Conf. HR Ludwig

CNC Machine Tools (Werkzeugmaschinen) - 53 92 051
Introduction - fundamental definitions

Professor Dr.-Ing. Hans-Reiner Ludwig, Institut fr Interdisziplinre Technik I
2
T
Fachhochschule Frankfurt am Main - University of Applied Sciences
Optimising of
mechanical manufacturing
processes
Mejoracin de la fabricacin
con tecnologias
del mecanizado
2
T
Contents

Introduction: Manufacturing processes and machine tools

Metal cutting with defined cutting edge
Processes: Turning, Planing, Drilling, Milling, Broaching
Kinematic correlations

Metal cutting with undefined cutting edge
Processes and characteristics: Grinding, Honing, Lapping

Optimisation of manufacturing processes:

Tutorial The success story of the Numerical Control (NC)

Practical examples
2
T
Contents






Practical examples
2
T
Introduction to metal cutting technologies
Manufacturing technologies according to DIN 8580
Proceso de fabricacin de norma DIN 8580

6. Hardening
Cambiar los propiedades
del material
1. Primery Shaping
Conformacin primaria

2. Forming
Formar

3.Cutting
Cortar

4. Joining
Machihembrar
5. Coating
Laminar

6 capital groups
6 grupos principales

3.1 Die cutting
DIN 8588
Estampar
3.2 metal cutting
with
defined
cutting edge
DIN 8589
Maquinar con corte
geomtrico definido
3.3 metal cutting
with
undefined
cutting edge
DIN 8589
Maquinar con corte
geomtrico indefinido
3.4 Discharging
DIN 8590
Evacuar
3.5 Decomposing
Desmontar

3.6 Cleaning
Limpiar

2
T
Machine Tools Mquinas-herramientas
Fundamental definitions Definiciones fundamentales
Machine Tools are defined as working engines,
wherein a tool and a workpiece
come to an interaction.
Both of them, the tool as well as the workpiece,
are to be mounted
in a well defined bearing.
Las mquinas-herramientas son mquinas activas.
Existe una interaccin entre la herramienta y la
pieza.
Ambos, la herramienta y la pieza, necesitan una gua bien
definida.

http://www.lathes.co.uk/thiel/ http://homepages.tig.com.au/~dispater/turning.htm
Henry Maudslay,
Early Lathe, 1800
Thiel, Milling Machine
1900
2
T

19
th
century:

Beds and frames
(cast iron)
Spindle bearings
(by slide bearings)
Linear bearings,
compound slide rest
1841
Machine Tools in history:
functions and assemblies
Mommertz: Bohren, Drehen, Frsen (1981) - Illustration of 1841
historical power
transmission by
central steam engine
beds and frames compound slide rest
on linear bearings
Henry Maudslay
spindle bearing
tailstock bearing
2
T
early 20
th
century:
Beds and frames
Spindle bearings
(by ball bearings)
Linear bearings,
compound slide rest
Electric drive
(central, one per machine tool)
Spur gears, belt transmissions,
gearboxes

Machine Tools in history:
functions and assemblies (2)
Weisser Lathe 1896 -
Tony Griffiths www.lathes.co.uk
main spindle
by ball bearings
spur gears
central electric drive
reduction spur gear
feed shaft
leading screw
Norton gear box
belt drive
1896

compound slide rest
on linear bearings
cast iron frame
2
T
late 20
th
century:
Beds and frames
Spindle bearings
Linear bearings
Servo motors
(one per NC-axis)
Gears & transmissions
Closed-loop devices
CNC - control units

The modern machine tool (example: double spindle lathe)
functions and assemblies
1995

AC spindle drives
AC spindle drives
servo drives
for nc-axes
servo drives
for nc-axes
servo drives
for nc-axes
servo drives
for NC-axes
CNC
control unit
each NC-axis equipped with
speed sensor and linear scale
or rotary encoder
Machine Tools (mquinas-herramienta)
Fundamental terms Trminos fundamentales

Machine Tool
Mquina-herramienta
CNC-Machine Tool
Mquina-herramienta CNC
Manufacturing Centre
Centro de fabricacin
herramientas
Manufacturing Cell
Clula de fabricacin

Manufacturing System
Sistema de fabricacin

Manufacturing process
(manual controlled)
Proceso de fabricacin
(controlado manual)

Manufacturing process
(numerical controlled)
Proceso de fabricacin
(controlado nmerico)

Automated tool changer
with tool magazine
Cambiador de herramientas
Automatizado con almacn

Automated handling of
workpieces or pallets
Sistema de manejo
automatizado para piezas

Automated flow of material
and data processing within
the manufacturing system
Flujo automatizado de
materiales y tratamiento de
datos en el sistema de
fabricacin
Increasing
grade of
automation

[Weck, 1991]
Aumento del
grado
automatizado

Optimisation in manufacturing -
REFA scheme of machine time
Machine time
per order (lot)
Machine
setting time t
set-up
Machine
Operation time t
op
Operation time
per unit t
unit
Fundamental
operation time
Distributed
operation time
Primary utilisation
time t
pr
Secondary utilisation
time t
sec
Idle time
t
id
Fundamental
setting time
Distributed
setting time
Analysis and optimisation
of setting processes
optimising technology
and tooling

automatic tool change
automatic change of
workpieces

optimising some side
conditions, such as
sister-tools

t
op
= m
.
t
unit

Contents






Practical examples
[ www.huka-tech.de]
[ www.wiedemann-drehteile.de]
[ www.poetshc-gmbh,de ]
[ www.heuer-werkzeuge.de ]
[ www.ingenhoele.at ]

Workpiece rotates -
tool is guided
on compound slide rest
La pieza gira,
la herramienta esta fija
en el carro cruzado

Turning Technologies Tecnologas de tornos
Face turning - plain turning
planear girar a lo largo

Range of workpieces
on turning machines
with driven tools:
width across flats,
slots, helices, ...
Seleccin de piezas
fabricado con un torno:
espirales, ojales,
ancho de llave

metal cutting with defined cuttinge edge
Overview: Planing, Shaping - cepillado, mortajado
Planing
Cepillado redondo
Gear shaping
Mortajado con movimiento evolvente
[
K
n
i
g
,

K
l
o
c
k
e
,

1
9
9
9
]

Planing: The workpiece (machine table)
operates the man motion
/Shaping: The tool operates the main
Motion

Cepillado: La pieza se mueve

mortajado: La herramienta se mueve

During the back-motion (vR)
the tool is lifted from the workpiece.

En la carrera de retorno, la
herramienta se levanta de la pieza

Shaping gear (tool)
Rueda de desplazamiento

[

w
w
w
.
l
a
n
d
s
c
h
a
f
t
s
m
u
s
e
u
m
.
d
e

]

[ www.alzmetall.de ]
3 Titex-Prototyp: Drills
for Dry, Hard and High Speed Operating
Taladradoras para operaciones secas, rapidas y
velocidades altas
2 Ghring: tools for
lowering and reaming
operations
EMUGE-Franken:
Tools for thread
machining
herramientas para
roscas
[

w
w
w
.
c
n
c
-
3
d
.
c
o
m

]

Tool rotates -
workpiece is fixed
La herramienta gira,
la pieza esta fija

Drilling Technologies Tecnologas de taladradoras
herramientas para
brochar y fresar
[

w
w
w
.
m
b
a
-
s
p
a
n
g
e
n
b
e
r
g
.
d
e

]

[ www.shw-beareitungstechnik.de ]
3 Kennametal:
keyway cutter, face milling head,
90-milling head
[

w
w
w
.
k
n
e
e
r
-
f
o
r
m
e
n
b
a
u
.
d
e

]

[

w
w
w
.
b
v
a
-
k
o
c
k
e
l
m
a
n
n
-
g
m
b
h
.
d
e

]

Tool rotates -
workpiece guided
on slide rest
La herramienta gira,
la pieza esta situado en
el carrito de soporte

Milling Technologies Mquinas fresadoras
Ranuradoras, fresadores para el
flanco, 90-fresador
Overview: milling (1) fresado (1)
Definitions according to the kinematics syncronous milling
Definiciones por la kinematica fresar sincrono

Conventional milling
fresar apuesto

[
K
n
i
g
,

K
l
o
c
k
e
,

1
9
9
9
]

Movimientro de corte en relacin a la herramienta,
movimiento de avance en relacin a la pieza
(mesa de la mquina).
fine milling / Feinfrsen

hobbing / Wlzfrsen

[Knig, Klocke, 1999]
Overview: milling (2)
[ www.froemag.com ]
2 Wikipedia:
outer shape
broaching tool,
comibination wrench
Herramienta para
brochar exterior, llave universal

Tool guided -
workpiece fixied
La pieza guia,
la herramienta esta fija

[ www.franklingear.com ] [ www.brigel.ch ]
2 www.avonbroach.com:
range of workpieces outer shape broaching
range of workpieces inner shape broaching
piezas fabricado con brochado formado exterior y interior
Broaching technologies Tecnologas brochadas
tool= pull broach
herramienta = brochado por traccin
Face broaching and hub broaching
brochado exterior y interior

turnbroaching of crankshafts
Brochar de giro de cingeales
finishing section
Alisar
Roughing section
Desbastar
guideshaft
Espiga gua

calibration section
Longitud paralela
v
c

[Lauffer, 1988]
Overview: broaching brochado
Contents






Practical examples
metal cutting with defined cutting edge
Kinematic correlations (1)
Conexiones cinemticas (1)
Cutting spped v
c
Velocidad de corte
... which is the peripheral velocity
... es la velocidad perifrica :

v
c
=
.
D
.
n

D = workpiece diameter in a
turning process
dimetro de la pieza al tornado
D = tool diemeter in drilling or
milling processes
dimetro de la pieza al fresado
y taladrado
n = number of revolutions
revoluciones

c = cut corte
Feed rate f
Avance
... which is the feed motion
per revolution es el avance por revolucin

v
f
= f
.
n

with milling and drilling
it is defined
para fresado y taladrado vale :
f = f
z
.
z
f
z
= feed per tooth avance por cuchilla
z = number ot teeth nmero de cuchillas
f = feed
avance
[Degner et.al. 1993]
metal cutting volume per time
(metal cutting rate)
Volumen de viruta por tiempo
(Proporcin de maquinar)

Zeitspanvolumen (Zerspanrate) Volumen de viruta

in the case of turning para torneado :
Q = a
p
.
a
f
.
v
c
= a
p
.
f
.
v
c
= a
p
.
v
f
.
.
d
m

in the case of boring up, lowering, reaming
para taladrado, avellanado, rascado :
Q = a
p
.
f
z
.
z
.
v
c
= a
p
.
v
f
.
.
d
m

in the case of drilling (into solid material) Para torneado (en material slido):
Q = a
p
.
a
f
.
v
c
=
.
a
p
2.
v
f

(because d
m
= a
p
) (porque d
m
= a
p
)

D = 2
.
ap
Essential operation time
Tiempo del mecanizado
principal:
t
h
= L
f
/ v
f

Kinematic correlations (4)
Conexiones cinemticas (4)
properties of tool material
Propiedades del material de corte

Classification of
cutting tool material:
Clasificacin de material
de corte:
tool steel Acero para
herramientas (HSS)
hard metals, cermets
Metales duros, cermet
(WC-Co, TiC/TiN-Co)
cutting ceramics
Cermicas cortantes
(Al
2
O
3
, Si
3
N
4
)
hard material
Diamante y nitrudo de boro
(PCD, CBN)
[Knig, Klocke 1999]
Mechanical Resistance related to the feed rate
T
h
e
r
m
i
c
a
l

R
e
s
i
s
t
a
n
c
e

r
e
l
a
t
e
d

t
o

t
h
e

c
u
t
t
i
n
g

s
p
e
e
d

Contents






Practical examples
metal cutting with undefined cutting edge
Grinding Technologies
El proceso: Rectificado

[ www.profiltec.com]
[ www.kofler-metallbearbeitung.de]
[ www.jo-technik.at ] [ www.krallmann.de ]
[ www.greubag.ch ]
[ www.werkzeugbau-langkamm.de]
[ www.junker.de ]
Circular Grinding
(Rundschleifen)
Rectificado cilndrico
Centerless Grinding
(spitzenlos schleifen)
Rectificado sin puntas
Circular Grinding
chucked, between centers
(im Futter, zwischen Spitzen)
Rectificado cilindrico
(entre puntas)

Flat Grinding (Flachschleifen)
Rectificacin de superficies
planas

tool rotating -
workpiece guided
herramienta rotante-
pieza guiada

Modelling and characteristics of grinding (1)
[Spur]
Chipping with geometric
undefined cutting edge:
particles of ahard material
(grain) are arbitrary em-
bedded in a more ductile
matrix (bonding).
Grain and bonding define the
properties of the abrasive
body.
Modelling:
Grinding as a statistical process
of grains, which take part on the
chipping process.

Relative motion between
grinding wheel an workpiece
as both are moving.
[Knig, Klocke 1999]
Modelling and characteristics of grinding (2)
[Spur]
Friction as a
significant factor:

Chipping begins in the field
III, as soon as the chipping
thickness h
cu
reaches the
depth of the effective
cutting depth T
.
The effective chipping
thickness h
cu,eff
increases
by friction, decreases by
lubrication.
[Knig, Klocke 1999]
Chipping with undefined cutting edge
Modelling and characteristics (3)
[Spur]
Thermical effects
on the workpiece
material
The workpiece takes a large
amount of the heat generated
by the process other than
in chipping with defined cutting
edge, where the greatest part
of the heat will flow into the
chip.

So one has to be aware from
property changes in the workpiece.

[Knig, Klocke 1999]
metal cutting with undefined cutting edge
Honing and lapping technologies
El proceso: bruido, lapeado

[ www.hunger-hydraulik.de]
[ www.u-w-jende.de ]
[ www.gehring.de ]
[ www.fgyger.ch ]
Koaxiales Honen
Bruido coaxial

tool oscillates -
workpiece fixed
herramienta oscilante-
pieza emportrada
[ www.htwm.de ]
[ www.kiffe-lohnfertigung.de ]
[ www.geo-tu-freiberg.de ]
workpieces guided -
tool = abrasive compound
piezas guiadas -
herramienta = material abrasivo
Process overview: honing
Kinematics und factors of Honing
[Knig, Klocke 1999]
Cross-grinding
as surface
characteristic
[Zurrin 1990]
Honing as a finishing process is
mostly used to improve the
surface quality of the workpieces
Process overview: lapping
Kinematics and factors of lapping
As honing, the lapping process
is firstly applied to improve the
surface quality of the workpieces
and more and more is replaced
by flat honing (superfinish) in
industrial manufacturing.
[Knig, Klocke 1999]
The lapping grains
move on cycloidical
pathes
Contents






Some practical examples
TUTORIAL

The success story of the Numerical Control ( NC / CNC )

Traditional lathe:

Constant number of rev.
n = 900 min
-1
Constant feed in Z-axis
f
Z
= 0,2 mm

CNC Turning Machine:

Constant cutting speed
v
c
= 180 m/min
Constant feed rate
related to the path

f = 0,2 mm
[Victor, Mller, Opferkuch: Zerspantechnik]
Workpiece
Z
Tool
X
Contents






Some practical examples
Gear manufactured
by milling
Material 15,10 %
Manufacturing
of the weak material

Turning multispindle
. 8,49 %
Broaching of keyway
3,17 %
Milling of teeth 47,50 %
Hardening 1,92 %
Hard manufacturing
Flat grinding 5,93 %
Deburring 0,53 %
Tool wear and
inspections 17,36 %
Hydraulic gear pump:

highest requirements on
form and orientation of the
face plane
[nach Spur]
Reduction of
manufacturing costs
to 31,73 %
Gear manufactured
by sintering
Material 9,97 %

Werkzeugverschlei,
Prfkosten 8,45 %
Hardening 1,92 %
Sintering
Forming (pressing) 2,37 %
Sintering 2,56 %
No manufacturing
before hardening
1
st
example: gear of a hydraulic pump
Sintering instead of metal cutting

Hard manufacturing
Flat grinding 5,93 %
Deburring 0,53 %
Bewertung von Produktionsverfahren
Professor Dr.-Ing. Hans-Reiner Ludwig,
Institut fr Automatisierungstechnik und Integrierte Produktionstechnik (IAP)
2
nd
example: Face milling tool innovation
3
rd
example: Face milling process substitution
Face milling GG 25

1. Pre- & Final-Milling with hard metal
t
op
= 100 %
one set of tool inserts = 100 %
number of pieces
up to tool life = 100%

2. Pre- & Final-Milling with coated
hard metal (TiN)
t
op
= 34 %
number of pieces
up to tool life = = 208 %

Face milling GGG 40

1. Pre-Milling HM K and Grinding
t
op
= 100 %
number of pieces
up to tool life = 100%

2. Pre- and Final-Milling
HM P
t
op
= 31 % (Pre-milling)
t
op
= 67 % (Final-Milling instead of
Grinding)
One set of tool inserts = 346 %
number of pieces
up to tool life = 210 %

no grinding
operation
new
tool material
4
th
example: lever 25MoCr4 (700 HV)
Hard milling of lateral surface instead of grinding
Fresado duro del contorno externo

Steps of optimisation Optimizacin a paso

0. Milling and Grinding
(two operations)
Fresado y afilado
(2 etapas de procesado)

1. Hard Milling
with CBN tool
Fresado duro con
herramienta NBC
(nitrudo de boro cbico)

2. Hard Milling
with ceramic tool
Fresado duro con cermica
cortante

1.
Grinding
cancelled
2.
Cheaper
tool material
0 1 2
4,2 1,25 1,25
325
320
1
140
240
4
Grinding Hard Milling
Example: lever 25MoCr4 (700 HV)
Hard milling of lateral surface instead of grinding
Fresado duro del contorno externo

Results of optimisation Resultado de optimizacin

Evenness Planeidad 3m
Roughness Rugosidad
R
t
1,6 m
Waviness Oleada
W
t
0,5 m

v
5
th
Example: Integration of two workpieces into one single piece
6
th
Example: Lean production
Sweeping plate (cradle) together
with the lever as one row-piece
manufactuerd by die-forging

1 workpiece
and screw
cancelled
Optimsed All-in-One-
Manufacturing

Manufacturing of the weak worlkpiece:
4 operations 1 operation
Surface hardening (carbonitrating)
Manufacturing of hardened workpiece:
4 operations 1 operation

[ nach Bosch Brninghaus-Hydromatik ]
flow through
manufacturing
20 8 days
Manufacturing
cost decreased
to 60%
no assembly
operation
3.
Integration
of workpieces
4.
Re-organisation:
Lean
Production
7
th
example: deep drilling process substitution
Taladrado profundo
Overview deep drilling / gun drilling on special machines
Definition:
l/D > 20

Oil under high pressure is used to
cool and lubricate the cutting
process as well as removing the
chips.
deep hole drill
BTA-prpcess
Ejector process

Aceite a alta presin se ultiliza para
la refrigeracin y lubricacin, asi como el
transporte de las virutas:
Taladro con un labio
Proceso-BTA
Proceso eyector

Regular manufacturing centre with:
high rigidity of the entire machine structure
(including linear and spindle bearing=
high kinematic precision
internal cooling under high presure

optimised drill: hard metall with internal cooling canals

l/D = 70

h
t
t
p
:
/
/
w
w
w
.
y
o
u
t
u
b
e
.
c
o
m
/
w
a
t
c
h
?
v
=
r
f
I
A
C
Y
O
U
1
g
Y
&
f
e
a
t
u
r
e
=
p
l
c
p
&
c
o
n
t
e
x
t
=
C
3
e
0
e
2
1
a
U
D
O
E
g
s
T
o
P
D
s
k
K
Y
b
F
M
j
6
j
O
8
q
1
l
o
i
l
7
S
4
f
Q
o

Vorschubgeschwindigkeit speed of feed [mm/min]
velocidad de avance
traditional techologies
Only the
standard
machine tools
Better performance
by higher feed rate
7
th
example: deep drilling process substitution
Taladrado profundo
Innovation deep drilling with specialised drill on standard machine

Conclusion:

Optimising manufacturing processes
means to look in all directions:

reducing cutting processes by optimising the row-parts

make operations faster by using tool innovation

replacing grinding processes by hard turning or
hard milling

Conf. HR Ludwig

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CNC Machine Tools (Werkzeugmaschinen) - 53 92 051

Introduction - fundamental definitions

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