TECHNICAL UNIVERSITY – SOFIA

English Language Department of Engineering

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MANUFACTURING DESIGN

PL II
COURSEWORK
FEED DRIVE FOR A HORIZONTAL MC FOR X-AXIS
M
SA

STUDENT:
FACULTY NUMBER:
Introduction:

The machining centre (MC) is a device for processing of different materials in industry ,
and mainly of metals.A MC is an automated machine.Which can perform a sequence of
operations with different tools without the assistance of an operator.That is why MC are very
popular in production lines designed for the mass production and utilize CNC control.
A MC has several main components one of which is the feed drive .Its used to accomplish
the feed motion of the automatically interchangeable tools.

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2.Design of the feed drive ;

2.1 Given data :

Gworkpiece : 3.5 kN
Vmax
Fmax
Travel
: 36 m/min

: 8 kN

: 510 mm
Work Table : 600.600 PL
2.2 General schemen of machining center :
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SA

2.3 Design:
a) Calculation of the thrust force ;

Ft= Fx max + µ.G + 2. µ f + 2.µ.N

Ft - the maximal axial force which the ball-screw will have to bear(thrust force)
µ - the friction coefficient for the guide ways , for this case µ = 0,12(plastic guide
ways)
f - force of preload
f=f1+f2+f3

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f1=a.h.Ppreload=50.600.0.1=3 kN
f2= a.h.Ppreload=50.600.0.1=3 kN
f3= b.h.Ppreload=30.600.0.1=1.8 kN
Ppreload = 0.1 MPa
G – load (G=W)
N – normal reaction force
N=(Fx max. y)/x
N=(8.600)/600=8 kN
PL
Ft =8 + 0,12.3,5 + 2.0,12.7,8 + 2.0,12.8 = 12,212 kN

b) Calculation of the required motor torque ;

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Ft .l
Tm 
2. .belt.b . s

Tm –the maximal torque required from the motor ;

belt -the effiency of the timing belt, belt = 0,96 ;
b. s - the effiency of the ball-screw, b. s = 0,985;
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n b.s. max – maximal speed of the screw, n b.s. max = V x max / Lb.s ;
Lb.s - lead of the ball-screw , Lb.s = 10 mm;
nmax= 12 / 0,01 = 1200 rpm
l – distance of travel of moving component for one revolution of the motor

l = V x max / nmotor max

l = 36 / 1200 = 0.03 m

12,212 .0,03
Tm   61,69 Nm
2.3,14 .0,96 .0,985
c) Selection of motor ;

According to the maximal torque obtained Tm I select motor Fanuc 15MB control

d) Calculation of the over loading time ;

Overloading time for the toughest mode is calculated - rough milling of a work piece
with maximum possible dimesions 600×600mm.
The tool and cutting parameters are taken from the Corokey catalogue as follows :

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Designation of the tool R290-063Q22-11M
Dc = 63mm – diameter of the mill
t =5 – number of teeth
ap = 10mm – depth of cut
fz = 0,25mm –feed per tooth

For the speed we obtain :

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s0 = fz .t = 0,25. 5 = 1,25 mm/rev – feed per revolution
Vc = 155 m/min – cutting speed

Nm=(1000.Vc)/  .Dc = (1000 . 155) / 3,14. 63 = 783,5rev/min

Milling will be performed on 8 passes.Time needed for one pass is :
tl= length / s0 .nm = 600 / 1,25. 783,5 = 0,6 min
The time for the whole operaion is:
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t = 8. t1 = 8. 0,6 = 4,8 min
As we can see the time for cutting is much smaller than the allowed 30 min, work in zone S3
so the motor will not be overloaded.

e) Selection of a ball-screw ;
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To select a ball-screw we have to fill in the following table, which shows the maximal
loads , speeds of the screw, and percentage time of the most common operations.

F ,kN n b.s. ,rpm time ,%

Rough milling 8,384 97,94 0,35

Finishing milling 3 39,18 0,55

Rapid traverse 2 1300 0,1

- rough milling

Dc = 63mm – diameter of the mill

t =5 – number of teeth
fz = 0,25mm –feed per tooth
s0 = fz .t = 0,25. 5 = 1,25 mm/rev – feed per revolution
Vc = 155 m/min – cutting speed
nm=(1000.Vc)/  .Dc = (1000 . 155) / 3,14. 63 = 783,5rev/min – speed of the motor

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n b.s. = nm.so/Lb.s= 783,5.1,25 / 10 = 97,94 rpm – speed of the ball screw

1,1
k
 50 
.z   = 824,60,95.0,250,8.5  
B
Frough = c.t x
.szy

z - number of teeth
sz - feed per tooth
B – cutting width
D – diameter of the tool
 Dc 

Where : c = 824 N is a coefficient

t – depth of cut
PL  63 
=5792 N
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Ft rough = Frough + µ.G + 2. µ f + 2.µ.N =5792 + 0,12.3.5+ 2.0,12.7,8+ 2.0,12.5792 = 7,184
kN
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- finishing milling

Dc = 63mm – diameter of the mill

t =5 – number of teeth
fz = 0,1mm –feed per tooth
s0 = fz .t = 0,1. 5 = 0,5 mm/rev – feed per revolution
Vc = 155 m/min – cutting speed
nm=(1000.Vc)/  .Dc = (1000 . 155) / 3,14. 63 = 783,5rev/min – speed of the motor
n b.s. = nm.so/Lb.s= 783,5.0,5 / 10 = 39,18 rpm – speed of the ball screw
1,1
k
 50 
.z   = 824,60,95.0,10,8.5  
x B
Ffinishing = c.t .szy =1452 N
 Dc   63 
 Ft finishing = Ffinishing + µ.G + 2. µ f + 2.µ.N = 1452+0,12.3.5++ 2.0,12.7,8+2.0,12.1452
= 2 kN

- rapid traverse ;

Frapid traverse = µ.G + 2. µ f = 0,12.3.5 + 2.0,12.7,8 = 2 kN

nrapid traverse=1300 rev/min

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The ball-screw is selected according to the mean load its carries , by calculation of the
mean cycle and the expected life.

Fm 

Fm =
3
 F .n .t
t

 n .t
Fm - the mean force

3
3

b.s
b.s

i
i

PL
7,184 .97 ,94 .0,35  3.39,18 .0,55  2.1300 .0,1
97 ,94 .0,35 .39,18 .0,55  1300 .0,1
= 5,07 kN
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nb.s mean = (  ni.ti)/ t i - the mean speed of the ball-screw

nb.s mean = 186 min-1

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The life in revolutions is L=Lhours.60. nb.s mean ,where :

Lhours is the desired life in hours , Lhours = 20000 hrs

L=20000.60.186= 223,2.106 revolutions

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 Ca  L 223,2.10 6
L=   . 106 , so Ca= 3 6 . Fm= 3 . 5,07.103 = 31042 N
 Fm  10 10 6

According to Ca we select thr following ball-screw :

model DFT4010-2.5 double but single flange tube type
 main characteristics :

- Lead :10 mm
- Screw shaft diameter : 40 mm
- Ball diameter : 6,35 mm
- Ball circle diameter :41 mm
- Root diameter : 34,4 mm
- Number of circuits : 2,5
- Stiffness 750 daN/ µm
The total length of the screw is lscrew = traverse+lnut+2c

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lnut is the length of the nut, lnut = 186 mm
c- reverse length , c= 35 mm

finally

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lnut =800+186+2.35 = 633 mm

- Screw length is : 1056 mm

f ) Check of the stiffness of the drive ;

This will give us the magnitude of the deformations,which occur when the drive is
loaded.
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C =   [N/µ],where C- stability, F-force ,  - deformation [µm]
F
 
SA

1 1 1 1
= + +
C C nut C screw Cbearing

Cnut = 750 N/ µm (we get this from the specification of the ball-screw)
Cbearing = 1900 N/ µm (we get this from the specification of the bearing)
4. Area.
Cscrew = , N/ µm
a.10 3

 - Young’s modulus ,  = 210 GPa

a - half of the length of the screw , a = 528 mm
 3,14 .0,0766 2
4.[ ]
Cscrew = 4 .2,1.1011= 7.327,8 N/ µm
3
528 .10

1 1 1 1 1
= + + =
C 750 7327 ,8 1900 1317 ,58

C = 1317,58 N/ µm

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g) Selection of a timing belt ;

nmax,motor =1500 rpm

nmax,screw = 1200 rpm

The transfer ratio is i = 1200 / 1500 = 4/5

Prated = 2,04 kW
Pd = Pr.(C1+C2+C3) , where
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Pd – the design power ,used for selection of timing belt ;
C1 – coefficient, depending on the working hours per day , C1=2,2 for 24 hrs/day
C2 – coefficient ,depending on the transfer ratio, C2 = 0,1 ;

Pd = 2,04.(2,2+0,1+0,2) = 5,1 kW
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For this power we select pitch class H

For pitch H and direver speed 1500 rpm we obtain :

min pitch dia 72,77 mm

flange O.D. 79 mm,
pulley code 18H

Considering the ratio is 1,25 we select pulleys :

 Smaller pulley : 32H Pitch dia.= 129,36 mm
Larger pulley : 40H Pitch dia.= 161,7 mm
Center distance : 495 mm

The belt code is 570H150

Specifications :

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Belt
570H150
Smaller pulley 32H150

h ) Motor torque chech ;

Larger pulley

PL 40H150
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Tmax = Ta + Tf

Tf – torque due to friction

Ta – torque due to acceleration
SA

Fr .tr .l 1500 .0,008

Tf = = = 1,711 Nm
2. . t .b . b.s 2.3,14 .0,96 .0,985

G l 2 10.10 3 0,008 2 2
Jw = .[ ] = .[ ] = 0,16081kgm
9,81 2. 9,81 2.3,14

Jw – moment of inertia of the load

Jm – moment of inertia of the motor
Jm=0,016 kgm2 (from the motor specifications)

Jp1 - moment of inertia of the pulley which is fixed to the shaft

Jp2 – moment of inertia of the second pulley
Jsc - moment inertia of the screw
Vsc – speed of the screw

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Jp1 = 7,85.pitch diagram4. Pulley width = 7,85.0,129364.0,044 = 0,000096721 kgm2 (32H)

Ta =
60

1500
1
ta

1
V
60
PL
Jp2 = 7,85.pitch diagram4. Pulley width = 7,85.0,16174.0,044 = 0,000236136 kgm2 (40H)
Jsc = 7,85.pitch diagram4. Pulley length = 7,85.0,3444.0,833 = 0,000009156 kgm2

Vm 1
.2. . (Jm+Jpl+Jw) + i. sc .2. . (Jp2 + Jsc) =
ta

.2 . (0,016+0,000096721+0,000744) + 0,8

1200 1
2. . (0,000009156 +
M
Ta =
60 0,1 60 0,1
0,000236136) = 26,69 Nm

Tmax = Ta + Tf = 26,69 + 2,1 = 28,79 Nm

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Tmax is lower than the maximal torque of the motor 10 MB , so the motor is suitable for our
purposes.Taking into account the long length of the screw in order to prevent excessive
deformations of the screw when its under load(bending,buckling,etc.) I choose to support its
bottom end with ball bearing of the type 6205-2RS with floating outer ring.It s a bearing of a
common type , capsulated and lubricated and requires no maintenance during its life time.