• Title/Summary/Keyword: Machine Tool Spindle System

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Tool Wear Monitoring System in CNC End Milling using Hybrid Approach to Cutting Force Regulation (하이브리드 방식의 절삭력 평준화를 통한 CNC 엔드 밀링에서의 공구 마모 모니터링 시스템)

  • Lee, Kang-Jae;Yang, Min-Yang
    • Journal of the Korean Society of Manufacturing Process Engineers
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    • v.3 no.4
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    • pp.20-29
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    • 2004
  • A Tool wear monitoring system is indispensable for better machining productivity with guarantee of machining safety by informing the tool changing time in automated and unmanned CNC machining. Different from monitoring using other signals, the monitoring of spindle current has been used without requiring additional sensors on machine tools. For the reliable tool wear monitoring, current signal only of tool wear should be extracted from other parameters to avoid exhaustive analyses on signals in which all parameters are fused. In this paper, influences of force components of parameters on measured spindle current are investigated and a hybrid approach to cutting force regulation is employed for tool wear signal extraction in the spindle current. Finally, wear levels are verified with experimental results by means of real-time feedrate aspects changed to regulate the force component of tool wear.

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Digital Controller Design of a Magnetic Bearing System for High Speed Milling Spindle (고속 밀링 주축용 자기베어링 시스템의 디지털 제어기 설계)

  • 노승국;경진호;박종권
    • Proceedings of the Korean Society of Machine Tool Engineers Conference
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    • 2004.04a
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    • pp.398-403
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    • 2004
  • The demand of high speed machining is increasing because the high speed cutting providers high efficiency of process, short process time, improved metal removal capacity and better surface finish. Active magnetic bearings allow much high surface speed than conventional ball bearings and therefore greatly suitable for high speed cutting. The automatic control concept of magnetic bearing system provides ability of intelligent control of spindle system to increase accuracy and flexibility by means of adaptive vibration control. This paper describes a design and development of a milling spindle system which includes built-in motor with power 5.5㎾ and maximum speed 70,000rpm, HSK-32C tool holer and active magnetic bearing system. Magnetic actuators are designed for satisfying static load condition. The Performances of manufactured spindle system was examined for its static and dynamic stiffness, load capacity, and rotational accuracy. This spindle was run up to 70,000 rpm stably, which is 3.5 million DmN.

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A Study on the Thermal Behaviro of Machine Tool Spindle System (공작기계 주축계 열적거동에 관한 연구)

  • 김종관
    • Journal of the Korean Society of Manufacturing Technology Engineers
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    • v.8 no.1
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    • pp.28-34
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    • 1999
  • According to the development of tool material and the improvement of machinability of cutting material like aluminium alloy, the higher spindle speed is needed. However, the higher speed causes the heat generation of bearings, the deformation of spindle unit parts, and the rotational accuracy of spindle to be worse. Therefore, it is essential to analyze and control the heat generation and the thermal behavior of spindle unit in order to have higher speed and better rotational accuracy. This paper shows the analogy between the analyzation of heat generation and thermal behavior of high speed spindle system by finite element method and the test results of actual temperature rise through running test, and shows the necessity of cooling the spindle and inner ring side of bearings for the thermal balance of high speed spindle system.

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Cutting process monitoring system development for E-manufacturing (E-manufacturing을 위한 가공공정 모니터링 시스템 개발)

  • 신봉철;윤길상;최진화;김동우;조명우
    • Proceedings of the Korean Society of Machine Tool Engineers Conference
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    • 2003.10a
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    • pp.30-35
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    • 2003
  • Recently, with the rapid growth of information technology, many studies have been performed to implement web-based manufacturing system. Such technologies are expected to meet the need of many manufacturing industries those want to adopt E-manufacturing system for the construction of globalization, agility, digitalization to cope with the rapid changing market requirements. In this research, areal-time web-based machine tool and machining process monitoring system is developed as a first step fur implementing I-manufacturing system. In this system, main spindle motor current and feed current are measured using hall sensors. And the relationship between the cutting force and the spindle motor RMS current at various spindle rotational speed is obtained. Also, a rule-based expert system is developed in order to monitor the machining process effectively. Finally, developed system is applied to real machining process to verify the effectiveness.

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A Study on Cutting Force Measurement Using a Cylindrical Capacitive Spindle Sensor (주축 변위 센서를 이용한 절삭력 측정에 관한 연구)

  • 김일해;장동영;한동철
    • Transactions of the Korean Society of Machine Tool Engineers
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    • v.11 no.2
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    • pp.17-23
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    • 2002
  • A cylindrical capacitance-type spindle displacement sensor was developed and its effectiveness as a system to monitor cutting forces during hard turning was tested in this research. The sensor was installed between the face of spindle cover and the chucking element and measured pure radial motion of the spindle under the condition with presence of roundness error at measured surface. To prove the effectiveness of the developed system hard aiming tests using ceramic inserts and tool steel as workpiece were conducted. The workpiece was hardened up to 65 Rc. The variations of pure radial motion of the spindle ware measured during the cutting tests. The signals from the sensor showed the same pattern of cutting force variations from the tool dynamometer due to the progress of tool wear. As the flank wear of the ceramic tool increased both static component of cutting forces and the amount of center shift of spindle orbit increased, Results from the research showed that the developed sensor could be utilized as an effective and cheap on-line sensing device to monitor cutting conditions and tool performance in the un-manned machining center.

Prediction of Machine Tool's Energy Consumption during the Cutting Process (공작기계의 절삭공정 소비 에너지 예측기술)

  • Lee, Chan-Hong;Hwang, Jooho;Heo, Segon
    • Journal of the Korean Society for Precision Engineering
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    • v.32 no.4
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    • pp.329-337
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    • 2015
  • In this paper, a simulation based estimation method of energy consumption of the spindle and feed drives for the NC machine tool during the cutting process is proposed. To predict energy consumption of the feed drive system, position, velocity, acceleration and jerk of the table are analyzed based on NC data and then the power and energy are calculated considering friction force and mass of the stages. Energy consumption of the spindle is estimated based on models from acceleration motion of rotating parts, friction torque and power loss of motors. Moreover, simulation models of cutting power and energy for the material removal along the NC tool paths are proposed.

Development of a tool to automate finite element analysis of a spindle system of machine tools (공작기계 주축 시스템의 유한요소해석 자동화를 위한 툴 개발)

  • Choi, Jin-Woo
    • Journal of the Korea Academia-Industrial cooperation Society
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    • v.16 no.4
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    • pp.2350-2355
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    • 2015
  • A tool was developed in this research for automation of one-dimensional finite element analysis (1D FEA) for design of a machine tool spindle system composed mainly of a shaft and bearings. As it is based on object-oriented programing, it uses the objects of a CAD system. It requires minimum data to be input to define the spindle system such as shaft cross-sections and bearing stiffness. Then, it automatically generates the geometric model based on the data and then, converts it into the FE model of 1D beams and springs. The graphic user interfaces developed allow a user to interact with the tool. This tool can be applied to identification of a near optimal design of the spindle system in minimum time and efforts by automating the FEA process with numerous design changes.

Analysis of Dynamic Characteristics of A High-speed Milling Spindle Due to Support Stiffness of Drawbar (고속주축의 드로우바 지지조건에 따른 동특성 해석)

  • 노승국;박종권;경진호
    • Proceedings of the Korean Society of Machine Tool Engineers Conference
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    • 2003.04a
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    • pp.484-487
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    • 2003
  • In designing AMBs (active magnetic bearings) for high-speed spindle system, the shaft is usually assumed as a rigid rotor. For automatic tool change process, there should be a tool clamping system with drawbar using spring or hydraulic force, and the drawbar in the spindle can be in various condition of support during design and manufacturing error. In this paper, the modal characteristics of drawbar in high-speed milling spindle system due to supporting stiffness between drawbar and shaft are analyzed by numerical method. The result shows enough stiff supports must be provided between shaft and drawbar to prevent occurring drawbar vibration lower than the natural frequency of 1$\^$st/ bending mode of spindle.

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Design of Special-purpose Machine Tool Based on a Multi-spindle Head (다축 스핀들 헤드 기반의 전용 공작기계 설계)

  • Maeng, Heeyoung;Park, Juwook;Park, Hongkeun
    • Journal of the Korean Society of Manufacturing Technology Engineers
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    • v.24 no.6
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    • pp.675-681
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    • 2015
  • When many holes on a plane are machined simultaneously, the positional precision and machining efficiency are very important. Multi-spindle heads are typical order making products of which the number of shafts and hole positions vary depending on the size or form of the product. For the automatic design of multi-spindle heads, the design modules for power transmission systems for drive, idle, and spindle shafts were developed, and a design technique the determining the optimum position and number of idle shafts according to gear positions was developed. In addition, for the precise determination of the multi-spindle head, the design methods for the guide planes of columns, and feed mechanisms were devised. In addition, the design modules for accurate clamping and automatic transportation mechanisms were developed. Finally, in order to simplify and standardize the design process, the design analysis and simulation verification modules are integrated.

An Unmanned Turning Process Technique Based on Spindle Motor Power Characteristics (주축 모터 출력 특성에 근거한 무인 선삭 가공 기술)

  • 박장호;허건수
    • Proceedings of the Korean Society of Machine Tool Engineers Conference
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    • 2001.10a
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    • pp.8-13
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    • 2001
  • In the turning process, the feed is usually selected by a machining operator considering workpiece, cutting tool and depth of cut. Even if this selection can avoid power saturation or tool breakage, it is usually conservative compared to the capacity of the machine tools and can reduce the productivity significantly. This paper proposes a selection method of the feed and the reference cutting force based on MRR(material removal rate), maximum spindle power and specific energy. In order to estimate and control cutting force accurately in transient and steady state, this study utilizes a synthesized cutting force estimation method and a Fuzzy controller. The experimental results present that these systems can be useful for the FMS(flexible manufacturing system) and unmanned automation system.

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