6 machining iiex2

8/11/2019 6 Machining IIEx2

1/31

1

Machining Part 2

New Developments 5 Axis

Diamond

Cryogenic

Environmental Issues


2/31

2

New Developments

New Configurations

5 Axis machines

Diamond turning Micro Machines

Hexapods

Fast Tool Servo

Cryogenic Machining/Gas PhaseLubricants


3/31

3

5 Axis Machining

David Kim


4/31

4

5 axis machining demos

http://www.youtube.com/watch?v=yU_RHiHudag&feature=related

http://www.youtube.com/watch?v=0u

2xC60-oMI&NR=1
http://www.youtube.com/watch?v=yU_RHiHudag&feature=relatedhttp://www.youtube.com/watch?v=yU_RHiHudag&feature=relatedhttp://www.youtube.com/watch?v=0u2xC60-oMI&NR=1http://www.youtube.com/watch?v=0u2xC60-oMI&NR=1http://www.youtube.com/watch?v=0u2xC60-oMI&NR=1http://www.youtube.com/watch?v=0u2xC60-oMI&NR=1http://www.youtube.com/watch?v=0u2xC60-oMI&NR=1http://www.youtube.com/watch?v=0u2xC60-oMI&NR=1http://www.youtube.com/watch?v=yU_RHiHudag&feature=relatedhttp://www.youtube.com/watch?v=yU_RHiHudag&feature=related


5/31

5

Diamond Turning

Optical surfaces (400-700nm) surface finish ~1nm, temp control0.01F

Bob Donaldson ?LLNL


6/31

6

Diamond Turning

Empire Precision

Davies et al


7/31

7

Micro machining

Diamond turning& micro-milling


8/31

8

Micro machining


9/31

9

Micro Machines & Factories

Micro machines

Micro Factory developed at Mech Eng Lab AIST Japan


10/31

10MS Thesis Thilo Grove Part available on Alibaba


11/31

11

Hexapod Milling Machines

Tool

Linear actuator

StewartPlatform

*

* Source: http://macea.snu.ac.kr/eclipse/background/background.html

Hexapod machining center(Ingersoll, USA)

Schematics
http://macea.snu.ac.kr/eclipse/background/background.htmlhttp://macea.snu.ac.kr/eclipse/background/background.html


12/31

12

Institut fr Werkzeugmaschinen und FertigungHexaglide from Zurich (ETH)

www.iwf.mavt.ethz.ch/
http://www.iwf.mavt.ethz.ch/http://www.iwf.mavt.ethz.ch/


13/31

13

Rotary Fast Tool Servo Machine for Eyeglass Lenses

D. Trumper & students


14/31


15/31

15

Asymmetric Turning Operation

Spectacle lenses Contact lenses

Human lens implants

Elements for laser vision

correction surgery

Camera lenses

Image train elements in

semiconductor processing

Camshafts

Not-round pistons


16/31

16

Fast Tool Servo State of the Art

x Asint

&&x A2 sint

F m&&x Lu/Trumper

Bandwidth 23 kHz

Stroke 30 m

RMS tracking error:1.7 nm

Peak acceleration:500g


17/31

17

Diamond Turning Machine Cross Section


18/31

18

Satisloh

http://www.satisloh.com/usa-canada/ophthalmic/generating/vft-orbit/
http://www.satisloh.com/usa-canada/ophthalmic/generating/vft-orbit/http://www.satisloh.com/usa-canada/ophthalmic/generating/vft-orbit/http://www.satisloh.com/usa-canada/ophthalmic/generating/vft-orbit/http://www.satisloh.com/usa-canada/ophthalmic/generating/vft-orbit/http://www.satisloh.com/usa-canada/ophthalmic/generating/vft-orbit/http://www.satisloh.com/usa-canada/ophthalmic/generating/vft-orbit/


19/31

19

Cryogenic Machininghttp://www.youtube.com/watch?v=GFOXbb7P2jc
http://www.youtube.com/watch?v=GFOXbb7P2jchttp://www.youtube.com/watch?v=GFOXbb7P2jc


20/31

2020

Cryogenic Cutting Tools

CYCLO CUT BrandCryogen to the cutting edgeSolid carbide end mills

and drills

Index end mills,

face mills, turning

and boring tools

CHIP

FLOW

MAGCryogenic

Vented,

Heat-sink

application

-321F


21/31

2121

Cryogenic Cutting Tools

CYCLO CUT BrandCryogen to the cutting edge

Solid carbide end mills

and drills

Index end mills,

face mills, turning

and boring tools

CHIP

FLOW

LN2through tool77K (-321F)$0.06/liter

Claims:30% - 50% higher feed rate(up to 2X)60% tool lifeNo cleaning of part

Easy disposal


22/31

22

Cutting Fluids

Issues: bacteria, recycling, effectiveness

Skerlos


23/31

23

Environmental issues Energy/Carbon

Machine, material (embodied energy),

building, temperature controlledenvironment, electric grid

Metal Working Fluids (MWF)

Recycling/Waste


24/31

24

Material Used

Material Removed

Materials

Machining

Factory Building

Recycled

Electric Grid

Elements of Energy/Carbon

Analysis

recycled

Mixing

Value

$


25/31

25

Ashby 2009


26/31

26


27/31

27

Electricity Breakdown

Constant start-up operations (idle)Run-time operations (positioning, loading, etc)

Material removal operations (in cut)

Electricity Requirements

Constant start-up operations (idle)

Run-time operations (positioning, loading, etc)


Machine Use Scenario

Arbitrary Number of work hours

Machine uptime

Machine hours (idle, positioning, or in cut)

Percentage of machine hours spent idle

Machine hours spent idle

Active machine hours per 1000 work hours

Machining Scenario

Percentage of machine hours spent positioning

Machine hours spent positioning

Percentage of machine hours spent in cut

Machine hours spent in cut

Electricity Use per 1000 work hours


Run-time operations (positioning, loading, etc)Material removal operations (in cut)

Total electricity use per 1000 work hours

Electricity Used per Material Removed

Material Machined

Material Removal Rate 20.0 cm3/sec 4.7 cm

3/sec 5.0 cm

3/sec 1.2 cm

3/sec

Material removed per 1000 work hours 40824000 cm3

9593640 cm3

4212000 cm3

1010880 cm3

Electricity used/Material removed 14.2 kJ/cm3

60 kJ/cm3

2.3 kJ/cm3

10 kJ/cm3

kWh

35%

315 hours

351 hours

40%

13.2%20.2%

65.8%

1.2

Aluminum Steel Aluminum Steel

160996 kWh 2744 kWh

6237 kWh

kWh

673 kWh10335471 kWh

1038 kWh149288

567 hours 234 hours

70%

243 hours

60%30%

810 hours 585 hours

90 hours

10%

900 hours900 hours

90% 90%

1000 hours 1000 hours

22 kW 5.8 kW

kW

1.8

166 kW

6.8 kW kW

11.3%

3.5%

Production Machining Center (2000)

85.2%

Automated Milling Machine (1998)

Electricity used in Machining-1


28/31

28

5.0 cm3/sec 1.2 cm

3/sec 1.5 cm

3/sec 0.35 cm

3/sec

4212000 cm3

1010880 cm3

510300 cm3

119070 cm3

4.7 kJ/cm3

20 kJ/cm3

4.9 kJ/cm3

21 kJ/cm3

Aluminum Steel

100

Aluminum Steel

kWh

5553 kWh 700 kWh

702 kWh

6003033 kWh kWh

1818 kWh 0 kWh

30%

234 hours 94.5 hours

40%

70%

351 hours 221 hours

60%

585 hours

585 hours 315 hours

315 hours

900 hours

35% 65%

900 hours

1000 hours

90% 90%

1000 hours

6.0 kW

3.4 kW

2.1 kW

0.7 kW

0 kW3.1 kW

0% (manual)

48.1% 69.4%

24.9%

31.6%

Manual Milling Machine (1985)

27.0%

Automated Milling Machine (1988)

Electricity used in Machining-2









Machine Use ScenarioArbitrary Number of work hours

Machine uptime

Machine hours (idle, positioning, or in cut)

Percentage of machine hours spent idle



Machining Scenario




Machine hours spent in cutElectricity Use per 1000 work hours






Material Machined

Material Removal Rate

Material removed per 1000 work hours

Electricity used/Material removed


29/31

29


Constant start-up operations (idle)Run-time operations (positioning, loading, etc)






Machine Use Scenario

Arbitrary Number of work hours

Machine uptime

Machine hours (idle, positioning, or in cut)Percentage of machine hours spent idle



Machining Scenario




Machine hours spent in cut

Electricity Use per 1000 work hours






Material Machined

Material Removal Rate 20.0 cm3/sec 4.7 cm

3/sec 1.5 cm

3/sec 0.35 cm

3/sec

Material removed per 1000 work hours 40824000 cm3

9593640 cm3

510300 cm3

119070 cm3

Electricity used/Material removed 14.2 kJ/cm3

60 kJ/cm3

4.9 kJ/cm3

21 kJ/cm3

Aluminum Steel

100

Aluminum Steel

kWh

160996 kWh 700 kWh

6237 kWh

600kWh kWh

5471 kWh 0 kWh

149288

30%

567 hours 94.5 hours

70%

70%

243 hours 221 hours

30%

585 hours

810 hours 315 hours

90 hours

900 hours10% 65%900 hours

1000 hours

90% 90%

1000 hours

22 kW 2.1 kW

0.7 kW

0 kW

166 kW

6.8 kW

11.3%

0% (manual)

69.4%

3.5%31.6%

Manual Milling Machine (1985)Production Machining Center (2000)

85.2%

Results are in terms of primary energy


30/31

30Ashby


31/31

31

CO2 emissions

From Electricity

6 machining iiex2

Documents