GF Machining Solutions New Milling Magic

Transcription

1 GF Machining Solutions New Milling Magic Gisbert Ledvon Director of Business Development Gary Michalek CEO, GAM Enterprises Dr. Arno Woern Head of R&D, Jakob Antriebstechnik

2 PRODEX AWARD Basel 2014 GF Machining Solutions New Milling Magic Machine and Spindle Gisbert Ledvon Director of Business Development INTEC AWARD Leipzig 2015 Protection (MSP) MM AWARD Stuttgart 2010

3 What does collision mean? A collision is the unplanned impact of at least two physical mass with each other at high kinetic energy (Collision speed v >> 0). Collision of mass Machine tool crash Crash Crash X Z Collision speed v coll Y

4 What happens during a collision? Collision force path Collision force F coll,z [kn] Harmful crash force tip v coll,z F coll,z Time [s] High impact force up to 10 tons Reaction time for numerical control is <5 ms Collision force F coll,z [kn] Collision speed v coll,z [m/s]

5 Why do most crashes happen? Frequency - Die & Mold: 0-15/month Cause and Error - Operator: Tool, clamping - Programming: Zero-point Effect and Damage - Tool deformation & crack - Bearing & slide deformation - Marks on Periphery & work piece - Machine geometry misaligned Most collisions are generated by human error! Source:

6 What happens to the motor spindle? Crash Motor spindle Clamping system: damage of collet Tool interface: crack of driving pin Ball bearing: marks in bearing ring Housing and shaft: deformations 60 % of motor spindle failures are crash related Exchange spindle amounts up to 80% of original price Source: Korff, D.: Schutzmechanismen, Shaker 2016

7 How complex is the repair of a crashed motor spindle? Crash 1. Check in 7. Shipment 2. Disassemble 3. Inspection 4. Repair & part replacement About 3 days of repair time 6. Test run 5. Re- Assemble Cost of repair amounts up to 70% of new spindle price

8 How much does a spindle crash cost? Model Invoice Fatal collision of spindle & workpiece Motor spindle repair On side assembly of spindle $ Repair of motor spindle $ Cost for shipment $ Sum for repair $ Machine breakdown Down time (3 days) $ Total average cost $ The crash protection has got a high priority for users Source: Korff, D.: Schutzmechanismen, Shaker 2016

9 How much are the total repair cost during life time of a machine tool? Example *downtime related repairs 5% 18 % 6% 16 % 14 % $ 1.520k $ 500k 16 % 25 % 75 % of Initial Invest Maintenance, Inspection Repairs* Base area Electrical energy Compressed air Cooling lubricant Others Total Initial Invest Period under review 10 years Total = 3 x Initial Invest Source: Korff, D.: Schutzmechanismen, Shaker 2016

10 A fatal crash means. Motor spindle damaged Machine geometry misaligned Machine downtime Huge costs!

11 GF Machining Solutions offers a new smart machine tool feature named Machine and Spindle Protection in all directions MSP

12 What is different? Machines equipped with MSP spindle and machine protection have a key to switch the machine into a safe mode. And an integrated mechanical protection unit

13 Safe Mode In safe mode the feed rate in the linear axes are adjusted to max 12m/min (470 ipm) For the C-axis it is 3150 /min (8.75rpm) and A-axis it is 2250 /min (6.25rpm)

14 How does MSP protect the spindle? Protection unit cuts harmful force transmission Provides reaction time & path for safe machine stop Collision force F coll,z [kn] Harmful crash force tip -90% Excessive load zone MSP Time [s]

15 How does the MSP work? Movie

16 How does MSP perform in action? static test dynamic test (collision with v = 20 m/min) actuation force 18 kn axial load radial load displacement in µm displacement in µm force in kn actuation moment 2,3 knm collision force in kn collision force in kn acceleration of the inertial mass of the spindle t coll time in s t react disengaging t react displacement in µm displacement in µm moment of tilt in knm t coll time in s MSP provides high stiffness & well-defined force break!

17 What happens after a crash with MSP? Retract the tool Remove the damaged tool from the spindle Check the machine geometry for example: Kinematic opt Proceed working with a new tool As easy as that!

18 On which machines is the smart machine tool feature MSP available? Mill P 800 U

19 Can you believe this part was machined after more than 200 crashes? Same spindle no repairs no adjustments Bild Teil

20 With this surface quality? After 200 Crashes!

21 With this surface quality?

22 Yes! With the New Milling Magic from GF Mikron

23 Learn more about spindle protection Visit GAM online:

24 Location South Hall Booth S8754

25 Visit our website GFMS.COM/US Gisbert Ledvon Phone: