Machining Center & CNC Su Jin Kim Mechanical Engineering Gyeongsang National University
Index 1. Manufacturing 2. Turning center 3. Machining center 4. Grinding & EDM 5. CNC & Virtual Machine
Machine Parts Manufacturing1 Metal Parts Cut/Drill Turn/Mill Finishing Heat treat Grinding Cleaning
Car Body Forming Joining Process1 Metal Parts Cutting Forming Surface Joining Painting
Machine Tools Machine tools production of the world : $687 in 2013 Korea is top 5 in production($53/y) and 7 in export ($22/y)
Machining (Cutting) 1. Cost: Expensive $100(Cylinder) $10,000(Mold) 2. Quality: Very high, precise 3. Flexibility: Any shape cut by tool, Small production 4. Rate: Slow
Turning A piece of material is rotated and a single point cutting tool is traversed along 2 axes of motion to produce the cylinder, tubular components and various rotational geometries.
Turning process Straight turning Taper turning Profiling (Couture turning) External grooving http://www.youtube.com/watch?v=5ab_etohesi&p=9b6d9eae75875d9d Su-Jin Kim GNU
Lathe Turning can be done manually, in a traditional form of lathe, which frequently requires continuous supervision by the operator.
Lathe 1 st Lathe of Korea Whacheon: http://www.hwacheon.co.kr
Turning center (CNC Lathe) Turning can be done by using a computer numerical control, known as CNC. Hyundai WIA : http://machine.hyundai wia.com
Combined Turning Center Turning center has additional milling axis Doosan: http://doosanmachinetools.com http://ma.gnu.ac.kr/vod/machining/turnmill.avi
Swiss Turn Small and precise parts turned by Swiss Turn. Two spindle(z1, Z2), Turning, Milling, Drilling Hanwha: www.hanwhatechm.co.kr
Precise Roll Lathe Grooving micro patterns on the surface of roll mold Optical film: LED back light, Traffic sign Whacheon: http://www.hwacheon.co.kr Base Film Coating Roll mold UV Lamp Micro Pattern Film
Large Vertical Lathe Hankook : http://www.hanmachine.com
Milling Cutting tool is rotated and traversed along 3 axes of motion to produce from simple rectangular plane, slot, hole and complex contour.
Milling operations Face cutter Endmill : Flat, Ball, Rounded Face Cutter Flat endmill (Slotting) Face: http://www.youtube.com/watch?v=9osnui_o6c4
Milling
Machining center (CNC Milling) Hyundai WIA : http://machine.hyundai wia.com Vertical M/C Horizontal M/C
Type of Machining center Whacheon: http://www.hwacheon.co.kr Slant Type C - Type Bridge Type SIRIUS-UL/G SIRIUS-650/850(N) SIRIUS-700/1250 Whacheon
Slat Type Whacheon 고성능스핀들 (20,000 rpm:opt) 카트리지형고속주축 1 특수윤활유와안정된 Jet 윤활 독창적인 ATC 4 높은신뢰성과내구성 ( 공구보유수 30 개 ) 신속한공구교환 Chip to Chip : 5초 Tool to Tool : 1.5초 ATC 테이블 가공영역과공구교환영역의완벽한분리로인하여 1) 고속가공시간섭을최소화하였으며 2) 고압 Coolant 사용이가능하게되었으며 3) 안정된고정도가공을가능케하였음 모타 스핀들 헤드프레임 컬럼 베이스 2 넓은가공영역 (1100 X 600) 안정된기계구조와다양한편리성 ( 경사형구조의고강성 Frame) 볼스크류 슬라이드 3 Table 2 축제어 다양한형상가공을가능 ( 로타리테이블 320mm) SIRIUS-UL 5 6 뒷면 : 강전반 편리한조작반 180도회전 / 분리형 MPG 핸들 21 조작반
C Type Whacheon SIRIUS-850 독창적인 ATC 캠구동방식으로고속화 RANDOM 선출방식채택비절삭시간단축 / 생산성향상모든구동이 CAM 과 Geared 모터를사용하여고속화실현과계절에따른유온의변화에영향을받지않는안정된작동보장 3 ATC 모타헤드 1 2 고출력스핀들모터 : 30/25kw 저속에서는강력절삭이가능한고토오크발휘고속사상가공에서도탁월한성능을발휘광출력빌트인모타 고성능의안정된주축고속회전 : #50, 8000 rpm (opt; 12,000) 고속회전시진동을최소화한주축은가공면의품질을향상시키고, 공구수명을연장시켜, 고정도금형가공을가능케합니다. 4 접근성이우수하고넓은테이블크기 (2150X850) 각축이송의편이성 6 각축이송부는직경이큰볼스크류와정밀앵큘러콘택트볼베어링을채택하였고, 직결연결방식에의한 AC 서보모터는장시간사용에도높은위치정도를실현함. 새들 컬럼 헤드프레임테이블 5 7 대형금형의고품위가공넓고안정된스트로크 : 2000/850/750 부드러운각축이송각슬라이드면은 Air 부상구조에의한무게보상시스템으로고부하가공에서도고정도를유지 베이스 8 급이송속도 (X/Y/Z) : 16 m/min
Bridge Type Whacheon 고성능주축 고속카트리지스핀들 #50, Max 8000 rpm (opt, 12,000) Jet 윤활방식의안정된주축냉각시스템 3 새들 1 고출력스핀들모터 : 30/25kw 저속에서는강력절삭이가능한고토오크발휘고속사상가공에서도탁월한성능을발휘광출력빌트인모터 독창적인 ATC 가공영역과공고수납공간을 4 완벽하게분리하였으며, 또한, 공구교환영역을가공영역과분리하여가공공간의효율성을증대시켰다. 6 부드러운각축이송각슬라이드면은 Air 부상구조에의한무게보상시스템으로고부하가공에서도고정도를유지급이송속도 (X/Y/Z) : 16 m/min ATC 테이블 헤드 컬럼 베이스 8 슬라이드 완벽한칩, 절삭유의처리장치 7 고강성기계구조 최고의절삭영역 -. 스트로크 : 2500/1250/750 -. 테이블크기 : 2800X1250 편리한작업성개폐와여닫이타입의기계카바구조는작업자의기계접근성을용이하게하고공작물의착탈작업을안전하고손쉽게수행토록설계되었음. 테이블양쪽측면에 Coil Conveyor 를부착하여, 가공중비산되는 Chip 과절삭유를 Coolant Tank 로회수하여작업환경을청결히유지하고, 완벽한 Chip 처리를실현하였음. 2 5
5 axis machining Has 2 tinting A C or B C axis on table or head. Doosan: http://doosanmachinetools.com Rotary table: http://ma.gnu.ac.kr/vod/machining/rotaty_table.mp4 Impeller : http://ma.gnu.ac.kr/vod/machining/5axis_machining_impeller.mp4
Huge 3+2 axis Milling Has additional rotation BC axis on head. Used for automobile door panel and bumper mold. http://ma.gnu.ac.kr/vod/machining/huge_machine_tools.avi Su-Jin Kim GNU http://ma.gnu.ac.kr/vod/machining/huge_5axis.avi
Grinding An abrasive material rubs against the metal part and removes a small amount of material. Tolerance is less than ±0.0025 mm. JinYeong: www.kojin.co.kr Grinding wheel Grinding wheel 25~50 m/s Workpiece 0.2~1 m/s Small depth 0.01~0.05 mm Workpiece http://ma.gnu.ac.kr/vod/machining/grinding_machine.mp4 김태용, GNU
EDM (Electrical Discharge Machining) Based on erosion of metals by spark discharges. EDM system consists of electrodes connected to a DC and placed in a dielectric fluid Daehan EDM: http://www.daehanedm.co.kr Electrode Spark Workpiece http://www.youtube.com/watch?v=q4finksdfww EDM
Wire EDM( Wire Electric Discharge Machining) A brass wire is fed through the workpiece submerged in a tank of dielectric fluid. It is used to cut plates as thick as 0.3 m and to make punches, tools, and dies from hard metals. - Wire electrode + Workpiece http://www.youtube.com/watch?v=pbuewfzb7p0 WireEDM http://ma.gnu.ac.kr/vod/machining/wireedm.wmv WireEDM
CNC NC code CNC Servo driver Servo motor Ball screw Table on the LM bearing CNC Servo motor Ball screw Servo driver LM bearing
Servo drive & motor Servo drive ( 서보제어기 ) & Servo moter( 서보모터 ) : Numerical signal is changed to mechanical torque. Rotation angle is feedback to drive. LS: http://ma.gnu.ac.kr/vod/automatic/cnc_ls.mp4
Ball screw Ball screw ( 볼나사 ) : Changer angular driving motion to linear motion NC-Screw: http://ma.gnu.ac.kr/vod/automatic/cnc_fanuc.mp4 Rack-pinion: http://ma.gnu.ac.kr/vod/automatic/rack_pinion.mp4
Stepping servo motor Servo control stepping motor and communicate with PC by USB port. http://ma.gnu.ac.kr/vod/automatic/step_servo_moter.wmv Step Servo Motor
LM Bearing (LM Guide) Linear motion bearing ( 직선이송가이드 ): General Sliding guide( 미끄럼가이드 ): High stiffness, Slow Hydro static bearing( 유정압베어링 ): Precision, High speed LM Bearing: http://ma.gnu.ac.kr/vod/automatic/lm_bearing1.mp4 LM Bearing: http://ma.gnu.ac.kr/vod/automatic/lm_bearing2.mp4
CNC CNC (Computer Numerical Control) 1948 : Parsons & MIT developed 1 st NC 2000 : PC NC & Intelligent CNC CNC 개방화 CNC 지능화 NC 개발 수동선반, 밀링머신 Open CNC I/F Open CNC API Ethernet
International FANUC(Japen) 70% > Siemens(Germany) 20% > Mitsubishi, Heidenhain, CSCAM, Doosan, Sentrol 10% Fanuc 30i SINUMERIK 840D
CSCAM HX2.0 Full Soft CNC EtherCAT: Digital servo interface Graphical tool path visualization CSCAM: http://cscam.co.kr http://cscam.co.kr
Servo Interface : Analog Vs. Digital http://cscam.co.kr
Doosan D300 PC based CNC with multi CPU Visualization of tool path and workpiece
Doosan Sketch turn Conversation program for Turning center Various machining pattern for turning & milling Easy access and simplified input http://www.doosanmachinetools.com/kr/product/software/sketch-turn.do
SENTROL 300 1985 Developed CNC device TEPS" for the first time in Korea Simultaneously controlled 16 axes Maximum number of I/O Point: 1040 Analog speed command and Digital servo interface USB memory port and direct key http://sentrol.net
SENTROL 353 HMI is normal PC screen can be independently developed Simultaneously control 3 axes + spindle axis Maximum I/0 grade: 48/32 Analog speed command type Servo Interface http://sentrol.net
Virtual Machine Simulation of machining process and machine tool operation Verification and optimization of machining process NCBrain: http://ncbrain.com
Smart Machine CAM + Simulation + NC Machine
NCBrain EYE The Virtual machine in CNC has EYE scanning workpiece. Prevent collision at manual and automatic control Cutting condition optimization http://www.ncbrain.com/en/contents/eye.php
References: Machine Tool Makers Hyundai WIA : http://machine.hyundai wia.com Doosan: http://doosanmachinetools.com Whacheon: http://www.hwacheon.co.kr
Reference Grinding: www.grinding.co.kr Grinding EDM: www.kojin.co.kr EDM http://www.daehanedm.co.kr CSCAM: www.cscam.co.kr (CNC) Centrol: www.sentrol.net (CNC) NCBrain: www.ncbrain.com (Virtual Machine)