21st Century Manufacturing Episode 11 pdf

294 Metel-Producte Manufacturing Chap. 7 ~~ OOI Chip t generated 00 tool Secondary zone of hea " Wmk materiale-e-Prim,." jl'l roo with bhrnt tool • heat ._ _ .• ~ Tertiary zone of heat genera I source . fheatgeneration. F1pre7.12 Regions o Experimental (dashedlines] Theory (full lines) 7.3 Controlling the Machining Process 295 Diamond is not the stable form of carbon at atmospheric pressure. Fortunately, it does not revert to the graphitic form in the absence of air at temperatures below 1,5OO°C.In contact with iron, however, graphitization begins just over 730°C,and oxygen begins to etch a diamond surface at about 830°C. It is also disappointing that diamond tools are rapidly worn when cutting nickel and aerospace alloys.Generally, they have not been recommended for machining high- melting-point metals and alloyswhere high temperatures are generated at the interface. The family with the highest hot hardness is the alumina-based (AI 2 0 3 ) group, and these are favored for high-speed facing of cast iron. Cast iron machines with a well- controlled "shower" of short chips that facilitate high-speed cutting. However, the Al 2 0 3 -based materials are also very brittle, and they have limited use for cutting steels. Empirically, it can be shown that tool life decreases with increases in cutting speed, as shown in Figure 7.13. It turns out that the prolific F W. Taylor also took great interest in this topic. The optimization of cutting speeds fell in naturally with his interests in the principles of scientific management. By the time the results of his Taylor equation were applied to the Midvale Steelworks, a productivity gain of 200% to 300% was achieved on the machine tools, which also created a 25% to l00'Yo increase in the wages of the machinists. Taylor found that if the data are replotted on log-log axes, a straight line is obtained for most tool-work combinations. This observation led to a wide series of plots of the type shown in Figure 7.14. The famous "Taylor equation" relates the cutting speed, V, and tool life, T, to the con- stants nand C, particular to each tool work combination. VT"=C (7.12) logT = ~ logY + -;;logC (7.13) T = (~);~:ddheldCOnS!ant (7.14) Tool life, T, is also sensitive to feed rate,f(with V and d held constant), and to depth- of-cut (with V and fheld constant), see Figure 7.15. Speed (It/min) flpre 7.13 Tool life venus cutting speed. 298 Metal-Products Manufacturing Chap. 7 logT General observation : straight line logY Flgure 7.14 Log-log plot of tool life versus cutting speed 10'T~ 10'T~ n l ~ log( logd ~ G 1 T=(71)~anddheldcon't.nt 1 T=(72)~.ndfh"ldoon't.nt Figure 7.15 Tool life variations with feed rate and depth-of-cut. However, it is found that 1 1 1 -<-<- »2 "1 n (7.15) This physically means that with (n2 >"1> n),changes in cutting speed, rather than feed rate or depth-of-cut, will result in greater amounts of tool wear. 7.3.4 Significance to Work Holding and FIX1uring The forces F c and F T generated during milling or turning are resisted by a family of work-holding devices called-depending on the context and the specific machining process-c-nxtures, jigs, clamps, vises, and chucks, The accuracy that can be obtained in a particular machining process is directly related to the reliability of these work- holding devices that allow standard manufacturing machines to process specific parts. Fixtures are a subset of work-holding units designed to facilitate the setup and holding of a particular part. The fixture must conform to specific surfaces on the part so that all 6 degrees of freedom are stabilized. Forces and vibrations inherent in the manufacturing process must be resisted by the fixture. A jig supports the work like a fixture while also guiding a tool into the workpiece. A jig for drilling, for instance, 7.3 Controlling the Machining Process 297 might contain a hardened bushing to guide the drill to a precise location on the part being processed. Both fixtures and jigs are usually custom configured to suit the part being man- ufactured. Hence tooling engineers have endeavored to give these devices flexibility and modularity so that they can be applied to the greatest possible set of part styles. Such flexibility is even more important today, since the trend in manufacturing is toward production in small batch sizes (Miller, 1985). Batch production represents 50% to 75% of all manufacturing, with 85% of the batches consisting of fewer than 50 pieces (Grippo et al., 1988).As the batch size for a particular part decreases, mod- ulanzing fixtures and jigs can help to minimize the setup costs per unit produced. Developments in microprocessor-based controllers, sensors, and holding devices in the last decade have made this goal more feasible. Today's fixture designers depend on heuristics such as the "3·2-1rule," which states that a part will be immobilized when it is rigidly contacting six points (Hoffman, 1985). Three points define a plane called the primary datum, and two additional points create the secondary datum. The tertiary datum consists of a single point contact. These six locations fix the part position relative to the cutter motions (see Figure 7.16). If friction is considered, fewer contacts can be used, so long as the applied cut- ting forces are not excessive. The choice of these datum points is often left up to the fixture designer. However, workpieces used in demanding applications can have their datums explicitly stated in the part drawing. These datums are also used to specify geometric relationships between part features such as perpendicularity, flat- ness, or concentricity. Information on tolerancing can be found in Hoffman (1985). Once a suitable set of contact locations on the part has been determined, a rigid structure must be devised to hold these contacts in space. Also, the contact type must be selected. Finally, a set of clamps is chosen that apply forces to the part so that it will remain secured. For complex parts, the final fixture will be a custom designed device that only works for that part with minor variations. A fixture is composed ofactive elements that apply clamping forces and passive elements that locate or support the part. For simple parts a custom designed fixture is not needed. Instead, simpler setups are built that use at least one active element and optional mechanical stops. In the absence of stops, the part can be manually located. Since the loaded position of each part of the same type must be measured, Figure 7.16 The "3·2-1"rule on the primary datum plane. Tertrary datum poinr / Primary datum plane Secondary datum line 298 Metal-Products Manufacturing Chap. 7 the time cost of using a simpler setup balances against the cost of building a special fixture. Figure 7.17 shows some common passive fissuring elements. The primary datum can be defined by a subplate that is fixed to the machine tool. When angled features are called for in the part drawing, a sine plate may be used. It can reorient the primary datum to any angle from 0 to 90 degrees. They are usually set manually. Angle blocks or plates perform the same function but are not adjustable. Parallel and riser blocks can lift the part up a precise amount. Fixed parallels can be used as a "fence" to prevent motion in the horizontal plane. Vee blocks give two line contacts so that cylindrical parts can be fixtured. Spherical and shoulder locators are used to establish a vertical or horizontal position. The spherical locator more closely approximates a point contact. This is desirable when the surface being clamped is wavy or when datums are explicitly defined in the part drawing. The parallel-sided machining vise is a versatile tool capable of both active clamping and locating prismatic workpieces (Figure 7.18). Special jaws can be inserted that conform to irregular part shapes. The vise consists of two halves, one that is fixed and one that moves toward the fixed portion of the vise.When the vise ~( ~~ Sineplate Right angleplate "tiIIiJ 8 rJ e Parallels Veeblocks Spherical Flat Shoulder locator locator locator ~ Subplate Figure7.}7 Passive Iixturing elernents Sideclamp Chuck FIpre 7.18 Activefixtureelements includingthe standardparallel-sidedvise. Toeclllmp Vise 7.3 Controlling the Machining Process 299 jaws have a shoulder and one additional stop, all degrees of freedom are eliminated. Under light machining loads, these additional locators may not be necessary. Chucks provide an analogous function for rotationally symmetric parts. They have multiple jaws that move radially and, in some cases, independently. A chuck is used in Figure 7.3 to locate and clamp the part. Although such three-jaw chucks have limited accuracy due to finite rigidity and clearances similar to the vise, their flexi- bility makes them the standard lathe fitting. Toe clamps and side clamps provide a smaller area of contact and do not locate the part. Toe clamps exert vertical forces on the workpiece and are often used when large or irregular parts, such as castings or flat plates, are being machined. Side clamps provide supplemental horizontal forces that support the part against stops. For safety reasons, they are rarely used alone since the part may become dislodged. The nature of the contact between the part and the fixture or chuck establishes the maximum clamping force that can be exerted on the part without crushing it and the number of degrees of freedom effectively removed. A greater area of contact means that the clamping forces can be lower. One area of research has been in devel- oping conformable fixtures that increase the area of contact for irregular workpiece shapes. Line contact and point contact induce greater stresses in the material but pro- vide a more precise workpiece location. Large area clamps can also hinder tool acces- sibility to the component being machined. This is a measure of how many faces of the part are exposed in a given setup and how easy it is to load the workpiece in the tool. The capacity of the fixture to handle different part shapes is a measure of its reconfig- urability. Other important qualities for fixtures are reliability, precision, and rigidity. The development of new workpiece fixturing devices is an important area of research. As a first example, modular tooling sets (Figure 7.19) are used extensively in industry and represent the state of the art in fixturing as practiced on the factory floor. They were first invented in Germany in the 19405. The basic concept of "modular" fixturing is well known: these systems typically include a square lattice of tapped and doweled holes with spacing toleranced to 0.0002 inch (O.DOS nun) and an assortment of precision locating and clamping ele- ments that can be rigidly attached to the lattice using dowel pins or expanding man- drels. The tooling's base can be rapidly loaded onto a machining center. This is then fitted out with a complement of active and passive fixturing elements and fasteners. The elements are assembled in "Erector set" fashion, using standard parts. Extraordinary part shapes might require special elements to be machined. Use of these sets can speed the design and construction of fixtures for small batch sizes.The sets can also reduce the cost of storing old fixtures, since they can be disassembled and reused. The setups can be rapidly replicated, once they have been recorded with photographs and notes. In order to achieve sufficient precision in the assembled fix- ture, all component surfaces are hardened and ground. When using modular fixturing, there is a general need for systematic algo- rithms for automatically designing fixtures based on CAD part models. Although the lattice and set of modules greatly reduce the number of alternatives, designing a suit- able fixture currently requires human intuition and trial and error. Furthermore, if the set of alternatives is not systematically explored, the designer may settle upon a suboptimal design or fail to find any acceptable designs. 300 Metal-Products Manufacturing Chap. 7 Figure7.!9 Modular toolingkit. Goldberg and colleagues (Wagner et al., 1997) have thus considered a class of modular fixtures that prevent a part from translating and rotating in the plane. The implementation is based on three round locators. each centered on a lattice point, and one translating clamp that must be attached to the lattice via a pair of unit- spaced holes, thus allowing contact at a variable distance along the principal axes of the lattice. World Wide Web users may now use any browser to "design" a polygonal part. Goldberg's FlXtureNet returns a set of solutions, sorted by quality metric, 7.3 Controlling the Machining Process 30' along with images showing the part as the fixture will hold it in form closure for each solution. The current version of FixtureNet isdescribed in Section 7.12.The links on the Website include an online manual and documentation. This initial service provides an algorithm that accepts part geometry as input and synthesizes the set of all fixture designs in this class that achieve form closure for the given part. This is one of the first fixture synthesis algorithms that is complete, in the sense that it guarantees finding an admissible fixture if one exists. Planning agents can call upon FixtureNet directly and explore the existence of solutions, practical extensions to three dimen- sions, and issues of fixture loading. As a second example, quick change tooling is helpful in factories that use exten- sive automated material handling. It can also reduce the setup time at the machining workstation. For instance, the automated pallet changer receives pallets of standard size and connections, carrying a diverse array of part shapes. It can act as the tool base for a modular work-holding system. In this way,a part can travel from a lathe to a mill with no refixturing time, potentially on material handling equipment with this same receiver. Standard connections to the equipment can be made in seconds. In flexible manufacturing systems (FMS), these pallets are built up and loaded off- line at manual workstations. As a third example, hydraulic clamping systems have been developed to replace manually actuated active elements. The oil charged cylinders provide a much more compact and controllable source of clamping power. Hydraulic circuits can be created that result in self-leveling supports, sequenced clamping order, and precise clamping forces. When accumulators are used, the hydraulic power source can be dis- connected without a reduction in clamping force. As a fourth example, the automatically reconfiguring fixture system described by Asada and colleagues (1985) is intended for sheet-metal drilling operations. The tool base has a number of tee slots into which a cartesian assembly robot inserts ver- tical supports. The supports feature a lock mechanism that permits them to be assem- bled with one "hand." The act of grasping the clamp unlocks it,after which it can be slid into position along the tee slot. The height of the locators can also be set by the robot. An operator selects contact points on a 3-D wireframe model of the part, and the system decomposes this into a series of manipulation tasks. As a final example, the reference free part encapsulation (RFPE) system is designed to "free up" the design space and greatly expand the possible range of the parts that can be designed and then machined (Sarma and Wright, 1997). RFPE allows the machining of parts with thin spars and narrow cross sections. RFPE uses a biphase material (Rigidax) to totally encapsulate a workpiece and provide support during the machining process (Figure 7.20). After the first side of a component has been machined, the Rigidax is poured around the features, returning the stock to the encapsulated, prismatic, bricklike appearance that can be easily reclamped. Machining then continues on the other sides. This iterative process at the manufacturing level of abstraction (encapsulate! machine side-ltrepour-to-reencapsulate/repositionlmachine side 2, etc.) has a dra- matic "decoustraintng'' effect on the designer. The RFPE fixturing rules are described by a smaller set than those for conventional fixturing. 302 Heat \1/ ~Fi""II"'" (~)Mdl Metal-Products Manufacturing Chap. 7 ) /(C)Fillillf.!l!1drotillitlfl Ftpre7.zo Reference free part encapsulation (RFPE) "deconstrains the design space" during fixturing for macbining. The use of RFPE does decrease the achievable tolerances to some degree. Without RFPE a machine tool offers a daily accuracy of +/-O.CK)l inch (0.025 mm).Also Mueller and colleagues (1997) have used simulation packages prior to cutting, and sensors during the machining PJ'OCeS8l to obtain tolerances down to +/-0.(0)2 inch (0.005 mm).During fabrication with RFPE, typical tolerances average +/-0.003 inch (0.075nun). Ongoing research will aim to improve the machining accuracy using RFPE techniques. 7.4 THE ECONOMICS OF MACHINING 7.4.1 Introduction A method is now introduced to optimize the costs of operating the machine tools in a production shop. Actually, the general method is applicable to many variable cost analyses in manufacturing. A detailed treatment of this topic is therefore generally 7.4 The Economics of Machining 303 relevant to shop-floor microeconomics. The general goals are to achieve one of the following' •Minimize the production cost per component •Minimize the production time per component •Maximize the profit rate The symbols shown in Table 7.2 are needed for the analysis. 7.4.2 Production Cost per Component The cost to produce each component in a batch is given by CpERPART = WT L + WT M + WT R r2f-] + y[ ?f-] In this equation, the symbols include W == the machine operator's wage plus the overhead cost of the machine. WT L = "nonproductive" costs,whichvarydepending on loading and fixturing. WT M == actual costs of cutting metal. WT R = the tool replacement cost shared by all the components machined. This cost is divided among all the components because each one uses up TM minutes of total tool life, T, and is allocated of TMIT of WT R' (7.16) Using the same logic,all components use their share TMIT of the tool cost, y. TABLE 7.2 Symbols and Explanations for the Analysis on the Economics of Machining Symbol Explanation Usual Usual Units uee rsn Wmin mlmin inches/rev rum/rev inches millimeters minutes minutes minutes minutes minutes $/minute $/minute V Cutting speed f Feed rate for the turning operation in Figure 7.3. It has been found empirically that speed is much more damaging to the tool than either feed rate or depth-of-cut.Thus V appears III the analysis more than for d. d Depth-of-cut in the turning operation T Tool life T/,[ Time cutting metal T Ii Replacemenl lime of a worn 1001 T, Part loading lime, which includes (loading + fixturing + advancing + overrun + Innl withdrawal + pari unlnading) W Average cost per minute of operating the machine plus the operator's wage Cost of the cutting edge of the tool. For a cemented carbide indexableinsert the cost ofa single edge is the cost of the insert divided by the number of edges (usually 3, 4. 6, or 8) [...]... penetration as the control variable In Proceedings of the North American Manufacturing Research Institution, 23: 71-78 Miller, S M 1985 Impacts of robotics and flexible manufacturing technologies on manufacturing cost and employment In The Management of Productivity and Technology in Management, edited by P R Kleindorfer, 73 -110 New York: Plenum Press Mueller, M E., R E DeVor, and P K Wright 1997 The... 1989 Self-sustaining, open-system machine tools In Proceedings oftke 17th North American Manufacturing Research Institution Conference, 17: 281-292 Grippo, P M., B S.Thompson, and M V Ghandi 1988 A review of flexible fixturing systems for computer integrated manufacturing. lnter1Ultional Journal of Computer Integrated Manufacturing 1 (2): 124-135 Hill, R 1956 The mathematical Press theory of plasticity... flexible fixtures reconfigured In Proceedings of the Robotics and Manufacturing AutomationASME 251-257 Backofen, W.A.1972 Deformation processing Reading, MA:Addison Cbryssolouris, G 1991 Laser machining New York: Springer-Verlag Cole, R E 1999 Managing quality fads: How American game New York and Oxford: Oxford University Press Cook, N H 1966 Manufacturing analysis Reading, Cliffs, NJ: by robot manipulators... in Section 7.5.6 Deeper understandings of the physics of sheet-metal forming and 31 Metal-Products Manufacturing Chap 7 machining-for example, the prediction of the cutting forces in Section 7.3.1-result in sensible investments in machine tools, forming machines, and rolling mills 7.6.2 Open-Architecture Manufacturing At the same time, more sophisticated control of the metal (cutting and metal) forming... be supported commercially, hence increasing the productivity of standard CNC machines and flexible manufacturing systems "Open-architecture" machinery control (Figure 7.32) will allow faster access between high-level computer aided design (CAD), computer aided process planning (CAPP), and computer aided manufacturing (CAM) • As a first example, especially for mold making and some aerospace parts, it... American Manufacturing Research Institution, 25; 123-128 See Rose,F.A.1974 Grid strain analysis technique for determining the press performance of sheet metal blanks In international Conference on Production Technology Melbourne Institution of Engineers Rowe, G W 1977 Principles of industrial metalworking Sarma, S., and P K Wright changes in 'simply Iixturable' 15 (2); 95 -112 ... (2); 95 -112 processes London, Arnold 1997 Algorithms for the minimization of setups components in milling Journal of Manufacturing Schofield, S M., and P K Wright part I: Design principles ASME 120; 425-432 and tool Systems 1998 Open architecture controllers for machine tools, Journal of Manufacturing Science and Engineering, Stevenson, M G., P K Wright, and 1 G Chow 1983 Further developments in applying... mutually perpendicular major and minor axes of these ellipses define the principal surface true strains 81 and 82· From the geometry of circles and ellipses: dj B1 = IO&'d and 82 = d· IO~d 314 Metal-Products Manufacturing Chap 7 where d d; d, = grid circle diameter before pressing = major diameter of ellipse after pressing = minor diameter of ellipse after pressing It is frequently more convenient to express... the training of press operators and die setters can be made considerably easier and quicker if gridded blanks are available for reference and demonstration 7.6 MANAGEMENT 7.6.1 OF TECHNOLOGY Precision Manufacturing Services and Their Clients Today's clients for "high-tech" machine shops and metal fabrication shops include the medical industry, the biotechnology industry, mold-making industries that... the shipbuilding, railroad, gun-making, construction, automobile, and early aircraft industry Since then it has also become the foundation for semiconductor fabrication and all forms of consumer product manufacturing As these devices become more specialized and miniaturized, the construction of equally specialized equipment will still be performed at these "high-tech" machine shops and metal fabrication . important today, since the trend in manufacturing is toward production in small batch sizes (Miller, 1985). Batch production represents 50% to 75% of all manufacturing, with 85% of the batches. (with V and fheld constant), see Figure 7.15. Speed (It/min) flpre 7.13 Tool life venus cutting speed. 298 Metal-Products Manufacturing Chap. 7 logT General observation : straight line logY Flgure 7.14 Log-log plot of. process is directly related to the reliability of these work- holding devices that allow standard manufacturing machines to process specific parts. Fixtures are a subset of work-holding units designed