6th Edition
Chapter 25:
Machining Centers, Machine Tool
Structures and Machining Economics
Copyright 2010 Pearson Education South Asia Pte Ltd
Chapter Outline
Introduction
Machining Centers
Machine-tool Structures
Vibration and Chatter in Machining Operations
High-speed Machining
Hard Machining
Ultraprecision Machining
Machining Economics
Introduction
Machining Centers
1.
2.
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 Centers
Machining Centers
Components of a Machining Center
Machining Centers
Components of a Machining Center
Machining Centers:
Types of Machining Centers
Vertical-spindle Machining Centers
Machining Centers:
Characteristics and Capabilities of Machining
Centers
1.
2.
3.
4.
5.
6.
Machining Centers:
Selection of Machining Centers
1.
2.
3.
4.
Machining Centers:
Selection of Machining Centers
EXAMPLE 25.1
Machining Outer Bearing Races on a Turning Center
Machining Centers:
Reconfigurable Machines and
Systems
Machining Centers:
Reconfigurable Machines and
Systems
Machine-tool Structures:
Materials
1.
2.
3.
4.
5.
6.
Machine-tool Structures:
Machine-tool Design Considerations
1.
2.
3.
4.
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
Machine-tool Structures:
Machine-tool Design Considerations
Assembly Techniques for Machine-tool Components
Machine-tool Structures:
Machine-tool Design Considerations
Linear Motor Drives
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
Copyright 2010 Pearson Education South Asia Pte Ltd
Machine-tool Structures:
Hexapod Machines
1.
2.
3.
1.
2.
3.
4.
5.
Dynamic stiffness is defined as the ratio of the appliedforce amplitude to the vibration amplitude
Basic guidelines:
1.
Minimize tool overhang
2.
Improve the stiffness of work-holding devices and
support workpieces
3.
Modify tool and cutter geometry to minimize forces or
make them uniform
4.
Change process parameters
5.
Increase stiffness of the machine tool and its
components
6.
Improve the damping capacity of the machine tool
Copyright 2010 Pearson Education South Asia Pte Ltd
High-speed Machining
High-speed Machining
1.
2.
3.
4.
5.
6.
7.
Machine-tool characteristics:
Spindle design for stiffness, accuracy, and balance at
very high rotational speeds
Bearing characteristics
Inertia of the machine-tool components
Fast feed drives
Selection of appropriate cutting tools
Processing parameters and their computer control
Work-holding devices that can withstand high
centrifugal forces
Copyright 2010 Pearson Education South Asia Pte Ltd
Hard Machining
Ultraprecision Machining
Ultraprecision Machining
General Considerations for Precision Machining
Machining Economics
1.
2.
3.
1.
2.
3.
4.
5.
6.
Machining Economics
Minimizing Machining Cost per Piece
Machining Economics
Minimizing Machining Cost per Piece
1
Tc Lm Bm Di 1 Ti Lm Bm
N
N
Tc
T
i
Ni N f
Copyright 2010 Pearson Education South Asia Pte Ltd
Machining Economics
Minimizing Machining Cost per Piece
fN
fV
C
1/ m
T
The number of pieces per insert face is N f
Tm
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Number of pieces per insert is given by N i mN f
Tm
Machining Economics
Minimizing Machining Cost per Piece
mfC 1/ m
LDV (1/ n ) 1
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n
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1
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L
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i
i
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m
n m
Machining Economics
Minimizing Machining Cost per Piece
1
Tc Lm Bm Di Ti Lm Bm
m
Lm Bm
Machining Economics
Minimizing Machining Cost per Piece
C
1
n 1
Tc
Ti
1 Tc
1
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n m
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