DESIGN AND DEVELOPMENT OF A PRECISION MACHINE TOOL

Submitted by Arjyajyoti Goswami 02/PRD/10

Submitted to. Prof. SHAMSHER

Department of MECHANICAL ENGINEERING

EMERGING TRENDS
 Surface finish of 1 m or less  Motion accuracy of 1 nm  Allowable temperature deviation upto 0.1C  Continued accuracy  All of above at a productive material removal rate

DESIGN OBJECTIVE
 To design a machining center

 To design a high precision machining center

 To achieve the desired precision at high speed so as to achieve a sustainable productive rate

DESIGN OF STRUCTURE OF THE MACHINE TOOL

 Independent axes to avoid accumulation of error

 Movement along Z axis is achieved by moving the worktable instead of the spindle

 Use of pair of linear motors to improve accuracy

Control of thermal deformation

Materials with good stiffness-to-weight ratio need to be considered to achieve high static and dynamic stiffness

All moving parts are of ceramic, to have low mass, high stiffness and lesser thermal deflection owing to their small thermal expansion co-efficient

Use of radiation shields and high thermal resistance mountings are made to form a thermal break and then cool them down.

The highly compressed air is subjected to the sudden expansion after going through the air turbine blades, and this sudden expansion provides the cooling effect Heat is generated within the bearing due to the shear effect between the static air and rotating high-speed spindle Both the cooling effect and the generated heat, cancels out each other and stable state is achieved within a very short time

SYMMETRICAL DESIGN Symmetrical designs are simpler to analyze

Require less information to build

Allow more accurate measuring and manufacturing methods

The loads on the symmetric structure can be self-canceling thus resulting in greater dynamic balancing

Vibration suppression
Vibration control can be achieved through PASSIVE or ACTIVE DAMPING METHODS Working conditions are continuously changing, so active vibration control is necessary for high-speed precision systems The basic idea is to use two moving counter balance masses along X and Y axes to suppress the vibration caused by spindle and worktable respectively

The total mass of two damping masses is equal to the mass of the X-axis slider, the resultant reactive forces exactly match the active force. The two fixed supports are very close to each other, torsion loads on the fixed supports are greatly reduced

X, Y and Z axes are equipped with 2 linear motors such that the resultant feed is always acting at the center of gravity

Tool Holding System

Compared to other tool holding devices, this tool holder provides stronger tool holding capability in high load operations

This also provides high speed and high accuracy tool change without deflection

LASER detection of Workpiece and Tool Position

LASER detection system are installed in the machine to automatically determine the positions of the cutting tool.

The position of workpiece can be measured with a touch probe, using the LASER measurement device as reference point

Once the positions of the workpiece and the tool are found, the offset between the cutting tool and the workpiece is obtained automatically

The repeatibility of the two LASER detection system is around 0.2-0.5 m.

Performance Evaluation
The run out of the spindle is less than 0.5 m

The deviation of measured tool diameter is around1.5 m , in 70 observations

The thermal displacement for most cases is less than 0.5 m

The maximum measured temperature change is less than 0.5C in the machine area

REFERENCES
Z.G.Wang, X.Cheng, K.Nakamoto, S.Kobayashi, K.Yamazaki, Design and development of a Precision machining tool using counter motion mechanisms, International Journal of Machine Tools and Manufacture 50 (2010) 357-365 M. Weck, J. Hennig, R. Hilbing, Precision cutting processes for manufacturing of optical components, lithographic and micromachining techniques for optical component fabrication, Proceedings of SPIE 4440 (2001) 145 151 J.A. Wickert, C.D. Mote Jr., Current research on the vibration and stability of axially moving materials, Shock and Vibration Digest 20 (1) (1988) 3 13 E. Shamoto, C.H. Park, T. Moriwaki, Analysis and improvement of motion accuracy of hydrostatic feed table, CIRP Annals 50 (1) (2001) 285 288