平衡軸鉆孔組合機(jī)床總體及多軸箱體設(shè)計(jì)【說(shuō)明書(shū)+CAD+UG】,說(shuō)明書(shū)+CAD+UG,平衡軸鉆孔組合機(jī)床總體及多軸箱體設(shè)計(jì)【說(shuō)明書(shū)+CAD+UG】,平衡,鉆孔,組合,機(jī)床,總體,整體,軸箱,設(shè)計(jì),說(shuō)明書(shū),仿單,cad,ug 畢業(yè)設(shè)計(jì)任務(wù)書(shū) 課題：平衡軸鉆孔組合機(jī)床總體及多軸箱體設(shè)計(jì) 專 業(yè) 機(jī)械設(shè)計(jì)制造及其自動(dòng)化 學(xué) 生 姓 名 施蕾 班 級(jí) BU機(jī)制101 學(xué) 號(hào) 1011501126 指 導(dǎo) 教 師 趙健 專 業(yè) 系 主 任 王 平 發(fā) 放 日 期 2014年12月31日 一、設(shè)計(jì)內(nèi)容 設(shè)計(jì)一臺(tái)平衡軸鉆孔組合機(jī)床，具體進(jìn)行總體設(shè)計(jì)及多軸箱設(shè)計(jì) 主要內(nèi)容有： 1．總體設(shè)計(jì) 1）制定工藝方案，確定機(jī)床配置型式及結(jié)構(gòu)方案。 2）“三圖一卡”設(shè)計(jì)，包括： (a) 被加工零件工序圖， (b) 加工示意圖，(c) 機(jī)床聯(lián)系尺寸圖， (d) 生產(chǎn)率計(jì)算卡，(e) 有關(guān)設(shè)計(jì)計(jì)算、校核。 2．多軸箱設(shè)計(jì) (a) 繪制多軸箱外形圖，(b)標(biāo)注位置尺寸，(c) 標(biāo)注轉(zhuǎn)向，（d）標(biāo)注工序內(nèi)容， 切削用量，主軸外伸尺寸，(e) 標(biāo)明動(dòng)力部件型號(hào)及其性能參數(shù)等 設(shè)計(jì)； 二、設(shè)計(jì)依據(jù) 1．課題來(lái)源：江蘇恒力組合機(jī)床有限公司 2．產(chǎn)品名稱：平衡軸鉆孔組合機(jī)床 3．被加工零件：平衡軸鉆孔組合機(jī)床 4．工件材料：HT250 5．加工內(nèi)容：鉆右側(cè)面上14個(gè)孔，9Xφ3.8深13.5，φ3.8平面至中心122.5，φ6.9 深17, 2Xφ3.8深13, φ6.5; 鉆左側(cè)面上7個(gè)孔，φ3深1，φ3.7深2.5，φ3.7深21, 2Xφ2.7深8 φ5.1深21，φ16.7深23 6. 生產(chǎn)綱領(lǐng)：大批大量 7. 批量：本機(jī)床設(shè)計(jì)、制造一臺(tái) 三、設(shè)計(jì)要求 1．機(jī)床應(yīng)能滿足加工要求，保證加工精度； 2．機(jī)床應(yīng)運(yùn)轉(zhuǎn)平穩(wěn)，工作可靠，結(jié)構(gòu)簡(jiǎn)單，裝卸方便，便于維修、調(diào)整； 3．機(jī)床盡量能用通用件以便降低制造成本； 4．設(shè)計(jì)圖樣總量：折合成A0幅面在3張以上；工具要求：應(yīng)用計(jì)算機(jī)軟件UG/NX 繪圖。過(guò)程要求：裝配圖需提供三維模型及爆炸圖； 5．畢業(yè)設(shè)計(jì)說(shuō)明書(shū)按照學(xué)校規(guī)定的格式規(guī)范統(tǒng)一編排、打印，字?jǐn)?shù)不少于1萬(wàn)字。 6．查閱文獻(xiàn)資料10篇以上，撰寫(xiě)1500～2000字左右的文獻(xiàn)綜述，并有不少于3000 漢字的外文資料翻譯； 7．到相關(guān)單位進(jìn)行畢業(yè)實(shí)習(xí)，撰寫(xiě)不少于3000字實(shí)習(xí)報(bào)告； 8．撰寫(xiě)開(kāi)題報(bào)告 9．進(jìn)行畢業(yè)設(shè)計(jì)基礎(chǔ)知識(shí)訓(xùn)練，按照規(guī)定要求考核。 四、畢業(yè)設(shè)計(jì)物化成果的具體內(nèi)容及要求 1．設(shè)計(jì)成果要求 1）畢業(yè)設(shè)計(jì)說(shuō)明書(shū) 1 份 2）三圖一卡 3）多軸箱總裝配圖 1 張 4）多軸箱體零件圖及其它零件圖 不少于5張 5）零件三維造型圖 1 張 2．外文資料翻譯（英譯中）要求 1）外文翻譯材料中文字不少于3000字。 2）內(nèi)容必須與畢業(yè)設(shè)計(jì)課題相關(guān)； 3）所選外文資料應(yīng)是近10年的文章，并標(biāo)明文章出處。 五、 畢業(yè)設(shè)計(jì)（論文）進(jìn)度計(jì)劃 起訖日期 工作內(nèi)容 備 注 1月3日～1月4日 布置任務(wù) 1月6日～1月19日 2月24日～3月9日 調(diào)查研究，畢業(yè)實(shí)習(xí) 2月24日～3月9日 方案論證，總體設(shè)計(jì) 3月10日～4月14日 技術(shù)設(shè)計(jì)（部件設(shè)計(jì)） 4月15日～5月4日 工作設(shè)計(jì)（零件設(shè)計(jì)） 5月5日～5月22日 撰寫(xiě)畢業(yè)設(shè)計(jì)說(shuō)明書(shū) 5月23日～5月24日 畢業(yè)設(shè)計(jì)預(yù)答辯 5月25日～6月4日 修改資料 6月5日～6月6日 評(píng)閱材料 6月7日～6月8日 畢業(yè)答辯 6月9日～6月15日 材料整理裝袋 六、 主要參考文獻(xiàn)： [1]陳慧. V型發(fā)動(dòng)機(jī)氣門(mén)挺桿孔加工組合機(jī)床設(shè)計(jì)[J]. 機(jī)床與液壓,2012(4):17-20 [2]張秀艷，李菊煥. 2100B1型柴油機(jī)氣缸體鉆2定位孔組合機(jī)床設(shè)計(jì)[J].制造業(yè)自 動(dòng)化，2013（10）：135-137 [3]袁旭群. 曲軸箱半精鏜缸孔并倒角組合機(jī)床的設(shè)計(jì)[J]. 機(jī)床與液壓, 2012 (4):27-29 [4]王崇今. 組合機(jī)床液壓系統(tǒng)設(shè)計(jì)[J].科技博覽，2013（4）：15 [5]吳慧萍，李前明. 立式單面四工位擴(kuò)鉸缸體挺柱孔組合機(jī)床[J]. 組合機(jī)床與自 動(dòng)化加工技術(shù)，2013（6）：119-123 [6]王夏. 淺談cy2108氣缸體頂面和底面多孔加工組合機(jī)床的設(shè)計(jì)[J].裝備制造計(jì) 術(shù)，2013（6）：92-93 [7]苗曉鵬 ,程建安. 薄壁長(zhǎng)筒零件深孔鏜削工藝與數(shù)控組合機(jī)床設(shè)計(jì)[J]. 組合機(jī) 床與自動(dòng)加工技術(shù)，2013（5）：117-119 [8]劉金勇.組合機(jī)床的結(jié)構(gòu)形式以及加工特點(diǎn)探究[J].科技風(fēng)，2013（1）：54 [9]顧琪 ,周臨震. 基于外部數(shù)據(jù)的組合機(jī)床通用部件設(shè)計(jì)與研究[J].機(jī)床組合與自 動(dòng)加工技術(shù)，2012（12）：96-98 [10]郭安斌. 變速箱體兩側(cè)面鉆孔組合機(jī)床夾具設(shè)計(jì)[J].科技向?qū)В?012（33）: 344 -346 七、其他 八、專業(yè)系審查意見(jiàn) 系主任： 年 月 日 九、機(jī)械工程學(xué)院優(yōu)集學(xué)院意見(jiàn) 院長(zhǎng)： 年 月 日 6 畢業(yè)實(shí)習(xí)報(bào)告 專 業(yè) 機(jī)械設(shè)計(jì)制造及其自動(dòng)化 學(xué) 生 姓 名 施蕾 班 級(jí) BU機(jī)制101 學(xué) 號(hào) 1011501126 指 導(dǎo) 教 師 趙健 日 期 2014年3月9日 一.概述 每年的七月份我校都會(huì)有預(yù)就業(yè)實(shí)踐。今年的預(yù)就業(yè)，通過(guò)學(xué)校的面世選拔我有幸參與了我們學(xué)院——優(yōu)集學(xué)院于上海西門(mén)子工業(yè)軟件有限公司合作的為期一年的預(yù)就業(yè)實(shí)踐。 企業(yè)介紹：西門(mén)子工業(yè)軟件（上海）有限公司，是德國(guó)西門(mén)子的一家在上海的分公司，主要是研發(fā)軟件和測(cè)試軟件，使其能夠發(fā)布，面向市場(chǎng)。更好的為各個(gè)行業(yè)所應(yīng)用。Siemens PLM Software是西門(mén)子工業(yè)自動(dòng)化事業(yè)部旗下機(jī)構(gòu)、全球領(lǐng)先的產(chǎn)品生命周期管理（PLM）軟件與服務(wù)提供商。PLM 是把更多創(chuàng)意轉(zhuǎn)化為成功產(chǎn)品的平臺(tái)，因?yàn)橹挥蠵LM才能提供以數(shù)字化方式創(chuàng)建、驗(yàn)證和管理詳細(xì)產(chǎn)品與過(guò)程數(shù)據(jù)所需的應(yīng)用深度和廣度，支持持續(xù)創(chuàng)新。該公司分為許多模塊，例如CAE,CAM,KDA.PM等。我屬于PM模塊的，實(shí)踐崗位是中級(jí)軟件應(yīng)用測(cè)試員。我的任務(wù)就是應(yīng)用學(xué)到到的nx知識(shí)在nx平臺(tái)上來(lái)測(cè)試該軟件是否存在漏洞，或者是該軟件研發(fā)出來(lái)的新功能新明令在每個(gè)版本上是否穩(wěn)定。 二．實(shí)踐過(guò)程和內(nèi)容 實(shí)踐之初，該公司領(lǐng)導(dǎo)組織了為期一個(gè)星期的培訓(xùn)活動(dòng)，讓我們熟悉該公司的大概情況和我們?cè)诮酉聛?lái)一年的大概的工作任務(wù)。培訓(xùn)過(guò)后我們學(xué)會(huì)了怎樣去下載ip 和group ,怎樣去應(yīng)用ip和group 。我們可以應(yīng)用腳本去啟動(dòng)本地的 UG，創(chuàng)建unit來(lái)啟動(dòng)nx軟件。該公司還培訓(xùn)了怎樣去錄Autotest,怎樣去開(kāi)pr test。 培訓(xùn)過(guò)后我們陸續(xù)進(jìn)入工作狀態(tài)，因?yàn)閷?duì)工作不是特別了解，有些東西還是比較陌生，所以每個(gè)實(shí)習(xí)生都被安排了一個(gè)組長(zhǎng)，由組長(zhǎng)來(lái)帶我們逐漸進(jìn)入和熟悉公司的工作流程。組長(zhǎng)對(duì)我們很有耐心，無(wú)論我們提出怎樣的問(wèn)題，他們都會(huì)很耐心的將給我們聽(tīng)，讓我們明白因果關(guān)系。 我是part modeling 組的，我們組的工作任務(wù)流程大概是這樣的： 每周一會(huì)有SLED（System Log Error Detection） 測(cè)試,就是每個(gè)人會(huì)分配不同的命令在指定的nx版本上測(cè)試這些命令，在運(yùn)用的過(guò)程中看看會(huì)出現(xiàn)什么漏洞，或比較嚴(yán)重的錯(cuò)誤。該任務(wù)是基于ip 的，所以往往在測(cè)試之前就要把應(yīng)用的ip 下載本地，在測(cè)試時(shí)，在本地創(chuàng)建個(gè)腳本啟動(dòng)nx來(lái)測(cè)試。每周三會(huì)有MG（Product Testing. Maintenance Gates）測(cè)試,該測(cè)是之前報(bào)過(guò)的pr被develper 修了，但是還沒(méi)有測(cè)試，我們的任務(wù)就是在最新的group上來(lái)檢驗(yàn)該pr是否被修好，如果沒(méi)有修好我們就會(huì)reopen it ,如果修好了，我們就將該pr的狀態(tài)改稱fx，檢測(cè)完這些pr后，我們就要進(jìn)行一些bug hunt around，手工測(cè)試來(lái)測(cè)試尋找其他類型的pr。該任務(wù)是基于Group的，所以在檢測(cè)前我們要在本地下載最新的group ，在本地創(chuàng)建該group的unit來(lái)啟動(dòng)nx。其他的時(shí)間自己就可以去自由測(cè)試或者去學(xué)習(xí)一些新的命令。我們還有FPV（Product Testing.QA_Final Prduct Validation）測(cè)試，這個(gè)時(shí)間是不穩(wěn)定的，測(cè)試時(shí)間往往是兩三周，該任務(wù)就是把某一功能應(yīng)用在不同的命令上，看該功能是否能通過(guò)，當(dāng)然在這期間也可以去手工檢測(cè)一些隱藏的pr。我個(gè)人覺(jué)得在FPV 這個(gè)過(guò)程中穴道的知識(shí)還是很多的。因?yàn)槲覀冊(cè)趯W(xué)校學(xué)習(xí)的那些應(yīng)用是比較片面的，有些命令我們不是特別熟悉甚至對(duì)我們來(lái)說(shuō)根本是沒(méi)有用過(guò)的，在該測(cè)試期間我們就要把每個(gè)命令的作用了解和掌握 ，該命令往往用在哪些方面，怎樣去運(yùn)用這些命令，我們都要去學(xué)習(xí)和揣摩，慢慢的吸收到后來(lái)很熟悉這些命令。 過(guò)了一段時(shí)間我們自己能熟悉的判斷怎樣的情況是pr，怎樣去區(qū)分是p1,p2,和p3，自己也能很熟練的書(shū)寫(xiě)pr test，file pr。 在我們比較熟悉公司的流程之后，Leader 也會(huì)讓我們參與一些項(xiàng)目中，我們會(huì)幫著AE 去完成一些任務(wù)，我們做的最多的就是Autotest,剛開(kāi)始會(huì)給我們分配一些比較簡(jiǎn)單的pr的Autotest ，就是將某個(gè)pr 的過(guò)程錄一遍，看看pr有沒(méi)有問(wèn)題。 后來(lái)我們就會(huì)錄一些命名，例如face blend,Subd,Delete face 等。這些case就是相對(duì)比較難的了，這過(guò)程中不僅要把這個(gè)命令錄一遍，而且還要對(duì)他進(jìn)行面與面之間的分析檢查，檢查在誤差內(nèi)是否正確，最后還要手工run 和athena run .要保證每個(gè)case的手工run 和athena run 要正確。在這期間我們也學(xué)到的之前所陌生的東西，由陌生到熟悉，再到掌握，一路過(guò)來(lái)我們的確學(xué)到了不少東西。 在這半年的時(shí)間期間我們也遇到了好多問(wèn)題，比如我們會(huì)隊(duì)某些命令不熟悉，不知道怎樣去運(yùn)用以前學(xué)到的知識(shí)來(lái)測(cè)試，該怎樣去測(cè)試，有時(shí)候是很盲目的。對(duì)于這些問(wèn)題我們實(shí)習(xí)生之間會(huì)先討論一下，看看是否能解決，之后我們會(huì)去咨詢我門(mén)的組長(zhǎng)，向他請(qǐng)教我們所不會(huì)的東西。 三．實(shí)踐體會(huì) 在這期間我們?yōu)楣疽沧隽艘恍┯袃r(jià)值的事情，我們找了一些有價(jià)值的pr，錄了許多case,減輕了正式員工的工作量，我們自身也學(xué)到了許多東西。 在這實(shí)習(xí)期間，我們實(shí)習(xí)生都學(xué)到了很多東西。像我，在剛來(lái)的時(shí)候，什么都感到陌生，對(duì)著全室英文的電腦，對(duì)著很室陌生的操作命令，總之感覺(jué)什么都是陌生的，什么都不適應(yīng)。雖然leader 告訴我們不要急躁，慢慢來(lái)，漸漸熟悉了解?？墒切睦镞€是不免緊張擔(dān)心，剛來(lái)得前幾個(gè)星期，我晚上睡覺(jué)總是想著怎樣去找pr，做夢(mèng)也是，那時(shí)覺(jué)得自己快瘋了呢。我們的組長(zhǎng)對(duì)我們是真的好，他看出了我們的急躁，他對(duì)我說(shuō)：要不急不燥，把態(tài)度擺正，你不要看找了多少個(gè)pr，要看你自己學(xué)到了多少東西，這一天有沒(méi)有浪費(fèi)，要學(xué)著去有想法的去做，而不是為了某一目的而去做，這樣自然會(huì)給自己造成壓力感，按著自己的想發(fā)去做自己感興趣的東西，態(tài)度決定一切。我受益匪淺，我就不那么急躁了，也慢慢的適應(yīng)了工作環(huán)境。 我其實(shí)一直以來(lái)就是個(gè)粗心大意的人，心不仔細(xì)，總是丟三落四。在這期間也完全暴露了我的這個(gè)缺點(diǎn)，在剛開(kāi)始的時(shí)候，pr test 老是出錯(cuò)，不是單詞用錯(cuò)就是字母拼錯(cuò)。組長(zhǎng)就是很有耐心的給我指出來(lái)，而且教我怎樣去寫(xiě)test ,怎樣去簡(jiǎn)化操作步驟，怎樣去判斷某個(gè)pr的根源是由哪個(gè)步驟引起的。我?guī)еo我灌輸?shù)乃枷肴プ鍪?，慢慢的我發(fā)現(xiàn)我雖然有時(shí)候還是會(huì)出錯(cuò)，但是明顯比之前少了很多，我試著自己去找問(wèn)題的根源，去盡量簡(jiǎn)化操作步驟，從和學(xué)長(zhǎng)的交流我學(xué)會(huì)了想東西一定要盡可能的想全面，做事要盡可能的細(xì)心，這樣才能盡可能的把事情作好。在這期間組長(zhǎng)會(huì)給我們開(kāi)個(gè)短會(huì)，針對(duì)每個(gè)同學(xué)的優(yōu)缺點(diǎn)進(jìn)行客觀的點(diǎn)評(píng)，我在這點(diǎn)評(píng)中重新審視自己的態(tài)度，調(diào)整自己的工作態(tài)度。 現(xiàn)階段，公司陸續(xù)為我們提供畢業(yè)設(shè)計(jì)的選題，我對(duì)其中的MCD 比較感興趣，該選題是比較罕見(jiàn)的，新的課題，具體的方面還在思考學(xué)習(xí)中，具體哪方面，等到學(xué)習(xí)了解后再做進(jìn)一步的選擇。 四．下一階段的工作 下一階段時(shí)間，公司組織人員給我們培訓(xùn)關(guān)于每次MCD的相關(guān)知識(shí)，有助于我們對(duì)MCD有進(jìn)一步的了解，讓我們能更好的選擇畢業(yè)設(shè)計(jì)的選題。確定選題之后我會(huì)慢慢進(jìn)入到畢業(yè)設(shè)計(jì)中，會(huì)去咨詢跟選題有所了解的公司前輩們，會(huì)利用周末時(shí)間來(lái)完成畢業(yè)設(shè)計(jì)。 十二月中旬左右會(huì)有關(guān)于teamcenter 的認(rèn)證考試，前段時(shí)間到先在我都在認(rèn)真的學(xué)習(xí)和復(fù)習(xí)關(guān)于teamcenter的相關(guān)知識(shí)，為認(rèn)證考試做準(zhǔn)備。Nx二次開(kāi)發(fā)也會(huì)在不久就開(kāi)課，我會(huì)按照公司和學(xué)校的要求積極參加其中，力求學(xué)到更多有價(jià)值的東西，對(duì)以后的工作會(huì)有一定的幫助的。 在這期間我也會(huì)為就業(yè)做些準(zhǔn)備，在工作之余，我會(huì)完善自己的就業(yè)簡(jiǎn)歷，多咨詢一下當(dāng)下的就業(yè)趨向。多向公司的前輩了解我們以后的就業(yè)方向，我會(huì)利用自己的額外時(shí)間來(lái)補(bǔ)充一下自己的專業(yè)知識(shí)，對(duì)本專業(yè)涉及的內(nèi)容有個(gè)大概了解，做到對(duì)本專業(yè)的就業(yè)趨向有個(gè)大概的了解。 4 外文翻譯 專 業(yè) 機(jī)械設(shè)計(jì)制造及其自動(dòng)化 學(xué)生姓名 施蕾 班 級(jí) BU機(jī)制101 學(xué) 號(hào) 1011501126 指導(dǎo)教師 趙健 外文資料名稱： Design of spindle box 外文資料出處： Department of Mechanical Engineering, National University of Singapore, Kent Ridge Crescent, Singapore 附 件： 1.外文資料翻譯譯文 2.外文原文 指導(dǎo)教師評(píng)語(yǔ)： 簽名： 年 月 日 Design of spindle box K. S. Lee and C. Luo Department of Mechanical Engineering, National University of Singapore, Kent Ridge Crescent, Singapore Abstract: This article mainly tells about the spindle box and the design of spindle box, including the modular machine tool motion control, high speed machining, the design and manufacture, and maintenance of knowledge, each item inside and he made a very in-depth explanation, the design of spindle box all aspects of a brief summary Keywords: Combination machine tools ; Spindle box ; design 1. Introduction While the specific intention and application for transfer and unit machine vary from one machine type to another, all forms of transfer and unit machine have common benefits. Here are but a few of the more important benefits offered by TRANSFER AND UNIT MACHINE equipment. The first benefit offered by all forms of transfer and unit machine is improved automation. The operator intervention related to producing workpieces can be reduced or eliminated. Many transfer and unit machine can run unattended during their entire machining cycle, freeing the operator to do other tasks. This gives the transfer and unit machine user several side benefits including reduced operator fatigue, fewer mistakes caused by human error, and consistent and predictable machining time for each workpiece. Since the machine will be running under program control, the skill level required of the transfer and unit machine operator (related to basic machining practice) is also reduced as compared to a machinist producing workpieces with conventional machine tools. The second major benefit of transfer and unit machine technology is consistent and accurate workpieces. Today's transfer and unit machines boast almost unbelievable accuracy and repeatability specifications. This means that once a program is verified, two, ten, or one thousand identical workpieces can be easily produced with precision and consistency. rd benefit offered by most forms of transfer and unit machine tools is flexibility. Since these machines are run from programs, running a different workpiece is almost as easy as loading a different program. Once a program has been verified and executed for one production run, it can be easily recalled the next time the workpiece is to be run. This leads to yet another benefit, fast change over. Since these machines are very easy to set up and run, and since programs can be easily loaded, they allow very short setup time. 1 This is imperative with today's just-in-time (JIT) product requirements. Motion control - the heart of transfer and unit machine The most basic function of any transfer and unit machine is automatic, precise, and consistent motion control. Rather than applying completely mechanical devices to cause motion as is required on most conventional machine tools, transfer and unit machines allow motion control in a revolutionary manner2. All forms of transfer and unit machine equipment have two or more directions of motion, called axes. These axes can be precisely and automatically positioned along their lengths of travel. The two most common axis types are linear (driven along a straight path) and rotary (driven along a circular path). Instead of causing motion by turning cranks and handwheels as is required on conventional machine tools, transfer and unit machines allow motions to be commanded through programmed commands. Generally speaking, the motion type (rapid, linear, and circular), the axes to move, the amount of motion and the motion rate (feedrate) are programmable with almost all transfer and unit machine tools. A transfer and unit machine command executed within the control tells the drive motor to rotate a precise number of times. The rotation of the drive motor in turn rotates the ball screw. And the ball screw drives the linear axis (slide). A feedback device (linear scale) on the slide allows the control to confirm that the commanded number of rotations has taken place3. Refer to fig.1. Fig.1 CNC system diagram Though a rather crude analogy, the same basic linear motion can be found on a common table vise. As you rotate the vise crank, you rotate a lead screw that, in turn, drives the movable jaw on the vise. By comparison, a linear axis on a transfer and unit machine machine tool is extremely precise. The number of revolutions of the axis drive motor precisely controls the amount of linear motion along the axis. How axis motion is commanded - understanding coordinate systems It would be infeasible for the transfer and unit machine user to cause axis motion by trying to tell each axis drive motor how many times to rotate in order to command a given linear motion amount4. (This would be like having to figure out how many turns of the handle on a table vise will cause the movable jaw to move exactly one inch!) Instead, all transfer and unit machine controls allow axis motion to be commanded in a much simpler and more logical way by utilizing some form of coordinate system. The two most popular coordinate systems used with transfer and unit machines are the rectangular coordinate system and the polar coordinate system. By far, the more popular of these two is the rectangular coordinate system. The program zero point establishes the point of reference for motion commands in a transfer and unit machine program. This allows the programmer to specify movements from a common location. If program zero is chosen wisely, usually coordinates needed for the program can be taken directly from the print. With this technique, if the programmer wishes the tool to be sent to a position one inch to the right of the program zero point, X1.0 is commanded. If the programmer wishes the tool to move to a position one inch above the program zero point, Y1.0 is commanded. The control will automatically determine how many times to rotate each axis drive motor and ball screw to make the axis reach the commanded destination point . This lets the programmer command axis motion in a very logical manner. Refer to fig.2, 3. Fig.2 The coordinate figure Fig.3 The coordinate figure All discussions to this point assume that the absolute mode of programming is used6. The most common transfer and unit machine word used to designate the absolute mode is G90. In the absolute mode, the end points for all motions will be specified from the program zero point. For beginners, this is usually the best and easiest method of specifying end points for motion commands. However, there is another way of specifying end points for axis motion. In the incremental mode (commonly specified by G91), end points for motions are specified from the tool's current position, not from program zero. With this method of commanding motion, the programmer must always be asking "How far should I move the tool?" While there are times when the incremental mode can be very helpful, generally speaking, this is the more cumbersome and difficult method of specifying motion and beginners should concentrate on using the absolute mode. Be careful when making motion commands. Beginners have the tendency to think incrementally. If working in the absolute mode (as beginners should), the programmer should always be asking "To what position should the tool be moved?" This position is relative to program zero, NOT from the tools current position. Aside from making it very easy to determine the current position for any command, another benefit of working in the absolute mode has to do with mistakes made during motion commands. In the absolute mode, if a motion mistake is made in one command of the program, only one movement will be incorrect. On the other hand, if a mistake is made during incremental movements, all motions from the point of the mistake will also be incorrect. Assigning program zero Keep in mind that the transfer and unit machine control must be told the location of the program zero point by one means or another. How this is done varies dramatically from one transfer and unit machine and control to another8. One (older) method is to assign program zero in the program. With this method, the programmer tells the control how far it is from the program zero point to the starting position of the machine. This is commonly done with a G92 (or G50) command at least at the beginning of the program and possibly at the beginning of each tool. Another, newer and better way to assign program zero is through some form of offset. Refer to fig.4. Commonly machining center control manufacturers call offsets used to assign program zero fixture offsets. Turning center manufacturers commonly call offsets used to assign program zero for each tool geometry offsets. Fig. 4 Flexible manufacturing cells A flexible manufacturing cell (FMC) can be considered as a flexible manufacturing subsystem. The following differences exist between the FMC and the FMS: 1. An FMC is not under the direct control of the central computer. Instead, instructions from the central computer are passed to the cell controller. 2. The cell is limited in the number of part families it can manufacture. The following elements are normally found in an FMC: Cell controller Programmable logic controller (PLC) More than one machine tool A materials handling device (robot or pallet) The FMC executes fixed machining operations with parts flowing sequentially between operations. 2 High speed machining The term High Speed Machining (HSM) commonly refers to end milling at high rotational speeds and high surface feeds. For instance, the routing of pockets in aluminum airframe sections with a very high material removal rate1. Over the past 60 years, HSM has been applied to a wide range of metallic and non-metallic workpiece materials, including the production of components with specific surface topography requirements and machining of materials with hardness of 50 HRC and above. With most steel components hardened to approximately 32-42 HRC, machining options currently include: Rough machining and semi-finishing of the material in its soft (annealed) condition heat treatment to achieve the final required hardness = 63 HRC machining of electrodes and Electrical Discharge Machining (EDM) of specific parts of dies and moulds (specifically small radii and deep cavities with limited accessibility for metal cutting tools) finishing and super-finishing of cylindrical/flat/cavity surfaces with appropriate cemented carbide, cermet, solid carbide, mixed ceramic or polycrystalline cubic boron nitride (PCBN) For many components, the production process involves a combination of these options and in the case of dies and moulds it also includes time consuming hand finishing. Consequently, production costs can be high and lead times excessive. It is typical in the die and mould industry to produce one or just a few tools of the same design. The process involves constant changes to the design, and because of these changes there is also a corresponding need for measuring and reverse engineering . The main criteria is the quality level of the die or mould regarding dimensional, geometric and surface accuracy. If the quality level after machining is poor and if it cannot meet the requirements, there will be a varying need of manual finishing work. This work produces satisfactory surface accuracy, but it always has a negative impact on the dimensional and geometric accuracy. One of the main aims for the die and mould industry has been, and still is, to reduce or eliminate the need for manual polishing and thus improve the quality and shorten the production costs and lead times. Main economical and technical factors for the development of HSM Survival The ever increasing competition in the marketplace is continually setting new standards. The demands on time and cost efficiency is getting higher and higher. This has forced the development of new processes and production techniques to take place. HSM provides hope and solutions... Materials The development of new, more difficult to machine materials has underlined the necessity to find new machining solutions. The aerospace industry has its heat resistant and stainless steel alloys. The automotive industry has different bimetal compositions, Compact Graphite Iron and an ever increasing volume of aluminum3. The die and mould industry mainly has to face the problem of machining high hardened tool steels, from roughing to finishing. Quality The demand for higher component or product quality is the result of ever increasing competition. HSM, if applied correctly, offers a number of solutions in this area. Substitution of manual finishing is one example, which is especially important on dies and moulds or components with a complex 3D geometry. Processes The demands on shorter throughput times via fewer setups and simplified flows (logistics) can in most cases, be solved by HSM. A typical target within the die and mould industry is to completely machine fully hardened small sized tools in one setup. Costly and time consuming EDM processes can also be reduced or eliminated with HSM. 3 Design & development One of the main tools in today's competition is to sell products on the value of novelty. The average product life cycle on cars today is 4 years, computers and accessories 1.5 years, hand phones 3 months... One of the prerequisites of this development of fast design changes and rapid product development time is the HSM technique. Complex products There is an increase of multi-functional surfaces on components, such as new design of turbine blades giving new and optimized functions and features. Earlier designs allowed polishing by hand or with robots (manipulators). Turbine blades with new, more sophisticated designs have to be finished via machining and preferably by HSM . There are also more and more examples of thin walled workpieces that have to be machined (medical equipment, electronics, products for defence, computer parts) Production equipment The strong development of cutting materials, holding tools, machine tools, controls and especially CAD/CAM features and equipment, has opened possibilities that must be met with new production methods and techniques5. Definition of HSM Salomon's theory, "Machining with high cutting speeds..." on which, in 1931, took out a German patent, assumes that "at a certain cutting speed (5-10 times higher than in conventional machining), the chip removal temperature at the cutting edge will start to decrease..." Given the conclusion:" ... seems to give a chance to improve productivity in machining with conventional tools at high cutting speeds..." Modern research, unfortunately, has not been able to verify this theory totally. There is a relative decrease of the temperature at the cutting edge that starts at certain cutting speeds for different materials. The decrease is small for steel and cast iron. But larger for aluminum and other non-ferrous metals. The definition of HSM must be based on other factors. Given today's technology, "high speed" is generally accepted to mean surface speeds between 1 and 10 kilometers per minute or roughly 3 300 to 33 000 feet per minute. Speeds above 10 km/min are in the ultra-high speed category, and are largely the realm of experimental metal cutting. Obviously, the spindle rotations required to achieve these surface cutting speeds are directly related to the diameter of the tools being used. One trend which is very evident today is the use of very large cutter diameters for these applications - and this has important implications for tool design. There are many opinions, many myths and many different ways to define HSM.Maintenance and troubleshooting 4 Maintenance for a horizontal MC The following is a list of required regular maintenance for a Horizontal Machining Center as shown in fig.5. Listed are the frequency of service, capacities, and type of fluids required. These required specifications must be followed in order to keep your machine in good working order and protect your warranty. fig. 5 Horizontal Machining Center Daily Top off coolant level every eight hour shift (especially during heavy TSC usage). Check way lube lubrication tank level. Clean chips from way covers and bottom pan. Clean chips from tool changer. Wipe spindle taper with a clean cloth rag and apply light oil. Weekly Check for proper operation of auto drain on filter regulator. On machines with the TSC option, clean the chip basket on the coolant tank. Remove the tank cover and remove any sediment inside the tank. Be careful to disconnect the coolant pump from the controller and POWER OFF the control before working on the coolant tank . Do this monthly for machines without the TSC option. Check air gauge/regulator for 85 psi. For machines with the TSC option, place a dab of grease on the V-flange of tools. Do this monthly for machines without the TSC option. Clean exterior surfaces with mild cleaner. DO NOT use solvents. Check the hydraulic counterbalance pressure according to the machine's specifications. Place a dab of grease on the outside edge of the fingers of the tool changer and run through all tools". Monthly Check oil level in gearbox. Add oil until oil begins dripping from over flow tube at bottom of sump tank. Clean pads on bottom of pallets. Clean the locating pads on the A-axis and the load station. This requires removing the pallet. Inspect way covers for proper operation and lubricate with light oil, if necessary. Six months Replace coolant and thoroughly clean the coolant tank. Check all hoses and lubrication lines for cracking. Annually Replace the gearbox oil. Drain the oil from the gearbox, and slowly refill it with 2 quarts of Mobil DTE 25 oil. Check oil filter and clean out residue at bottom for the lubrication chart. Replace air filter on control box every 2 years. Mineral cutting oils will damage rubber based components throughout the machine. Troubleshooting This section is intended for use in determining the solution to a known problem. Solutions given are intended to give the individual servicing the TRANSFER AND UNIT MACHINE a pattern to follow in, first, determining the problem's source and, second, solving the problem. Use common sense Many problems are easily overcome by correctly evaluating the situation. All machine operations are composed of a program, tools, and tooling. You must look at all three before blaming one as the fault area. If a bored hole is chattering because of an overextended boring bar, don't expect the machine to correct the fault. Don't suspect machine accuracy if the vise bends the part. Don't claim hole mis-positioning if you don't first center-drill the hole. Find the problem first Many mechanics tear into things before they understand the problem, hoping that it will appear as they go. We know this from the fact that more than half of all warranty returned parts are in good working order. If the spindle doesn't turn, remember that the spindle is connected to the gear box, which is connected to the spindle motor, which is driven by t