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Manufacturing Laboratories, Inc. Mikron Smart Machine Discussion.

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Presentation on theme: "Manufacturing Laboratories, Inc. Mikron Smart Machine Discussion."— Presentation transcript:

1 Manufacturing Laboratories, Inc. Mikron Smart Machine Discussion

2 Manufacturing Laboratories, Inc. MLIs Activities (Past and Current) Operating full-time since 1989 as a provider of high-performance machine technology specializing in machining vibrations. Previously designed and built special one-of-a-kind machine tools and accessories. Currently member of: NCMS (National Center for Manufacturing Systems), Ann Arbor, Mi NCDMM (National Center for Machining and Mfg.), Latrobe, PA AMRC (Advance Mfg. Research Center) Sheffield, U.K. Provides consulting on both machining and machine/spindle design. Develops/facilitates strategies and techniques for High Performance machining. Markets dynamic analysis and optimization products for the shop floor since 1996.

3 Manufacturing Laboratories, Inc. Whats MLI Goals In the field of high-performance machining create acceptance of the affect of dynamics (frequency behavior) in the cutting process. Provide equipment that measures dynamic influences on the machining process and allows customer to control and manipulate dynamic affects. Provide on-machine process monitoring and control equipment for dynamic effects.

4 Manufacturing Laboratories, Inc. MLIs Product Mix MetalMAX is our main product. A predictive analytical package to determine optimum dynamic operating conditions without machining and track this information for use in NC programming. Validation and diagnostic functionality delivered by Harmonizer® Harmonizer® separately marketed machine monitoring and control packages for detection and control of adverse vibrations.

5 Manufacturing Laboratories, Inc. MetalMAX: Whats Needed? Modal analysis kit specifically configured and designed for measurement of machine tools. Frequency/modal Analysis. Sensors. Well established cutting theory. All combined in user friendly software. Setup man or engineer with progressive attitude. (does not require a vibration expert). MLIs MetalMAX kit with computer.

6 Manufacturing Laboratories, Inc. A Typical Measurement Setup Schematic of Measurement Setup for Bump, Ping or Modal test EXCITATION (HAMMER) RESPONSE (ACCEL) Sensor Interface Module PC Accelerometer STRIKE Hammer Power Cable Sensor Cable Machine tool and Spindle *Can also measure work piece in a similar fashion and combine behavior with cutting tool measurement.

7 Manufacturing Laboratories, Inc. Stability Plot 20 mm 3-fluted Tool in 30 kW 24 krpm Spindle Process Damping Region Unstable Torque Limit Chatter Frequencies Stable

8 Manufacturing Laboratories, Inc. Purpose? Machine the Part the First Time… Air frame tray, unsupported tab approx. 50-mm high by 1.5-mm thick. Guessing?Knowing

9 Manufacturing Laboratories, Inc. Check Results Monitor cutting operation Determine if it is stable, chattering or resonating. Make fine adjustments if needed.

10 Manufacturing Laboratories, Inc. Record Results Record data for later comparison or analysis. Track behavior as function of cutting tool, machine, work piece. Provide means to inform NC programmers, tool room, etc. of dynamic limitations.

11 Manufacturing Laboratories, Inc. MetalMAX Provides Modal Analysis of cutter and work-piece. Prediction of stable depths of cut and spindle speeds. Refinement of process parameters for optimal dynamic cutting accuracy. Monitoring and adjustment (if needed) of cutting process. Recording of results in database for later use.

12 Manufacturing Laboratories, Inc. Vibration Monitoring Harmonizer utilizes Broad banded frequency analysis. Audio detection of machining vibration. Identification of chatter and suspected resonant conditions Deterministic process parameter (speed and feed) corrections to minimize vibration. Harmonizer implementations include: Handheld vibration monitor Most basic and lowest performing. Web Based Occasional use, as needed, requires TCP/IP connection. Can also implement web-based monitoring. General computer software Full functioning vibration analyzer with chatter control features. NC Integrated NC control linking with adaptive capacity.

13 Manufacturing Laboratories, Inc. Spectral Analysis with identified chatter frequencies Vibration signal Must know: Max. Allowable speed Spindle Speed Number of teeth Nothing else Technique Identifies Chatter Recommends new spindle speed. Detecting Chatter

14 Manufacturing Laboratories, Inc. Chatter Eliminated Can either increase cutting depths (a p or a e ) or feed rate. Eliminating Chatter

15 Manufacturing Laboratories, Inc. First Part Machined Correctly! 0.5 mm wall and floor thickness, 1 mm diameter pins, walls and pins 30 mm high.

16 Manufacturing Laboratories, Inc. Example: Increased Power and Increased Quality at lower speed Spindle Speed: 20,000 RPM Axial Depth of Cut 25 mm Radial width of cut 0.25 mm Cut Power 0.3 kW BAD SURFACE Aluminum > 475% increase in Power and MRR Spindle Speed: 16,580 RPM Axial Depth of Cut 25 mm Radial width of cut 1.8 mm Cut Power 1.75 kW GREAT SURFACE!!! Same behavior in other materials

17 Manufacturing Laboratories, Inc. Possible Inclusion of Harmonizer® into Mikron Smart Machine APS Non-intrusive additional sensor (microphone), audio (displacement) detection. Can utilize current vibration sensor(s), accelerometer, etc. Provides broad banded frequency analysis of cutting condition. Detects the presence of chatter and resonance. Besides enhancing APSs machining monitoring/warning/diagnostic capabilities, Harmonizer can also provide deterministic process parameter corrections.

18 Manufacturing Laboratories, Inc. Areas for Cooperative Work Add Harmonizer technology to Mikron APS Product High Frequency Chatter and Resonant Detection. On machine suggested speed and feed corrections. Part try-out corrections (controller linkage). Automated tool testing and optimization (control links with NC programs). Application Engineering and Field Service Support with MetalMAX product. Train and equip field service with dynamic solution package. Added diagnostic and service capabilities. Product representation through Mikron Distributors/sales offices. Help setup as part of a services division the capability to deliver dynamic analysis services. Provide support resources for MLI sales.

19 Manufacturing Laboratories, Inc. Packages for Machining Vibration Prediction and Control Machining simulations Prediction and Monitoring of the Cutting Process Machining Vibration Solutions DrillSim* Recording and tracking information for use by NC Programmers

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