manufacturing laboratories, inc. mikron smart machine discussion
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Manufacturing Laboratories, Inc.
Mikron Smart Machine Discussion
Manufacturing Laboratories, Inc.
MLI’s 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.
Manufacturing Laboratories, Inc.
What’s 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.
Manufacturing Laboratories, Inc.
MLI’s 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.
Manufacturing Laboratories, Inc.
MetalMAX: What’s 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”).
MLI’s MetalMAX™ kit with computer.
Manufacturing Laboratories, Inc.
A Typical Measurement Setup
Schematic of Measurement Setupfor “Bump”, “Ping” or “Modal” test.
4
3
2
1EXCITATION
(HAMMER)
RESPONSE
(ACCEL)
Sensor Interface Module
PC
Accelerometer
STRIKE
Hammer
Power Cable
Sensor Cable
Machine tooland Spindle
*Can also measure work piece ina similar fashion and combine behavior
with cutting tool measurement.
Manufacturing Laboratories, Inc.
Stability Plot20 mm 3-fluted Tool in 30 kW 24 krpm Spindle
ProcessDampingRegion
Unstable
Torque Limit
ChatterFrequencies
Stable
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
Manufacturing Laboratories, Inc.
Check Results
Monitor cutting operation
Determine if it is stable, chattering or resonating.
Make fine adjustments if needed.
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.
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.
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.
Manufacturing Laboratories, Inc.
Spectral Analysiswith identified
chatter frequencies
Vibrationsignal
Must know: Max. Allowable
speed Spindle Speed Number of teeth Nothing else
Technique Identifies Chatter Recommends new
spindle speed.
Detecting Chatter
Manufacturing Laboratories, Inc.
Chatter Eliminated
Can either increase cutting depths (ap or ae) or feed rate.
Eliminating Chatter
Manufacturing Laboratories, Inc.
First Part Machined Correctly!
0.5 mm wall and floor thickness, 1 mm diameter pins, walls and pins 30 mm high.
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
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 APS’s machining
monitoring/warning/diagnostic capabilities, Harmonizer can also provide deterministic process parameter corrections.
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.
Manufacturing Laboratories, Inc.
Packages for Machining Vibration Prediction and Control
Machining simulations
Prediction and Monitoringof the Cutting Process
Machining Vibration Solutions
DrillSim*
Recording and tracking information for use by NC Programmers
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