demand for sustainable solutions for the production technology industry. At the Technische Universitat (TU) Berlin, Germany, a collaborative research center (CRC) is focusing on new solutions for the sustainable machining of high performance alloys, with developments from machine tool frames to cutting tool technology being undertaken. An innovative machine tool concept with a modular frame, which allows a high level of flexibility, has been developed. Furthermore, add-on upgrading systems for older machine tools, which are particularly relevant for developing countries, have been developed. These systems allow the accuracy of outdated machine tools to be increased, thus making the machine tools comparable to modern systems. Finally the cutting process also requires solutions for dry machining, as the use of cooling lubricant is environmentally damaging and a significant cost contributor in machining processes. Two solutions are being developed at the TU Berlin: an internally cooled cutting tool and a heating concept for ceramic tools to allow dry machining of high temperature alloys, for example, for the aerospace industry.

Solutions for Sustainable Machining

2016 ◽  
Author(s):  
Eckart Uhlmann ◽  
Bernd Peukert ◽  
Simon Thom ◽  
Lukas Prasol ◽  
Paul Fürstmann ◽  
...  
Keyword(s):  
Machine Tools ◽  
High Performance ◽  
Manufacturing Industry ◽  
Cutting Tool ◽  
The United States ◽  
Dry Machining ◽  
Machining Processes ◽  
Sustainable Machining ◽  
Sustainable Solutions ◽  
High Level

The manufacturing industry contributes over 19% to the world’s greenhouse gas emissions [1, 3] and 31% of the total energy consumed annually in the United States of America [2, 3]. There is therefore an increasing demand for sustainable solutions for the production technology industry. At the Technische Universitaet (TU) Berlin, Germany, a collaborative research center (CRC) is focusing on new solutions for the sustainable machining of high performance alloys, with developments from machine tools frames to cutting tool technology being undertaken. An innovative machine tool concept with a modular frame, which allows a high level of flexibility, has been developed. Furthermore, add-on upgrading systems for older machine tools, which are particularly relevant for developing countries, have been developed. These systems allow the accuracy of outdated machine tools to be increased, thus making the machine tools comparable to modern systems. Finally the cutting process also requires solutions for dry machining, as the use of cooling lubricant is environmentally damaging and a significant cost contributor in machining processes. Two solutions are being developed at the TU Berlin: an internally cooled cutting tool and a heating concept for ceramic tools to allow dry machining of high temperature alloys, for example for the aerospace industry.

scholarly journals Assessment of the safety of use of portable machine tools

2018 ◽  
Vol 189 (3) ◽  
pp. 192-205
Author(s):  
Monika Nowak ◽  
Agnieszka Terelak-Tymczyna
Keyword(s):  
Machine Tool ◽  
Working Conditions ◽  
Machine Tools ◽  
Numerical Control ◽  
Milling Machine ◽  
Safety Issues ◽  
Large Size ◽  
Score Method ◽  
Characteristic Features ◽  
Risk Reducing

The article presents safety issues related to on-site machining with the use of portable machine tools. Their advantage is the possibility of machining elements at places in which they are used. This especially refers to large-size constructions, welded elements and any items whose disassembly is technically difficult. The authors present tasks performed by the operators of portable machining equipment, working conditions, construction and characteristic features of portable machine tools on the example of a portable boring machine, milling machine and flange facing machine. The presented characteristics can influence the safety of work with these machines. The information given in the article were used to asses risk at the position of a portable machine tool operator. The assessment was conducted using the Risk Score method taking into account four stages of using portable machine tools, i.e. transport, assembly/disassembly, machining and maintenance. The result of the conducted risk analysis is the proposal of possible risk reducing actions. Due to the specificity of the operation of portable machine tools which significantly impedes the development of a machine tool which would be safe in and of itself, the proposed actions refer mainly to organisational solutions. The work presents also the thesis that it is possible to decrease the risk at this position thanks to the use of numerical control in a portable machine tool. Such a solution may reduce exposure to some identified threats. The issue is presented on the example of a prototype of a portable flange facing machine developed in the Institute of Mechanical Technology ZUT in Szczecin.

Research on Modal Analysis of Precision Micro Slitting Turn-Milling Machine Tool Based on Hammer Experimental Method

2019 ◽  
Vol 295 ◽  
pp. 67-72
Author(s):  
Zhong Peng Zheng ◽  
Xin Yang Jiang ◽  
Xin Jin
Keyword(s):  
Machine Tool ◽  
Modal Analysis ◽  
Experimental Method ◽  
Machine Tools ◽  
Processing Parameters ◽  
Milling Machine ◽  
Vibration Model ◽  
Vibration Modal ◽  
Turn Milling ◽  
Machine Structure

In order to improve the dynamic stability of precision micro slitting turn-milling machine tools, reduce or avoid the vibration problem during the cutting process, optimize the machine structure and processing parameters, the modal analysis of precision micro slitting turn-milling machine tool based on hammer experimental method was researched. In this paper, by analyzing the mechanism of precision micro slitting turn-milling machine tools, the multi degree-of-freedom mathematical vibration model of precision slitting turn-milling machine tools is constructed. The precision micro turn-milling machine tool is analyzed based on the hammer experiment analysis. The modal analysis obtained the first five natural frequencies and resonance speeds of the precision micro slitting turn-milling machine tool,including ST26, NN-25UB8K2 and NN-20UB87. The research results show that hammer experimental method can evaluate the vibration modal analysis of precision micro slitting turn-milling machine tools to some extent. The experimental modal analysis results guide and optimize the structural design and processing technology of precision micro slitting turn-milling machine tools.

Mathematical Approach for Geometric Error Modeling of Three Axis CNC Vertical Milling Machine

2016 ◽  
Vol 842 ◽  
pp. 303-310 ◽  
Author(s):  
Widyanti Kwintarini ◽  
Agung Wibowo ◽  
Yatna Yuwana Martawirya
Keyword(s):  
Machine Tool ◽  
Machine Tools ◽  
Machining Process ◽  
Cnc Machine Tools ◽  
Milling Machine ◽  
Cnc Machine ◽  
Geometrical Errors ◽  
Vertical Milling ◽  
Vertical Milling Machine ◽  
Accuracy And Repeatability

The aim of this paper overviews about to find out the errors that come from three axis CNC vertical milling machine. The errors come from, the CNC milling machine can be modelled into mathematical models and later on these error models will be used to analyse the errors in the measured data. Many errors from CNC machine tools have given significant effects toward the accuracy and repeatability of manufacturing process. There are two error sources come from CNC machine tools such as tool deflection and thermal distortions of machine tool structure. These errors later on will contribute to result in the geometrical deviations of moving axis in CNC vertical milling machine. Geometrical deviations of moving axis such as linear positioning errors, roll, pitch and yaw can be designated as volumetric errors in three axis machine tool. Geometrical deviations of moving axises happen at every axis in three axis CNC vertical milling machine. Geometrical deviations of moving axises in linear and angular movement has the amount of errors up to twenty one errors. Moreover, this geometrical errors play the major role in the total amount of errors and for that particular reason extra attention towards the geometrical deviation errors will be needed along machining process. Each of geometrical error of three axes vertical machining center is modeled using a homogeneous transformation matrix (HTM). The developed mathematical model is used to calculate geometrical errors at each axis and to predict the resultant error vector at the interface of machine tool and workpiece for error compensation.

INTEGRATION OF REAL-TIME CONTROL SIMULATION TO A VIRTUAL MANUFACTURING ENVIRONMENT

2002 ◽  
Vol 01 (01) ◽  
pp. 67-87 ◽  
Author(s):  
BYUNG-KWON MIN ◽  
ZHENGDONG HUANG ◽  
ZBIGNIEW J. PASEK ◽  
DEREK YIP-HOI ◽  
FORBES HUSTED ◽  
...  
Keyword(s):  
Machine Tool ◽  
Real Time ◽  
Machine Tools ◽  
Manufacturing Systems ◽  
Early Stage ◽  
Virtual Manufacturing ◽  
System Level ◽  
Manufacturing Environment ◽  
Manufacturing Environments ◽  
Virtual Manufacturing Environment

This paper presents a new integrated approach for simulation developed to improve the accuracy of virtual manufacturing environments. While machine tool simulation and virtual manufacturing for factory simulation have been frequently used in early stage plant development, each of these technique has been researched and implemented separately. This paper focuses on the utilization of real-time simulation of machine tools or active axes in manufacturing systems and integration of this simulation capability with virtual manufacturing environments. Machine-level simulation results are generated in real-time with a real machine tool controller and are fed to a virtual manufacturing environment. To integrate these two simulation techniques, system-level software is utilized as a communication platform. This system-level software was originally developed to control and configure whole manufacturing systems. The method has been successfully implemented within a testbed with full-scale machine tools. The results demonstrate that the proposed method advances the virtual manufacturing environments toward improved accuracy of factory level simulation, reduced effort for modeling and expanded functionality of machine-level simulations.

scholarly journals Active vibration control for a CNC milling machine

2013 ◽  
Vol 228 (2) ◽  
pp. 230-245 ◽  
Author(s):  
DG Ford ◽  
A Myers ◽  
F Haase ◽  
S Lockwood ◽  
A Longstaff
Keyword(s):  
Control System ◽  
Tool Wear ◽  
Machine Tool ◽  
Vibration Control ◽  
Surface Finish ◽  
Machine Tools ◽  
Active Vibration Control ◽  
Milling Machine ◽  
Cnc Machine ◽  
Active Vibration

There is a requirement for improved three-dimensional surface characterisation and reduced tool wear when modern computer numerical control (CNC) machine tools are operating at high cutting velocities, spindle speeds and feed rates. For large depths of cut and large material removal rates, there is a tendency for machines to chatter caused by self-excited vibration in the machine tools leading to precision errors, poor surface finish quality, tool wear and possible machine damage. This study illustrates a method for improving machine tool performance by understanding and adaptively controlling the machine structural vibration. The first step taken is to measure and interpret machine tool vibration and produce a structural model. As a consequence, appropriate sensors need to be selected and/or designed and then integrated to measure all self-excited vibrations. The vibrations of the machine under investigation need to be clearly understood by analysis of sensor signals and surface finish measurement. The active vibration control system has been implemented on a CNC machine tool and validated under controlled conditions by compensating for machine tool vibrations on time-varying multi-point cutting operations for a vertical milling machine. The design of the adaptive control system using modelling, filtering, active vibration platform and sensor feedback techniques has been demonstrated to be successful.

Revival of 1920s Belt-Driven Machine Tools with Virtual Reality

2012 ◽  
Vol 163 ◽  
pp. 155-161
Author(s):  
Y.S. Chang ◽  
J.J. Fang
Keyword(s):  
Virtual Reality ◽  
Machine Tool ◽  
Virtual Environment ◽  
Machine Tools ◽  
Mechanical Engineering ◽  
Milling Machine ◽  
History Of

Taking one of the belt-driven machine tools, horizontal milling machine, as the protagonist, the study constructs a virtual environment based on OpenGL and Microsoft Foundation Class without using any well-developed commercial VR software. Belt-driven mechanism was developed in the 1920s, at which time the motor was first invented and rather expensive. Because of difficult preservation and underlying hazards in mechanical antiques, resurgence of the horizontal milling machine in virtual reality is proposed and an exhibition room is permanently settled to memorize the history of mechanical engineering in the 1920s. Aside from the application of exhibition, this developed system also allows users to operate the machine tool in the same manner as in reality.

The Study of Cutting Forces About Dynamic Stability of Milling Machine Tools

2008 ◽  
Author(s):  
Petru A. Pop
Keyword(s):  
Machine Tool ◽  
Cutting Force ◽  
Dynamic Stability ◽  
Cutting Forces ◽  
Machine Tools ◽  
Cutting Process ◽  
Depth Of Cut ◽  
Milling Machine ◽  
Dynamic Tests ◽  
Machining System

The paper has presented a study of cutting forces about dynamic stability of milling machine tools. For that has required the analysis of dynamic machining system (DMS), represented by the interaction between elastic structure of machine tool and cutting process. The cutting force occurred during cutting process is dependent by a certain factors as thickness cut, physics-mechanics properties of workpiece, geometry of shaped edge tool, etc. An important factor, which has direct influenced about DMS, is present of vibration, in special at chatter frequency due to real perturbation and damages of DMS. The magnitude of cutting force depends largely on the tool-work engagement and depth of cut. The dynamic installation has used for study of milling cutting process assured the acquisition of vibration and cutting force on each three axes of milling machine tool. The calculus and interpretation of dynamic tests had done by MATLAB R14.v7.01 Program. Dynamic tests have been more that 150 recordings, by variation of cutting depth for each spindle speeds of machine until occurring chatter. It had used for testing four milling cutters with different geometric parameters and differential pitch of cutter. These dynamic tests are emphasizing the direct influences of cutting forces about dynamic machining system. Thus, by reducing, the magnitude of cutting forces due to suppressing the vibrations and implicit enhanced the dynamic stability of milling machine and quality of machining workpiece.

Mini Special Issue on Machine Tool Structure and its Design Optimization

2015 ◽  
Vol 9 (6) ◽  
pp. 679-679
Author(s):  
Hidenori Shinno
Keyword(s):  
Machine Tool ◽  
Design Optimization ◽  
Machine Tools ◽  
Rapid Change ◽  
Tool Development ◽  
Special Issue ◽  
Design Concepts ◽  
Machine Tool Structure ◽  
Dynamic Rigidity ◽  
Manufacturing Environments

Demands for machine tools that are highly accurate, productive, flexible, and compact have been growing in the aerospace, automotive, energy, factory automation, and other industries. Rationally meeting these severe, complex requirements has led to numerous research and development activities involving machine tools. Few machine tool technologies have been established, however, despite the machine tool industry’s long history. Within the next several years, the rapid change and enlargement of the This mini special issue on machine tool structure and its design optimization features 8 papers classified under the following themes: - Enhancing high static and dynamic rigidity - Minimizing and optimizing thermal deformation - Proposing new structural analysis methods for machine tools - Selecting and applying new structural materials to the machinetool structure - Applying new structural designs and mechanisms These papers present new design concepts, design methods, and innovative examples in machine tool development. I believe that successfully combining these core technologies will provide machine tool compatible with future manufacturing environments. In closing, I would like to express my sincere gratitude to the authors and reviewers for their interesting and dedicated contributions to this special issue.

Sign in / Sign up

Export Citation Format

Share Document