THERMAL SIMULATION OF CNC MILLING MACHINE DRIVES

The publication deals with the design of thermal simulation of CNC milling machine drives. The first part of the publication defines the individual parts of the thermal model concept and their mutual influence. Subsequently, simulations of drives were created. The first thermal model is defined for a stepper motor which is a drive for the linear axes of a CNC milling machine. Subsequently, the design of the thermal drive of the spindle is analysed, which uses a DC motor with permanent magnets. Using previous models of the drive, a model of the entire CNC milling machine was designed. In the last part, the model was compared with real measurements, which evaluated the tolerances of the system.

Optimization of an autonomous robotic drilling system for the machining of aluminum aerospace alloys

This paper aims to identify the capability of a highly flexible industrial robot modified with a high-speed machine spindle for drilling of aluminum 6061-T6. With a focus on drilling feed rate, spindle speed, and pecking cycle, the hole surface roughness and exit burr heights were investigated using the Taguchi design methodology. A state of the art condition monitoring system was used to identify the vibrations experienced during drilling operation and to establish which robot pose had increased stiffness, and thus the optimum workspace for drilling. When benchmarked against a CNC machine the results show that the CNC was capable of producing the best surface finish and the lowest burr heights. However, the robot system matched and outperformed the CNC in several experiments and there is much scope for further optimization of the process. By identifying the optimum pose for drilling together with the idealized settings, the proposed drilling system is shown to be far more flexible than a CNC milling machine and when considering the optimized drilling of aerospace aluminum this robotic solution has the potential to drastically improve productivity.

Effect of feed rate and depth of cut on face milling process on surface roughness of Al-Mg alloy using CNC milling machine 3 axis

The purpose of this study was to determine the effect of feed rate and depth of cut on the surface roughness of Al-Mg aluminum using a DIY CNC Milling Machine and Krisbow Universal Milling Machine as a comparison. The open-loop control system is a control system used in the design of DIY CNC Milling machines. A PC with Mach3 software is used as a PC Based Direct Digital Controller to control the system. In this study, the feed rate variation 24 mm/minute and 42 mm/minute and depth of cut 0.25 mm, 0.5 mm, and 0.75 mm were used. After the face milling process, the surface roughness test was carried out using the Mitoyo Surface Roughness Tester to determine the level of surface roughness of the machining results the DIY Milling Machine and Krisbow Universal Milling Machine as a comparison. The results showed that as the feed rate and depth of cut increased, the surface roughness values of both tools increased.

Research and Practice of Intelligent Tool Setting Device for CNC Milling Machine

The utilization of intelligent tool setting device of CNC milling machine can reduce the probability of tool setting error, better guarantee the normal operation of CNC milling machine and the safety of relevant operators, and avoid unnecessary losses. Based on this, this paper first analyses the coordinate system of CNC milling machine and the concept of tool setting, then studies the operation method of tool setting device of CNC milling machine, and finally gives the design and practice of intelligent tool setting device of CNC milling machine.

Development and Implementation of a Mini CNC Milling Machine

The development of mechanical processing machines with integrated CNC systems allows the manufacturing industry to produce complex products quickly with high quality. CNC has become a main course for mechanical students in technical and vocational universities. CNC machine training is required to enhance student’s skills to learning in design and manufacturing technology. However, the cost to buy a CNC machine is not cheap. In a developing country like Vietnam, along with the limited budget of most universities, this is an obstacle for students to have the opportunity to use CNC machines. To help students have a teaching aid in learning, improve practice capacity. The article proposes an alternative to design and manufacture a simple, inexpensive milling machine with all the required functions. The CAD models design of the machine model structure were done using Solidwork and NX software. Most of the machine’s parts are manufactured and assembled in the Faculty of Engineering Mechanics and Automation laboratory of Engineering and Technology, Vietnam National University Hanoi. The study’s main objective is to propose a process for designing and manufacturing a mini vertical 3-axis CNC milling machine with low cost but full features similar to an industrial CNC machine. The machine model introduced in the article can be used as a teaching aid, improving practical capacity for students of machine building

Experimental Investigation on Surface Roughness and Metal Removal Rate of Aluminium 2024 Alloy

The purpose of this work is to investigate experimentally the surface roughness and MRR while machining of aluminium 2024 alloy which is prepared by powder metallurgical technique. Aluminium 2024 alloy prepared with different composition such as Pure Al, 1.5 W% of Mg and 2-6 % of Cu powders. Powders are blended with ball milling machine according to the composition required and specimens are prepared in square shape die (25*25mm) by applying uniaxial load of 200Mpa. The sintering process was performed at 594 0C for 60 min and cooled at room temperature. SEM and XRD analysis was carried out to know various characteristics like green density, dimensional changes during sintering, sintering density, mechanical properties and microstructures. Finally the Surface roughness and MRR during machining with CNC milling machine at different depth of cuts was also evaluated. Keywords: Aluminium 2024 alloy, surface roughness, MRR, SEM and XRD analysis