Lopez de Lacalle L.N., Lamikiz A. Machine Tools for High Performance Machining

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Machine Tools for High Performance Machining

L.N. López de Lacalle • A. Lamikiz

Editors

Machine Tools

for High Performance

Machining

123

L.N. López de Lacalle, PhD

A. Lamikiz, PhD

Departamento de Ingeniería Mecánica

Escuela Técnica Superior de Ingenieros

Industriales

Universidad del País Vasco

Calle Alameda de Urquijo s/n

48013 Bilbao

Spain

ISBN 978-1-84800-379-8 e-ISBN 978-1-84800-380-4

DOI 10.1007/978-1-84800-380-4

British Library Cataloguing in Publication Data

Machine tools for high performance machining

1. Machine-tools

I. Lopez de Lacalle, L. N. II. Lamikiz, A.

621.9'02

ISBN-13: 9781848003798

Library of Congress Control Number:

2008932947

Apart from any fair dealing for the purposes of research or private study, or criticism or review, as permitte

under the Copyright, Designs and Patents Act 1988, this publication may only be reproduced, stored o

transmitted, in any form or by any means, with the prior permission in writing of the publishers, or in the cas

of reprographic reproduction in accordance with the terms of licences issued by the Copyright Licensing

Agency. Enquiries concerning reproduction outside those terms should be sent to the publishers.

The use of registered names, trademarks, etc. in this publication does not imply, even in the absence of

specific statement, that such names are exempt from the relevant laws and regulations and therefore free fo

general use.

The publisher makes no representation, express or implied, with regard to the accuracy of the informatio

contained in this book and cannot accept any legal responsibility or liability for any errors or omissions tha

may be made.

Cover design: eStudio Calamar S.L., Girona, Spain

Printed on acid-free paper

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“Eman ta zabal zazu”.

(in the Basque language)

“Bear fruit and make it known”.

(translated)

– from the motto of the University

of the Basque Country

vii

Preface

The machine tool has been, is and no doubt will be, a key factor in industrial and

equipment evolution, and as such, improving man’s quality of life. Both its evolu-

tion and perfectioning have come about due to the sectors where used and have

likewise improved their products due to machinery improvements.

Machines have changed greatly in the last 30 years, particularly with the incor-

poration of numerical control. They have gone from being mechanical machines to

real mechatronic systems, where control, drives and sensorisation are key ele-

ments. This trend is unstoppable since, thanks to the combination of improvements

in materials and mechanical design with control and algorithms executed by the

same, better precision, greater speed and worker-friendly inter-relations have been

achieved.

However, in the last 15 years an even greater change has occurred, traditional

machines, i.e., lathes, milling machines, grinders, etc., have evolved into multi-

process/multitask machines, some of which are capable of milling, drilling, turn-

ing, boring, hobbing, measuring and even tempering with laser in the same ma-

chine. Every year new concepts appear in this line from the classic machining

centre to the turning centre, multitask machines, lathe-milling machines, turning-

grinding machines, etc. In some cases one hears about the “factory in a machine”,

which means all operations are performed in the same machine. Designers have

done away with many machinery stereotypes, creating designs to solve the user

problems. Perhaps we could say “milling machines” are no longer manufactured

but rather “machines which mill”, or lathes are no longer manufactured but “ma-

chines with turning capabilities”. However, we may be exaggerating since the

production sector tradition and custom tends to see them as classical machine

types, depending on the predominance of their functions or machine architectures,

etc. The tradition is the tradition and metal production is a “conservative” sector.

The wide variety of machinery and options available has complicated the up-

date of classical sources, like books. A single author is unlikely to know all the

aspects, technologies or even the production conditions of each sector to write

a single book. Thus, the aim of this work has been to seek the contribution of

viii Preface

authors specialised in different technological fields and industrial sectors. Each

masters one of the technologies comprising machine tools, from control bases to

structure, spindles and drives, etc. Furthermore, the authors of each chapter have

not only had a fluid relation in the past but continue to do so today, thus enabling

text coherence and a common view.

In Europe, the USA, and Japan machine tooling is a sector which has under-

gone a great technological evolution in recent years. In this context, important

research and development projects are underway, e.g., the Integrated Project

NEXT (Next generation production systems), currently in progression in Europe,

or the CENIT “eee-Machine” project in Spain. Asian countries like China and

Korea have joined these poles and in recent years India and Turkey too. Competi-

tion is high, not only at a technological level but also a monetary level. Two key

aspects are: a) cost reduction; this might result from greater production, and b) the

need to adapt machines to each customer’s needs. Both aspects are contradictory,

and are settled using modular design ideas, greater bindings with supplier chains,

and the offer of multiple accessories on the same basic machine models.

Nevertheless, we must not lose sight of the importance of environmental impact

and machines life cycle analysis. Consuming little electricity, reducing coolant use

and eliminating electromagnetic radiations are important requirements today. The

machine must be “eco-efficient”, i.e., with minimum impact and maximum pro-

ductivity and/or precision.

Machinery precision has also grown. In a hundred years we have gone from

tenths of millimetres to below hundredths, and in some cases machines border the

micron frontier.

This text is the final result of that work, which attempts to update knowledge

on machine tool machine design, construction and use. It is based on the premise

that the reader is already familiar with machinery in general and as such familiar

with the basic books. Furthermore, it is directed at the reader seeking a source

containing the advances of recent years, on display at the main sector fairs, such as

the Hanover EMO, Chicago IMTS and JIMTOF. Researchers commencing their

work on the machine tool and production sector may find this book useful.

Finally, the authors would like to point out they have gathered information

from classical sources and directly from machines existing on the market. The

machine tool is a living element with an important industry. It is impossible to

generalise without mentioning the companies which invent, improve and re-design

these machines. We should also like to express our gratitude to the companies

willing to lend their images and ideas. Indeed one of the virtues of this book is its

reference to real technology and not solely academic technology.

Bilbao, Spain, April 2008 L. N. López de Lacalle

A. Lamikiz

Acknowledgements

Thanks are given to all the companies cited below for the pictures and information.

List of companies with pictures included in this book, using the commercial names

in alphabetical order:

ABB

Agie

Airbus

Air Products

Alzmetall

American Axle and Manufacturing

Automation Tooling Systems

Boehringer (MAG Boehringer)

Busak Shamban

Chiron

CMZ Machinery

CMW (Hexapode)

Danobat

Delphi

Dixi

DMG (Deckel Maho Gildemeister)

Doimak

Droop & Rein

DS Technologie (Dörries Schar-

mann)

Ecoroll

Edel (Die Edel Maschine)

Emag

Etxe-Tar

Fagor Automation

Fanuc

Fatronik-Tecnalia

Fidia

Forest Liné

Fraunhofer IPT

GF AgieCharmilles

GMN

Gnutti

Goratu

Haas Automation

Handtmann

Heidenhain

Heller

Henri Liné

Hermle

Hiwin

Hyprostatik

Ibag

Ibarmia

INA-FAG

Index Werke

ISW-Stuttgart

IWF-Zürich

Jobs

Kaufmann

Kern

KMT Lidköping

x Acknowledgements

Kondia

Kugler

Lagun

Laip

Lealde

M.A. Ford

Magna Powertrain

Makino

Maritool

Mazak

Micromega

Mikron

Mori Seiki

MTorres

NCG, NC Gesellschaft

Nemak

Neos Robotics

Nicolas Correa

Nomoco

Ona Electroerosión

Overbeck Danobat

Precitech

Pinacho

Pietro Carnaghi

Redex Andantex

Röders

Parallel Robotic Systems

SAE International

Sankyo Seiki

Schaudt (Studer Schaudt)

Schneeberger

Shuton

Siemens

Sisamex

SKC

SLF

Spring Technologies

Sumitomo

Starragheckert

System 3R

Tekniker-IK4

THK

Toyoda

Tschudin

Ultra Tech Machinery

Weisser

WFL Millturn Technologies

Zayer

Content

Contributors..................................................................................................... xix

1 Machine Tools for Removal Processes: A General View..................... 1

L. Norberto López de Lacalle and A. Lamikiz

1.1 Basic Definitions and History........................................................ 1

1.1.1 Historical Remarks........................................................... 2

1.2 The Functions and Requirements of a Machine Tool.................... 8

1.2.1 User and Technological Requirements ............................ 9

1.3 The Basic Mechanism ................................................................... 13

1.4 The Machine Structure .................................................................. 16

1.4.1 Machine Foundations....................................................... 18

1.4.2 Structural Components Materials..................................... 18

1.4.3 Structural Analysis........................................................... 19

1.4.4 Modularity........................................................................ 22

1.5 Guideways..................................................................................... 23

1.5.1 Guides with Limit Lubrication......................................... 25

1.5.2 Rolling Guides ................................................................. 25

1.5.3 Hydrostatic Guides........................................................... 26

1.6 The Definition of the Main Motion ............................................... 27

1.7 The Definition of the Drive Trains ................................................ 29

1.8 The CNC Implementation ............................................................. 30

1.9 Machine Verification..................................................................... 33

1.10 Typical Machines for Several Applications and Sectors ............... 34

1.10.1 A Machine for Big Structural Turbine Parts .................... 34

1.10.2 A Horizontal Milling Centre

for Automotive Components............................................ 35

1.10.3 A Milling Centre for Moulds ........................................... 37

1.10.4 A Milling Machine for Big Dies and Moulds .................. 37

1.10.5 Conventional Machines for Auxiliary Operations ........... 38

1.10.6 CNC Milling Machines for General Production .............. 40