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HIGH PERFROMANCE MACHINING TECHNOLOGY from MAL Manufacturing Automation Laboratories Inc Vancouver, B.C., CANADA http://www.malinc.com. M.A.L. Products. MAL Inc. has two lines of Products to boost productivity of machining operations - PowerPoint PPT Presentation
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23年 4月 22日
©University of British Columbia - Manufacturing Automation Laboratory
M.A.L. Products
HIGH PERFROMANCE MACHINING TECHNOLOGY
from
MAL Manufacturing Automation Laboratories Inc
Vancouver, B.C., CANADA
http://www.malinc.com
23年 4月 22日
©University of British Columbia - Manufacturing Automation Laboratory
Products
MAL Inc. has two lines of Products to boost productivity of machining operations
• ShopPro – Practical, easy to learn and use, integrated tap testing, chatter avoidance and diagnostics software for milling
• CUTPRO – Advanced Simulation and Testing Software tool box to design, optimize, measure and diagnose machining operations, cutters and machine tools.
23年 4月 22日
©University of British Columbia - Manufacturing Automation Laboratory
Instrumentation
ShopPro/CUTPRO Instrumentation Set
1. Labtop computer
2. National Instruments NI9233 USB Measurement Box
3. Impact hammer and accelerometer
4. Microphone
23年 4月 22日
©University of British Columbia - Manufacturing Automation Laboratory
ShopPro Steps
3 Simple Steps in Using ShopPro
1. Enter material type and basic cutter geometry
2. Tap test the cutter on the machine or define dynamic parameters
3. Chatter stability lobes (vibration free speeds and depth of cuts), torque, power and material removal rates will be displayed instantly.
The noise from the machine can be recorded, and ShopPro provides automated diagnosis and advice.
23年 4月 22日
©University of British Columbia - Manufacturing Automation Laboratory
ShopPro
Step 2 - Tap Test the tool to obtain machine stiffness
23年 4月 22日
©University of British Columbia - Manufacturing Automation Laboratory
ShopPro
Step 3- Machine Sweet Spots (depth of cut, spindle speed) are displayed with Torque, Power and MRR
23年 4月 22日
©University of British Columbia - Manufacturing Automation Laboratory
CUTPRO Modules
CUTPRO Machining Software Modules• MALTF – Advanced Tap Testing System• MALDAQ – Multi Channel Data Collection • MODAL – Modal Analysis with machine data base and tool
tuning modules• MILLING – Advanced cutter design, optimization and
simulation system for milling • TURNING, DRILLING and BORING Modules • SpindlePro – Finite Element Modeling and Analysis of
Spindle Drives• Virtual CNC – A complete 5 axis modular CNC system
design with drive design, sensors, amplifiers, friction, trajectory generation, interpolation and control modules
23年 4月 22日
©University of British Columbia - Manufacturing Automation Laboratory
CUTPRO :Parametric Tool Definition in APT
23年 4月 22日
©University of British Columbia - Manufacturing Automation Laboratory
Helical flute is wrapped around the solid end mill.
geometry.arbitrary with millend solidany for power torque,
forces, total thefindcan weup, themsumming and in each
projectingBy edge. cuttinghelical on the point each on act ,, forces alDifferenti
x,y,z
PdFdFdF art
23年 4月 22日
©University of British Columbia - Manufacturing Automation Laboratory
CUTPRO: Prediction of milling forces from tool geometry and orthogonal
cutting material data.
23年 4月 22日
©University of British Columbia - Manufacturing Automation Laboratory
Cutter:Taper helical ball end mill, rake angle=10°, relief angle=10°, D=6.0, R=3.0, Rr =0, Rz =3.0, h=38.0, lead=105.0mm, a=0°, b=4.0°, Nf =1Cutting Mode: Slot cutting Cutting Coefficients: Orthogonal cutting coefficients for Ti6Al4Vby using orthogonal to oblique transformation
CUTPRO: Tapered Helical Ball End Milling (Jet Engine Machining)
23年 4月 22日
©University of British Columbia - Manufacturing Automation Laboratory
CUTPRO: Inserted Helical End Mill
23年 4月 22日
©University of British Columbia - Manufacturing Automation Laboratory
CUTPRO: Prediction of Serrated Cutter Forces
23年 4月 22日
©University of British Columbia - Manufacturing Automation Laboratory
Source of Vibrations in Machine Tools
FlexSource.ai
23年 4月 22日
©University of British Columbia - Manufacturing Automation Laboratory
CUTPRO : Vibration Model of Milling System
23年 4月 22日
©University of British Columbia - Manufacturing Automation Laboratory
REGENERATION MECHANISM
23年 4月 22日
©University of British Columbia - Manufacturing Automation Laboratory
FRF file
CMPfiles
Modal Analysis ModuleMilling Module
TF measurement MALTF
Stability LobesProcess simulation and
chatter stability lobe prediction in CUTPRO
23年 4月 22日
©University of British Columbia - Manufacturing Automation Laboratory
Increase the material removal rate by 500% and avoid poor
surface finish and tool/spindle damage
n=15400 [rpm], DOC=4.0 [mm] N=17000 [rpm], DOC=4.5 [mm]
Milling Mode: SlottingMachine tool: Mori Seiki SH403Tool:Jabro,16.0 [mm], 2-fluted cylindrical endmill
Feed rate: 0.1 [mm/tooth]
2884 [Hz]Chatter frequency
567 [Hz]Tooth passingfrequency
Surface finish Surface finish
23年 4月 22日
©University of British Columbia - Manufacturing Automation Laboratory
Slot milling of Al7050 with 2 Fluted, 16mm diameter end mill.
N=17,000 [rev/min],
depth of cut = 4.5 [mm]
NO CHATTER
N=15,400 [rev/min],
depth of cut = 4.0 [mm]
CHATTER
23年 4月 22日
©University of British Columbia - Manufacturing Automation Laboratory
Sound - Metal Cutting
Time [s]0 0.5 1 1.5 2 2.5 3
-6000
-4000
-2000
0
2000
4000
6000
0
20000
40000
60000
80000
100000
120000
140000
160000
180000
Power Spectrum - Metal Cutting
f - Frequency [Hz]0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
0
20000
40000
60000
80000
100000
120000
140000
160000
180000
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
0.45
0.5
0.55
0.6
ShopPro: Detection of Chatter with a microphone
23年 4月 22日
©University of British Columbia - Manufacturing Automation Laboratory
Sound - Metal Cutting
Time [s]0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8
-1400-1200-1000-800-600
-400-200
0200
400600
80010001200
0
1
2
3
4
5
6
7
8
9
10
11
Power Spectrum - Metal Cutting
f - Frequency [Hz]0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
5500
6000
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
0.45
0.5
0.55
0.6
Stability Lobes
Spindle Speed [rev/ min]5000 10000 15000 20000 25000 30000
0
1
2
3
4
5
6
7
8
9
10
11
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5Chatter Zone
Stable Zone
Power / Torque
Spindle Speed [rev/ min]5000 10000 15000 20000 25000 30000
0
1
2
3
4
5
6
7
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5__ _ Power__ _ Torque
Chatter is avoided by selecting proper speed recommended by ShopPro
23年 4月 22日
©University of British Columbia - Manufacturing Automation Laboratory
High Speed Milling of Spiral
Material: AL 7050-T7451, 100x100x50 [mm]Tool: Jabro 16 [mm] diameter, 50 [mm] length Number of flutes:2Roughing 17400 [rpm] Depth of cut: 7mm slotting Chip load: 0.2 mmFinishing: 20,000 [rpm] Depth of cut: 1mm, Width of cut:10 mm, Chip load:0.25 mmThickness of the wall: 0.15 [mm] Height of the wall: 35 [mm]Feed rate: 0.25 [mm/tooth] Machine tool: Mori Seiki SH403Cycle time:9 min 20 sec.
23年 4月 22日
©University of British Columbia - Manufacturing Automation Laboratory
Impeller Milling UBC + P&WC NSERC Chair
BEFORE AFTER
Surface roughness improved by 8.4 fold
• Cycle Time Reduction: 62%• Cycle Time Reduction: 62%
23年 4月 22日
©University of British Columbia - Manufacturing Automation Laboratory
10600 17600
4.5 [mm]
Force in X and Y directions
Surface finish
Example - 2
23年 4月 22日
©University of British Columbia - Manufacturing Automation Laboratory
Types of cutters in CUTPRO
-Milling Module
23年 4月 22日
©University of British Columbia - Manufacturing Automation Laboratory
Customers and/or Research Partners
+ Universities and many more…