Competitive Advantage of Dry Machining

Transcription

1 Competitive Advantage of Dry Machining

2 Dry machining system components dry machining machine minimum lubrication system tooling workpiece

3 Competitive advantage of dry machining Dry machining motivation Dry machining potential Tool system requirement Machine system requirement Conclusion

4 Motivation - total manufacturing costs cooling lubrication costs 16% remaining costs 80% tools 4% Quelle: Statistisches Bundesamt 1993

5 Motivation - cooling lubrication costs installations 40% other 7% energy 7% personnel 10% Cooling lubricant 14% disposal 22% Quelle: Statistisches Bundesamt 1993

6 Motivation - non-process-related effects Workpiece cleaning unnecessary Anti-corrosive effect Ecological compatibility Dermatological / toxic contamination eliminated Greater machine availiability due to absence of cooling lubricant periphery Greater machine availability due to chemical compatibility and sealing Quelle (Foto): Heidelberg Manufacturing

7 Potential - tool life machining cast L wet L wet opt. L dry Standard tools Spindle speed 6,000rpm Standard tools Dry machining tools Synchronous spindle Spindle speed 8,000rpm Dry machining tools Standard tools Synchronous spindle Spindle speed 8,000rpm Quelle: Heidelberg Manufacturing

8 tool life L[%] Potential - tool life machining steel L wet L wet opt. L dry standard tools synchronous spindle spindle speed 10,000rpm standard tools dry machining tools synchronous spindle spindle speed 10,000rpm dry machining tools standard tools synchronous spindle spindle speed 10,000rpm Quelle: Heidelberg Manufacturing performance increase from w et to dry machining drilling ream ing tapping L, w et L, w et opt. L, dry

9 torque T [%] feed force F [%] torque T [%] feed force F [%] Potential - reduced machining force Twist drill D = 6.8 mm HM non-coated Three lipped core drill Whistle notch Machining position Horizontal Tool taper SK 40 Cutting force measurement 4-component platform Material GGG 40 Cooling lubricant Emulsion 8% Quelle: Heidelberg Manufacturing drill new wet 20 dry cutting speed Vc [m/min] drill VB = 0.2 mm wet 20 dry cutting speed Vc [m/min] drill new wet 80 dry cutting speed Vc [m/min] drill VB = 0.2 mm wet 80 dry cutting speed Vc [m/min]

10 Potential - High Performance Cutting Parameters in GG 20 - GGG 40 Milling Tapping Reaming Drilling Vc = 1000 m/min f = 2000 mm/min Vc = 65 m/min Vc = 600 m/min f = 0.8 mm/u Vc = 300 m/min f = 0.6 mm/u Quelle: Heidelberg Manufacturing comparison HPC-w orkpiece casting milling tapping ream ing drilling tool life L [%] HPC dry w et opt. w et

11 Tool system requirement Optimised substrate Optimised cutting angle Large chip area Channel guide for inner feed to chip area Up to 80% of wet machining tools are unsuited for dry machining Quelle (Foto): Heidelberg Manufacturing

12 Machine system requirement - Concept 2000 Optimal chip clearance Smooth cabin walls without horizontal surfaces Steep surfaces in machine bed Central chip ejection Rinse connection built into cabin wall

13 Machine system requirement - Concept 2000 Fully enclosed machine working area, integrated head cover Dirt accumulation room cordoned off by concertina wall No detrimental affect to service area due to lubricant or swarf Integrated cover for guides and ball screw No shock loading from telescopic cover

14 Machine system requirement ML-System Dry machining with very fine oilair aerosol Aerosol feed internal and / or external via jet nozzles on tool grip Mix can be programmed with M-function Mix preparation in booster, brief reaction time Process stability up to 20,000rpm Wet and dry machining on one machine without change-over

15 Conclusion Chiron is your partner for High Speed Manufacturing Dry machining compatible machines - Concept 2000 Optimal minimum lubrication system, process reliable up to high speeds Competent tool development Parallel wet and dry machining without change-over Transitional changeover to dry machining possible HPC benefits are ensured by short ancillary time