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

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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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