Assessment of the Manufacturing Possibility of Thin-Walled Robotic Portals for Conveyance Workplaces

338 338 Ad ances in Science and Technology Resea ch Jou nal Volume 12, No. 1, Ma ch 2018, pages 338–345 DOI: 10.12913/22998624/87063 Resea ch A icle ASSESSMENT OF THE MANUFACTURING POSSIBILITY OF THIN-WALLED ROBOTIC PORTALS FOR CONVEYANCE WORKPLACES Pe e Michalik1, Joze Dob anský1, Leopold H abo ský2, Michal Pe uš3 1 Technical Uni e si y o Kosice, Facul y o Manu ac u ing Technologies wi h sea in P eso , Baye o a 1, 08001, Slo akia, e-mail: pe e [email p o ec ed] 2 VŠB - Technical Uni e si y o Os a a, 17. lis opadu 15/2172, 708 33 Os a a - Po uba, Czech Republic, e-mail: leopold.h abo sky@ sb.cz 3 Milpoš 177, 082 71, Slo akia, e-mail: [email p o ec ed]om ABSTRACT The pape discusses e alua ion o machining solu ions o o e sized hin-walled obo ic po al componen o con eyance wo kplaces. The ollowing po al CNC machining cen e s ha e been selec ed. Fi s ly, a FSGC 300 “po al ype” po al was p oposed, wi h a 50000 mm “X” axis and Heidenhain con ol sys em, he second po al was a DMU 340 po al wi h he maximum axis “X” o 6000 mm and Siemens Sinume ik con ol sys em and he las po al was he VF-10 / 40 one, wi h he maxi- mum axis “X” o 3048 mm and Fanuc con ol sys em. Fu he , he me hod o ixing a hin-walled obo ic po al is designed and indi idual op ions a e e alua ed o hei economy. The CAM so wa e applica ion used o p og amming he p oduc ion was SolidWo ks. Keywo ds: obo ic, hin walled, CNC machine cen e , CAM applica ion. INTRODUCTION A p esen , machining is an in eg al pa o he p oduc ion o a wide ange o p oduc s. The ma e ial is sha ed o in a o m o chips. The unc ion o machining is o ob ain a componen o he equi ed size and shape. The desi ed p ecision and quali y is achie ed by g adual emo al o he ma e ial. The echnology is implemen ed as he machine, ool, jig and wo kpiece. The echnolo- gies used o achie e he desi ed dimensions o he selec ed wo kpiece a e milling, d illing, ca ied ou in wo s eps o se ing up he wo kpiece om di e en sides. The pape ocuses on he p ob- lem ela ed o machining hin-walled con eyance wo kplace segmen o speci ic dimensions. This is a small ba ch job wo k posing a p ob- lem o handling a limi ed componen size [1]. The wo kpiece is designa ed o he obo po al. The inpu semi- inished p oduc is a segmen welded om aluminum alloy p o iles. Machining p op- e ies o his ma e ial a e no he bes . I is no ough and causes he chips o s ick o he ool. A measu e o a oiding damage o he wo kpiece o ool is he choice o sui able ools wi h op imum cu ing condi ions [2, 3]. S udies and p ac ice con i m be e su ace p ope ies and i s quali y is achie ed by inc eas- ing cu ing pa ame e s, such as cu ing speed and eed a e [4]. Po al s uc u es o obo s can be made o cas ings o welded. Cas ing o aluminum- based load bea ing s uc u al elemen s o han- dling and measu ing de ices equi es adhe ence o he desi ed pa ame e s, pa h leng h, empe a- u e, mel angle and wall mold empe a u e [5]. In he p ocess o cas ing hin-walled s uc u es, i is necessa y o moni o he cooling p ocess, i.e. he cooling cu e. Mou alo a e al. ound key pa- ame e s o machine se up o he manu ac u e o high-p ecision componen s wi h he equi ed su - Recei ed: 2018.01.15 Accep ed: 2018.02.01 Published: 2018.03.01 339 Ad ances in Science and Technology Resea ch Jou nal Vol. 12 (1), 2018 ace quali y o p ecision quali y [6]. Wi h welded s uc u es, i is necessa y o check he welds [7]. In case o chip machining o di e en s uc- u al elemen s on CNC machine ools, i is nec- essa y o ake in o accoun he shapes o p o- g ammed ool pa hs, whe he hey a e linea o ci cula , which a ec s he o e all p ecision o he manu ac u ed componen . Conway e al. s udied a ious ool acks [8]. I is also necessa y o moni o he ex en o de o ma ion in d illing, w iggling and bo ing chip ope a ions. Ramesh e al. in es iga ed machining o a composi e [9]. The s uc u e o chip-machined o e sized hin-walled componen s should be checked o dimensional s abili y unde changes in empe a u e. D’Aleo e al. designed o esis i e empe a u e de ec o a ays on aluminium sub- s a es [10, 20]. Compu e models o de e mining in e nal s esses due o chip machining, welding o cas ing a e mo e commonly use in esea ch and p ac ice. S ohmandl p oposed a simula ion o he educ ion o de ec i e p oduc s [11, 21]. Koszu a al. designed applica ion FEM in he analysis in he cons uc ion o ame [12, 22]. DESIGN OF ALTERNATIVES Di e en e sions o h ee milling machine ools we e selec ed o ea men o he hin- walled obo ic po al o he con eyance wo k- place. The obo ic po al model [13] is illus a ed in Figu e 1. I was c ea ed in Au odesk In en- o [14, 17, 19] wi h p esc ibed p ecision [15]. Thin-walled obo ic po al was designed o pipe con eyo wo kplace [16, 18]. The ma e ial o he hin-walled obo ic po al is Alloy 3,1645 EN AW-2007 aluminum, which should be aken in o accoun a clamping, du ing which he po al comes in o con ac wi h s eel as ene s. In o de o achie e desi ed p oduc ion capaci y, p eci- sion o he obo ic po als and easonable li e o he cu ing ools, he selec ed cu ing condi ions should be obse ed, he s i ness o he ools and he clamping jigs. Fo machining i sel , mo e ze o poin s a e e- qui ed o be c ea ed in he p og am so ha a mini- mal adjus men e o is p oduced, which is also a ec ed by he ype o he applied op oelec onic measu ing p obe Figu e 2. The o al e o will be minimal i ze o poin s a e placed di ec ly in he cen e o he hin-walled obo ic po al. THE FIRST ALTERNATIVE CNC PORTAL MACHINING CENTER FSGC 300 The FSGC machining cen e o e ed is a machine wi h a po al s uc u e Figu e 3. I is equipped wi h a mo able po al and base pla es o cas i on o clamping he wo kpiece. These pla es a e a s anda dized design op ion o FSGC machines. The machine can be equipped wi h a special clamping de ice ins ead o cas pla es o a combina ion o hem. The e is a wide ange o accesso ies and equipmen o machine ools o choose om. The heads, au oma ed ool eplace- men , ool cooling, measu ing p obes and mo e. P ecision is exp essed in cha ac e is ic alues ac- co ding o he VDI / DGQ 3441s anda d, Table1. Modula s uc u e o he machine allows a wide ange o moun ing dimensions o he FPPC ma- chine. Tha is ue o bo h, he wid h, bu espe- cially he leng h. Fo i e-side machining, he ma- chine can be equipped wi h a 2-axis head loca ed in he s uc u e o wi h con inuously con olled indexing Figu e 4 [23]. Table 1 shows he basic FSGC 300 pa ame e s. Fig. 1. Model o hin-walled obo ic po al Fig. 2. Op oelec onic wo kpiece p obe Ad ances in Science and Technology Resea ch Jou nal Vol. 12 (1), 2018 340 THE SECOND ALTERNATIVE FIVE-AXIS CNC PORTAL CENTER DECKEL MAHO DMC 340 U These i e-axis machines wi h highly s a- ble po al design o e maximum p ecision and g ea es dynamics (Fig. 5). In addi ion o d ill- ing and milling, he machine can also make he same se ings. To maximize p oduc i i y, he DMC palle change allows o adjus - men s du ing machining. La ge componen s may weigh up o 16 ons, hey equi e la ge wo k a ea while lea ing minimum ace. This concep is lexible, access o wo k a ea can be op imized, as can be he o he p ocesses. Thei con ol sys em uses cycling cycles only, i de- Fig. 3. Model milling po al machining cen e FSGC 300 [23] Fig. 4. Milling po al machining cen e FSGC 300 [23] Table 1. Basic pa ame e s o he FSGC 300 machine S oke o X-axis [mm] 4 000 – 50 000 S oke o Y-axis [mm] 4 700 S oke o Z-axis [mm] 1 500 (2 000) Leng h o able [mm] 4 000 – 50 000 Wid h o able [mm] 3 000 Load o able [kg·m2] 5 000 Dis ance be ween columns [mm] 4 300 Feeds X,Y,Z [mm] 2 500 Ve ical spindle – mechanical 27 kW / 5000 pm / 800 Nm / ISO50 Indexed head (machining o i e sides) 30 kW / 5000 pm / 800 Nm / ISO50 Con inuously d i e head ( i e-axis machining) 70 kW / 15000 pm / 167 Nm / HSKA100 341 Ad ances in Science and Technology Resea ch Jou nal Vol. 12 (1), 2018 ec s, con ols and moni o s scales, au oma ic speed se ing based on componen ib a ion, measu emen cycles o lase measu emen senso s [24]. I enables calib a ion o he measu ing sen- so in he wo k a ea and ansmi he measu ed da a o he con ol sys em. The se ies o po als shows maximum p ecision and empe a u e s abili y wi h s anda d posi ioning accu acy up o 10 μm. Comp ehensi e cooling deli - e s long-las ing p ecision (Fig. 6). Full cool- ing du ing machining ensu es highe compo- nen p ecision. Posi ioning accu acy up o 8 μm wi h he possibili y o packaging accu acy. Using he Celos con ol sys em o e s a s an- da d use in e ace o all new cu ing-edge machines om DMG Mo i. Celos Apps appli- ca ions enable consis en managemen , docu- men a ion, and isualiza ion o o de , p ocess, and machine da a on a mul i- ouch moni o . They also simpli y, s anda dize, and au oma e machine ope a ion [18]. Table 2 shows he ba- sic pa ame e s o he DMC 340 U machine. THE THIRD ALTERNATIVE MILLING 3-AXIS CENTER MLD - VF-10/40 All con ol sys ems o he e ical machin- ing cen e s HAAS use a common concep o how hey a e o be ope a ed. They a e easy o use and p og am, so hey equi e less aining. Because o hei compa ibili y, he exis ing p og ams can simply be eused, educing o al cos o owne - ship. 3D b eakdown de ec ion unc ion HAAS In e e ence Con ol p o ec s he machine, manu- ac u ed componen s and ools. The esul is min- imal down ime o p o ec expensi e equipmen and p e en damage o wo kpieces and machines. Hund eds o HAAS so wa e ea u es o imp o e in elligence, mobili y, secu i y, and p oduc i i y Fig. 5. Milling po al machining cen e 5 axis CNC DECKEL MAHO DMC 340 U [25] Fig. 6. The unco e ed unc ional g oups o 5 axis CNC po al cen e DECKEL MAHO DMC 340 U [24] Table 2. Basic pa ame e s o he machine 5 axis CNC po al cen e DECKEL MAHO DMC 340 U Max. X a els [mm] 3400 Max. Y a els [mm] 3400 Max. Z a els [mm] 1600 Max. able load [kg] 10000 Table leng h [mm] 2000 Table wid h [mm] 2500 High dynamics wi h eed speed [mm/min] 40000 Milling able wi h a o que [Nm] 10200 Powe MASTER mo o spindle wi h up o [Nm] 1000 Magazine wi h up o ools 234 B - axis wi h gea - d i en spindle 8000 pm, 52 kW, 1800 Nm o que Ad ances in Science and Technology Resea ch Jou nal Vol. 12 (1), 2018 342 enable he CNC con ol sys em o ailo he ap- plica ion pe ec ly and achie e g ea e e iciency. The h ee-axis CNC e ical cen e has an au o- ma ic sc ew wi h a chip, a p og ammable cool- ing nozzle, a colo emo e handle, 15 “colo LCD moni o , USB po , key lock, powe ailu e de- ec ion module, 1 GB p og am memo y, a gallon (360 li e s) sys em o lood cooling luid, s anda d swi ch sys em, ancho ki ha is highly ecom- mended o ins alla ion (Fig. 7). Table 3 shows he basic MLD - VF machine pa ame e s. SOLUTION CLAMPING OF COMPONENT The i s s ep is o ensu e he clamping o he blank (Fig. 8). The clamping is done by placing he wo kpiece on he CNC machining able’s lon- gi udinal able and by posi ioning o he clamping elemen s. Using he a ailable clamps, he wo k- piece is as ened, and i s mo emen is p e en ed. A necessa y s ep is using non-me allic pla es o p e en he con ac be ween me al and aluminum. The clamping should be done wi h a ailable Fig. 7. The 3-axis milling cen e MLD–VF–10/40 [26] Table 3. Basic pa ame e s o he machine 3 axis CNC MLD - VF-10/40 Max. X a els [mm] 3048 Max. Y a els [mm] 813 Max. Z a els [mm] 762 Max. able load [kg] 1814 Table leng h [mm] 3048 Table wid h [mm] 711 Max Tool Diame e [mm] 152 Max Tool Leng h [mm] 406 Ve ical spindle – mechanical 22.4 kW / 8100 pm / 339 Nm Magazine wi h up o ools 24 + 1 Max Tool Weigh [kg] 5.4 Fig. 8. Solu ion clamping o componen Figu e 9. A ailable clamping elemen s 343 Ad ances in Science and Technology Resea ch Jou nal Vol. 12 (1), 2018 clamping elemen s, which a e gene ally used o o he di e en blanks. The clamping elemen s shown o Figu e 9, consis ing o a numbe o di e en shapes, s op- pe s, spacing pilla s and a clamping sc ew. The cu ed wo kpiece has a su icien weigh o p e en i s mo emen . The p oblem o he s uc u e i sel lies in he ac ha i is no a ull ma e ial. The e a e undesi able ib a ions and i- b a ions ha need o be sho ened. The chuck is a non-magne ic ma e ial and canno be applied by an elec omagne . All clamping elemen s can only be applied o he longi udinal able o p e- en mo emen and pa ially educe he slope o he pa . S opping can be done by hand-sc ewed me ic h eaded pins. The ins alla ion o he hin- walled obo ic po al will be secu ed by means o he sc ews and suppo pilla s (Fig. 10). Be o e ea ing he holes, i is necessa y o pe o m he simula ion o he machining, as shown in Figu e 11. All he pa ame e s emain unchanged. Machining is pe o med using spi al amping. Milling is pe o med only a he p e- sc ibed dep h om he uppe su ace o he seg- men . CAPACITIVE COMPARISON The p oduc ion ime was 7.5 hou s. The numbe o hin-walled obo ic po als p oduced was 650. The coe icien o machine u iliza ion 0.9, he coe icien o s anda d pe o mance 0.9. Unique ope a ion 7.5 hou s (Table 4). ECONOMIC COMPARISON Based on he economic compa ison, he mos sui able al e na i e was chosen om among he p oduced hin-walled obo ic po als o he con- eyance wo kplaces. All ad an ages and disad- Fig. 10. Design o es ablishing and suppo ing a hin- walled obo ic po al Table 4. Capaci i e compa ison Cycle ime (no mal-hou ) To al ime (no mal-hou ) Requi ed numbe o machines (numbe ) CNC po al cen e FSGC 300 0.1638 189.42 1.17090535 CNC po al cen e DECKEL MAHO DMC 340 U 0.1596 179.45 1.16860823 CNC cen e MLD - VF-10/40 0.3688 395.72 2.03560782 Fig. 11. Simula ion machining o holes wi h he use o Au odesk In en o HSM 2018 Table 5. Capaci i e compa ison Machine FSGC 300 DMC 340 U MLD - VF-10/40 Cycle ime (hou ) 2.74 2.69 5.08 Numbe o pieces o u ns (numbe ) 2 2 1 Con ol sys em Heidenhain Sinume ic Fanuc Machine p ice (EUR) 650 000 1 000 000 140 000 Ad ances in Science and Technology Resea ch Jou nal Vol. 12 (1), 2018 344 an ages ha e been aken in o accoun . Cos pe wo k hou was EUR 32.00 (Table 5). Ope a ing cos s need o be aken in o accoun . CONCLUSIONS Requi emen s o high quali y and p ecision in he p oduc ion o inal assembled equipmen a e me by chip machining. P oduc ion o a hin- walled obo ic po al needed o be designed. In- di idual manu ac u ing s eps equi ed a design o a sui able CNC machining cen e and he blank clamping p ocedu e. Du ing he manu- ac u ing p ocess, he applied cu ing o ces had o be elimina ed o p e en ool and wo kpiece damage. The clamping p oposed o indi idual ope a ions will mee he equi emen s o desi ed p ecision, ime sequence o s eps and es ablish- men o cu ing condi ions. In he p ac ical pa , a CAM applica ion was de eloped and simula ed by he NC p og am, which calcula ed, op imized ool pa hs and p e en ed possible collisions o wo king ools wi h clamping elemen s. Simula- ion o machining is sys ema ically desc ibed by indi idual blocks o NC machining. Based on he economic calcula ions and ypes o con ol sys ems o he p oduc ion o hin-walled o- bo ic po al, he CNC po al machine ool cen e FSGC 300 is ecommended. Acknowledgemen s This wo k is a pa o esea ch p oj- ec VEGA 1/0045/18, VEGA 1/0492/16, KEGA,004TUKE-4/2017. 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