Machine Tool Service for Mass-Production Machining Systems

2018 ◽  
Vol 12 (4) ◽  
pp. 507-513
Author(s):  
Makoto Fujishima ◽  
◽  
Takashi Hoshi ◽  
Hiroki Nakahira ◽  
Masafumi Takahashi ◽  
...  
Keyword(s):  
Machine Tool ◽  
Production System ◽  
Mass Production ◽  
Machine Tools ◽  
Production Systems ◽  
Production Volume ◽  
Machining Processes ◽  
In Series ◽  
Tool Service ◽  
Large Production

Mass-production machining systems that are comprised of machine tools are often configured in series by dividing the machining processes in order to manage the large production volume. This indicates that if one of the machines stops owing to a mechanical malfunction, the entire production line needs to be stopped. Thus, machine tools in mass-production systems are required to be highly reliable and easy to maintain. Predictive maintenance, which enables operators to detect any signs of failure in the machine tool components, needs to be performed for the machines as well. In this work, various approaches for the improvement of the maintainability of machine tools used in a mass-production system are reported.

scholarly journals Measuring the bore straightness during reaming with sensoric tools

2020 ◽  
Vol 14 (4) ◽  
pp. 535-544
Author(s):  
Andreas Bretz ◽  
Eberhard Abele ◽  
Matthias Weigold
Keyword(s):  
Mass Production ◽  
Cost Efficiency ◽  
Machine Tools ◽  
Processing Time ◽  
Process Chain ◽  
Machining Processes ◽  
High Quality ◽  
Random Samples ◽  
Hydraulic Valves ◽  
Productive Time

Abstract Reaming plays a crucial role in production to meet the high quality requirements of precision bore machining. It is either directly responsible for the final component quality or influences subsequent processes such as honing. The narrow tolerances are usually monitored by measuring random samples in mass production due to cost efficiency. Having a closer look at an exemplary process chain for the production of hydraulic valves shows the possibility to adapt the honing parameters which reduces processing time and costs. However, the bore straightness after the reaming process has to be known. In this paper an approach is presented which allows to record the bore straightness within the productive time. For this purpose, a sensory reaming system is developed. It can be used without additional components in the machine tool and thus integrated into existing machining processes. Cutting tests show that the system is able to measure the bore straightness as good as sensing probes used in machine tools.

scholarly journals Flexibility of production systems and prepare-finish time

2006 ◽  
pp. 23-30 ◽  
Author(s):  
Milan Vukicevic
Keyword(s):  
Production System ◽  
Mass Production ◽  
Production Systems ◽  
Production Cycle ◽  
Finish Time ◽  
Significant Element ◽  
Wide Range ◽  
Eastern Japan

One of the specificities of the large-serial and mass production is the almost neglected percentage of prepare-finish time in the production cycle. In the conditions of today dominant discontinuous production, it becomes a significant element of the production cycle. The eastern (Japan) doctrine of increasing the flexibility of the production systems, is based inter alia also on the extreme reduction of the prepare-finish time. For this reason, the aim of this study was to identify the types and percentages of individual jobs within the group of prepare-finish jobs. The sample consisted of 3 (three) production systems for the production of joinery, with the discontinuous production system. The research shows that the percentage of time of the jobs installation of work instruments, regulation of processing regime, and removal of work instruments is extremely long and that it ranges between 11.83% and 18.93% of the shift time. The reasons of the high percentage of these jobs are the wide range of products and the absence of the rationalisation of prepare-finish jobs. Within the efforts to minimize the effects of disruption and to increase the flexibility of the production systems, the rationalisation of prepare-finish jobs is the unavoidable condition.

Seru Production System

2021 ◽  
pp. 113-138
Author(s):  
Emre Bilgin Sarı ◽  
Sabri Erdem
Keyword(s):  
Production System ◽  
Mass Production ◽  
Lean Manufacturing ◽  
Manufacturing Systems ◽  
Job Shop ◽  
Production Systems ◽  
Cost Effective ◽  
Opportunity To Respond ◽  
Manufacturing Management ◽  
The Impact

Seru production system is a flexible, cost-effective, workforce competence-oriented manufacturing management system that provides the opportunity to respond quickly to customer demand. As in parallel to technology and physical improvements, customer demands are also effective for development of production systems. The impact of change in demand has been seen on changeover from job shop to mass production, flexible, and lean manufacturing systems. Seru production system is more appropriate for targeting work both cost-effectively like mass production and maximum diversification like job shop production. This chapter clarifies the Seru production system and explain its use and benefits in the clothing industry. In the application, a shirt production is illustrated according to the principles of mass production, lean production, and Seru production. Thus, different types of production systems have been benchmarked. There will be potential study areas for proving the efficiency of Seru soon.

Simulation-Based Dimensioning of the Required Actuator Force for Active Vibration Control

2018 ◽  
Vol 12 (5) ◽  
pp. 658-668 ◽  
Author(s):  
Robin Kleinwort ◽  
◽  
Philipp Weishaupt ◽  
Michael F. Zaeh
Keyword(s):  
Machine Tool ◽  
Vibration Control ◽  
Machine Tools ◽  
Active Vibration Control ◽  
Depth Of Cut ◽  
Force Model ◽  
Machining Processes ◽  
Simulation Based ◽  
Active Vibration ◽  
The Right

The material removal rates of machine tools are often limited by chatter, which is caused by the machine’s most flexible structural modes. Active vibration control systems mitigate chatter vibrations and increase the chatter-free depth of cut. The systems can be used for already-in-use machine tools in particular as a retrofit solution. Unfortunately, no dimensioning techniques exist to help in finding the right actuator size required for a specific machine tool. This publication presents a simulation-based dimensioning methodology that determines, based on a stability analysis, the required actuator force and bandwidth. First, the critical machining processes, based on machine tool specific parameters, are identified. Then, the required actuator force and bandwidth are determined with the help of a coupled simulation model that consists of a cutting force model, the machine’s structural dynamics, and a model of the active vibration control system.

scholarly journals Модели и интеллектуальные инструментальные средства адаптивного планирования экономического роста производственных систем

2020 ◽  
Author(s):  
T.G. Aygumov ◽  
V.B. Melekhin
Keyword(s):  
Production System ◽  
Production Systems ◽  
Control Object ◽  
Adaptive Planning ◽  
Missed Opportunities ◽  
Intelligent Decision Making ◽  
Intelligent Decision ◽  
Unstable Environment ◽  
Current Production ◽  
Large Production

Рассмотрены основные проблемы, связанные с планированием развития сложных производственных систем в нестабильных условиях современной инвестиционной экономической среды. Предложены два принципа построения адаптивных планов производственной деятельности и развития крупных производственных систем, основанные на применении математического аппарата нечетких множеств для обобщения знаний в интеллектуальных системах принятия решений. Первый принцип планирования сводится к построению пассивного адаптивного плана развития, структура которого остается неизменной на протяжении всего отчетного периода работы производственной системы. Реализация такого плана сводится к достижению одного из запланированных результатов в соответствии с изменениями, происходящими в окружающей среде объекта управления. Недостатком такого планирования является проявление упущенных возможностей в тех случаях, когда производственная система могла бы повлиять своими силами на текущую производственную ситуацию и пойти по более эффективному пути развития. Второй принцип базируется на выборе наиболее эффективного плана функционирования и развития производственной системы, реализация которого осуществляется путем ее активного влияния на происходящие в окружающей среде изменения. Показано, что сочетание обоих принципов адаптивного планирования позволяет производственной системе эффективно функционировать и развиваться в нестабильной окружающей среде при наличии спонтанно происходящих в ней изменений.The main problems associated with planning the development of complex production systems in unstable conditions of the modern investment economic environment are considered. Two principles of constructing adaptive plans for production activities and the development of large production systems based on the use of the mathematical apparatus of fuzzy sets to generalize knowledge in intelligent decision-making systems are proposed. The first planning principle comes down to building a passive adaptive development plan, the structure of which remains unchanged throughout the reporting period of the production system. The implementation of such a plan is reduced to the achievement of one of the planned results in accordance with changes in the environment of the control object. The disadvantage of such planning is the manifestation of missed opportunities in those cases when the production system could influence on its own the current production situation and take a more efficient development path. The second principle is based on the selection of the most effective plan for the functioning and development of the production system, the implementation of which is carried out by its active influence on changes in the environment. It is shown that a combination of both principles of adaptive planning allows the production system to function and develop efficiently in an unstable environment in the presence of changes occurring spontaneously in it.

A Digital Twin of Multi-Axis Machine Tool for Micro Process Planning

2020 ◽  
Author(s):  
Fumiki Tanaka
Keyword(s):  
Machine Tool ◽  
Process Planning ◽  
Machine Tools ◽  
High Performance ◽  
Production Systems ◽  
Planning System ◽  
Digital Twin ◽  
Virtual Machining ◽  
Process Planning System ◽  
Case Data

Abstract Achieving high performance of machining production systems requires the use of multi-axis machine tools. In order to maximize the performance of multi-axis machine tools, micro process planning for creating machining data is important. Many researches on micro process planning mainly focused on 3-axis machining. As promising approaches among them, a micro process planning system was proposed that reuses actual machining cases and analyzes case data to derive the necessary rules. However, it is not always effective for multi-axis machining, because enough case data are not collected for micro process planning of a specific multi-axis machine tool. In this study, a digital twin of multi-axis machine tool in cyberspace is proposed to collect real and virtual machining case data for micro process planning.

scholarly journals Risk-Optimized Design of Production Systems by Use of GRAMOSA

2014 ◽  
Vol 2014 ◽  
pp. 1-9
Author(s):  
Michael Lütjen ◽  
Abderrahim Ait Alla
Keyword(s):  
Production System ◽  
Production Systems ◽  
System Development ◽  
Discrete Event ◽  
Mathematical Optimization ◽  
Optimized Design ◽  
Domain Specific Modeling ◽  
In Series ◽  
Production Technologies ◽  
Optimized Allocation

Today production and logistic systems are getting more complex. This is a problem which the planning and design of such systems have to deal with. One main issue of production system development in series production is the planning of production processes and systems under uncertainty. New and existing production technologies are often not fully adoptable to new products. This is why some of the main characteristics, like, for example, cost, time, or quality, are not definable at the beginning. Only value ranges and probabilities can be estimated. However, the adaptation process is controllable, which means that the adaptation results are depending on the existing development budget and its resources. This paper presents an approach for the optimized allocation of development resources regarding the adaptation risks of production technologies and processes. The modeling concept GRAMOSA is used for integrated modeling and discrete event-based simulation of the aspired production system. To this end a domain-specific modeling language (DSML) is applied. The further risk-based analysis of the simulation results and the optimized allocation of the development budget are done by use of mathematical optimization.

Design and Evaluation of a New-Type Multifunctional Machine Tool - Functional Requirements and Design -

1997 ◽  
Vol 9 (6) ◽  
pp. 427-433 ◽  
Author(s):  
Nobuhiro Sugimura ◽  
◽  
Shigeru Ueno ◽  
Nozomi Mishima ◽  
Soichi Hachiga ◽  
...  
Keyword(s):  
Machine Tool ◽  
Machine Tools ◽  
Scale Model ◽  
Manufacturing Processes ◽  
Functional Requirements ◽  
Machining Processes ◽  
Mechanical Products ◽  
New Type ◽  
Set Up ◽  
Basic Configuration

The objective of this research is to develop a new type of flexible and multifunctional machine tool which can be integrated into such manufacturing processes as machining, inspection and the heat treatment of mechanical products. The functional requirements of the multifunctional machine tools were initially analyzed based on a questionnaire given to both the users and the designers of machine tools. The basic configuration of the machine tool is proposed to conform to the functional requirements. The configuration designed has two main spindles, for both the tool and the work, one subspindle, and eight rotational and linear feed axes. All the machining processes of turning, milling, 5-axis machining of sculpted surfaces, grinding, slotting gear shaving and laser processing can be carried out using the proposed machine tool without the need for manual set-ups. A simulation model and a scale model are developed that simulate the manufacturing motion processes and the set-up processes of the machine tool.

Design, Modeling and Functionality Allocation in Mechatronic Production Systems

2008 ◽  
Author(s):  
Reimund Neugebauer ◽  
Welf-Guntram Drossel ◽  
Steffen Ihlenfeldt ◽  
Markus Wabner
Keyword(s):  
Machine Tool ◽  
Machine Tools ◽  
Manufacturing Systems ◽  
Metal Cutting ◽  
Production Systems ◽  
Intervention Strategies ◽  
Electronic Unit ◽  
Mechatronic Systems ◽  
Thermal Errors ◽  
Damping Of Vibrations

This paper reviews current developments in mechatronic systems for metal cutting and forming machine tools. The integration of mechatronic modules to the machine tool and their interaction with manufacturing processes are presented. Sample mechatronic components for precision positioning and compensation of static, dynamic and thermal errors are presented as examples. The effect of modular integration of mechatronic systems on the reconfigurability and reliability of the machine tools is discussed along with intervention strategies during machine tool operations. The performance and functionality aspects are discussed through active and passive intervention methods. A special emphasis was placed on active and passive damping of vibrations through piezo, magnetic, and electro-hydraulic actuators. The modular integration of mechatronic components into the machine tool’s structure, electronic unit, and CNC software system is presented. The paper concludes with the current research challenges required to expand the application of mechatronics in machine tools and manufacturing systems.

Approach to Forecast Energy Consumption of Machine Tools within the Design Phase

2013 ◽  
Vol 769 ◽  
pp. 278-284 ◽  
Author(s):  
Karl Doreth ◽  
Jan Henjes ◽  
Stefan Kroening
Keyword(s):  
Energy Consumption ◽  
Machine Tool ◽  
Machine Tools ◽  
Production Systems ◽  
Design Phase ◽  
Empirical Information ◽  
Complex Simulation ◽  
Data Feedback ◽  
Acquisition Costs

For environmental and economic reasons, energy- and resource- efficient operations of cutting machines are increasingly important. The determination of properties and functions of machine tools, which affect future energy consumption in operation, essentially takes place within the design phase by combining required components. Therefore, it is necessary to develop approaches to find an efficient optimum between energy consumption, productivity, acquisition costs and operating costs within the design phase of a machine tool. However, the energy consumption of a machine tool depends on the application scenario. In addition to that, it is difficult to forecast the energy consumption of several components because of their mutual interaction. Existing approaches to forecast the energy consumption of a machine tool within design phase are based on complex simulation or mathematical models which are difficult to parameterize for the design of a machine tool and thus, for the comparison of various configuration alternatives. An alternative for forecasting energy consumption is the use of empirical information. That information can be acquired by measuring the energy consumption of machine tools in operating production systems. This paper presents an approach to forecast the energy consumption of machine tools within the design phase, which will be developed by the Institute of Production Engineering and Machine Tools. It will be based on the data feedback (empirical information) from a machine tool operating in an existing manufacturing system. For this purpose, a logger module will be developed, which continually captures the energy consumption by means of the machine integrated sensors. That information will be sent back to an energy navigator module, which processes that information in order to forecast the energy consumption of a new designed machine tool. Also, the lifecycle costs will be calculated in order to rate cost and benefits of each machines lifecycle in terms of energy consumption.

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