Copyright 2007 Society of Manufacturing Engineers. MANUFACTURING INSIGHTS High Speed Machining NARRATION (VO): NARRATION (VO): INCREASE THROUGHPUT,

Transcription

1 MANUFACTURING INSIGHTS High Speed Machining SCENE 1. HSM12A, tape 06, 06:04:08-06:04:38 zoom in, high speed machining THE TERM HIGH SPEED MACHINING, OR 'HSM', HAS BEEN IN THE LEXICON OF MANUFACTURING TERMS FOR A LONG PERIOD OF TIME, BUT THE PROCESS HAS ONLY GAINED IN ACCEPTANCE IN RECENT YEARS. SCENE 2. HSM13A, tape 14, 17:21:27-17:21:50 zoom in, high speed machining HSM13B, CGS: Reduce Cycle Times Increase Throughput Shorten Machining Time Minimize Non-Machining Time HSM13C, tape 11, 13:03:14-13:03:23 zoom out, parts produced using high speed machining THIS INCREASING RECOGNITION IS DUE TO HIGH SPEED MACHINING S SYNTHESIS OF TECHNOLOGICAL ADVANCES THAT, WHEN COMBINED, ALLOW MANUFACTURERS TO REDUCE CYCLE TIMES, INCREASE THROUGHPUT, SHORTEN MACHINING TIME, AND MINIMIZE NON-MACHINING TIME WHILE YIELDING HIGH PRECISION PARTS HAVING A FAVORABLE COST/PERFORMANCE RATIO. SCENE 3. HSM14A, tape 15, 18:02:00-18:02:15 HSM14B, tape 10, 11:32:39-11:33:00 fast high speed machining TYPICALLY, HIGH-SPEED MACHINING IS ACCOMPLISHED USING SPINDLE SPEEDS THAT RANGE BETWEEN 12,000 TO 30,000 RPM AND HIGHER. THESE SPINDLE SPEEDS ARE COUPLED WITH RAPID AXIS MOVEMENTS, TRANSVERSE RATES, ACCELERATIONS, AND DECELERATIONS TO MAXIMIZE MATERIAL REMOVAL. GENERALLY, HIGH SPEED MACHINING IS PERFORMED USING A SHALLOW AXIAL DEPTH OF CUT IN ORDER TO ACHIEVE GOOD SURFACE FINISH WHILE

2 AVOIDING DAMAGE TO THE WORKPIECE, CUTTING TOOL, OR SPINDLE. SCENE 4. HSM15A, tape 02, 02:25:22-02:25:44 BUT HIGH SPEED MACHINING IS MUCH MORE THAN SIMPLY RUNNING A CUTTING TOOL AT MAXIMUM FEED RATES AND TAKING MULTIPLE SHALLOW CUTS. IN FACT, THIS APPROACH TO MACHINING CAN BE LESS EFFICIENT THAN TAKING FEWER PASSES HAVING SOMEWHAT GREATER DEPTHS. SCENE 5. HSM16A, tape 10, 11:18:19-11:18:31 zoom out, worker removing part from high speed machine HSM16B, tape 14, 17:19:52-17:20:21 HSM16C, CGS: Machining Center Tooling Programming/Software THE ULTIMATE GOAL OF HIGH SPEED MACHINING IS TO PRODUCE A FINISHED PART IN THE LEAST AMOUNT OF TIME. THIS IS ACCOMPLISHED BY REDUCING INEFFICIENCIES IN THE CUTTING PROCESS, BY MAXIMIZING THE RELATIONSHIP BETWEEN SPEEDS, FEEDS, AND DEPTH OF CUTS AND BY COMPLETELY INTEGRATING THE VARIOUS TECHNOLOGIES THAT ENCOMPASS THE HIGH SPEED MACHINING CENTER, IT S TOOLING, AND THE PROGRAMMING AND SOFTWARE. --- TOUCH BLACK --- SCENE 6. HSM17A, CGS: Machining Center HSM17B, tape 14, 17:27:53-17:28:09 pan, high speed machines THERE ARE A VARIETY OF ADVANCED HIGH SPEED MACHINING CENTERS AVAILABLE. THE BEST ARE CHARACTERIZED BY A COMPACT, RIGID, AND ROBUST DESIGN. SCENE 7. continue previous shot

3 HSM18A, tape 06, 06:04:55-06:05:05 HSM18B, tape 14, 17:18:52-17:19:03 zoom out, dry machining HSM18C, tape 10, 11:58:14-11:58:25 tool storage, tools indexing HSM18D, tape 02, 02:02:18-02:02:35 zoom out, parts on fixtures, indexing HSM18E, tape 10, 11:45:30-11:45:55 part/fixture moving into machine THEY SHOULD BE POWERFUL, PROVIDE EXTREMELY HIGH SPINDLE SPEEDS AND ACCELERATION..., BE EQUIPPED FOR NEAR OR COMPLETELY DRY MACHINING..., OFFER OPTIONS SUCH AS ADDITIONAL TOOL STORAGE AND TOOL MONITORING..., SUPPLEMENTARY PART FIXTURING..., AND FAST PART DELIVERY AND REMOVAL. SCENE 8. HSM19A, tape 02, 02:21:05-02:21:25 zoom in, controller to machining process THE MACHINE CONTROL SYSTEM SHOULD BE FAST, RESPONSIVE AND FLEXIBLE. IT SHOULD HAVE INTERPOLATION CAPABILITIES, SUB-PROGRAMS FOR COMPLEX PART MACHINING, AND THE ABILITY TO TOTALLY INTEGRATE WITH OTHER IN-HOUSE SYSTEMS. SCENE 9. HSM20A, tape 14, 17:08:53-17:09:15 c.u., zoom out, spindle turning tool, machining part DIRECT CONNECTION OF THE MOTOR TO THE SPINDLE IS PREFERRED OVER THE USE OF BELTS AND GEAR DRIVE TRAINS. BECAUSE THESE INTEGRAL SPINDLES ARE COUPLED DIRECTLY TO THE MOTORS, THEY CAN ACCELERATE AND DECELERATE FASTER THAN THE DRIVE TRAIN SYSTEMS. SCENE 10. HSM21A, CGS: Tooling HSM21B, tape 06, 07:11:24-07:11:37 high speed machining emphasizing tooling HIGH SPEED TOOLING MUST BE ABLE TO WITHSTAND THE INCREASED SPINDLE SPEEDS, FEED RATES AND HEAT BUILD-UP IN THE PROCESS.

4 SCENE 11. HSM22A, CGS: Hollow Shank Taper/HSK HSM22B, tape 02, 02:04:38-02:04:48 zoom in, hsk tool holder HSM22C, tape 14, 17:31:54-17:32:20 zoom in, high speed machining using hsk tool holder HOLLOW SHANK TAPER OR HSK TOOL HOLDERS WERE DEVELOPED FOR HIGH SPEED OPERATIONS AND ARE PREFERRED OVER CONVENTIONAL CAT V-FLANGE OR STEEP SHANK TOOL HOLDERS IN MANY APPLICATIONS. SCENE 12. HSM23A, tape 14, 17:02:46-17:03:29 using hsk tool holder HSM23B, CGS: High Torque Transmission High Repeatability Accuracy Excellent Adaptation to High Speed Cutting Uniformity Minimal Runout High Clamping Force Reliability & Safety Static & Dynamic Stiffness HOLLOW SHANK TAPER TOOL HOLDERS OFFER THE ADVANTAGES OF: HIGH TORQUE TRANSMISSION, HIGH REPEATABILITY ACCURACY, EXCELLENT ADAPTATION TO HIGH SPEED CUTTING, UNIFORMITY, MINIMAL RUNOUT, HIGH CLAMPING FORCE, RELIABILITY AND SAFETY, AND STATIC AND DYNAMIC STIFFNESS. SCENE 13. HSM24A, tape 03, 03:19:55-03:20:06 zoom out, cutting tool clamped into tool holder HSM24B, tape 11, 13:34:34-13:34:50 thermal clamped cutting tool placed into tool holder HSM24C, CGS: Mechanical Hydraulic Thermal HOW CUTTING TOOLS ARE CLAMPED INTO THE TOOL HOLDERS IS ALSO VERY IMPORTANT. THE THREE PRIMARY CUTTING TOOL CLAMPING SYSTEMS USED FOR HIGH SPEED MACHINING ARE: MECHANICAL, HYDRAULIC, AND THERMAL. SCENE 14. HSM25A, tape 05, 05:52:50-05:53:10 high speed machining HSM25B, tape 06, 07:05:50-07:05:59 zoom out, cutting tool with ceramic inserts THE SUCCESS OF ANY CUTTING OPERATION IS DETERMINED BY WHAT HAPPENS AT THE POINT OF

5 HSM25C, tape 06, 07:10:13-07:10:32 zoom out, cutting tools CONTACT BETWEEN WORKPIECE AND CUTTING TOOL. THERE ARE A VARIETY OF CUTTING TOOL MATERIALS, BOTH COATED AND UNCOATED, AND CUTTING TOOL GEOMETRIES USED THAT OFFER BETTER-THAN-AVERAGE TOUGHNESS AND GOOD HEAT RESISTANCE FOR HIGH SPEED OPERATIONS. SCENE 15. HSM26A, CGS: Programming/Software HSM26B, tape 681, 08:09:22-08:09:50 use of conventional machining software AN INITIAL PITFALL COMPANIES FACE WHEN FIRST USING HIGH SPEED MACHINING IS ATTEMPTING TO RE-USE CONVENTIONAL PROGRAMMING AND SOFTWARE. SCENE 16. HSM27A, tape 01, 01:45:26-01:45:50 zoom out, esprit software being used HSM27B, outgoing music, up and under USING SOFTWARE INTENDED SPECIFICALLY FOR HIGH SPEED MACHINING OPERATIONS WILL YIELD SUPERIOR QUALITY AND CONSISTENT, OPTIMIZED RESULTS. SCENE 17. continue music HSM28A, tape 14, 17:01:18-17:01:32 worker using controller ALSO, EXTENSIVE TRAINING IS ESSENTIAL FOR ALL EMPLOYEES INVOLVED, SO THAT THEY BECOME COMFORTABLE WORKING WITHIN THE PARAMETERS OF HIGH SPEED MACHINING. --- TOUCH BLACK ---