New strategy for the optimal design and manufacture of high performance milling heads

Bustillo, Andrés; Plaza, Lucía; Rodríguez, Marta Domènech

doi:10.3989/revmetalm.1101

Cited by 7 publications

(7 citation statements)

References 22 publications

(21 reference statements)

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“…In this regard, this FEM model has been developed following a standard FEM methodology for machine tools (Bustillo, Plaza, and Rodriguez 2011). The outputs of the FEM model are the vibration modes of the machining centre.…”

Section: Modelling Of Process-machine Interactionmentioning

confidence: 99%

“…The replacement of cast iron by welded steel, a material with a higher Young's modulus, is already well established at an industrial level. Aluminium is used in other contexts (Bustillo, Plaza, and Rodriguez 2011), because of its lower density, but very few industrial casting processes use this material and it is not easily welded; so much so that its industrialisation is not very common. Tests on the structural components of a machining centre have also used other non-conventional materials such as composites (Suh, Lee, and Kegg 2002;Lee et al 2004) and aluminium glued honeycomb (Zatarain et al 2004).…”

Section: Introductionmentioning

confidence: 99%

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New methodology for the design of ultra-light structural components for machine tools

Bustillo¹,

Oleaga

Zulaika

et al. 2014

International Journal of Computer Integrated Manufacturing

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Energy consumption is the key to the ecological impact of many machine tools, especially milling machines. One promising strategy for minimising the energy consumption of machine tools is to reduce the mass of their structural components. This solution, however, has a clear drawback: the mechanical stiffness of the machine is reduced, impairing its performance and, in the long run, its productivity. This study proposes a new methodology to overcome such limitations, which involves the design of machine tools with ultra-light structural components, and the development of strategies to counteract the loss of productivity as a consequence of lightweight machines. The new methodology includes the use of modular boxes built with carbon-fibre trusses, calculation of the dynamic stiffness of the new design, the identification of its weaknesses in terms of its cutting processes, and the design and integration of active damping systems in the machine to soften the expected vibrations under the most critical cutting conditions. This methodology has been tested in the new design of a ram of a bridge-type machining centre of medium size. The results show that a 60% reduction in mass can be achieved and that an active damper system can compensate a 60% reduction in mechanical stiffness, maintaining a level of performance that is comparable to heavier standard machines under high-cutting conditions.

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Section: Modelling Of Process-machine Interactionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

New methodology for the design of ultra-light structural components for machine tools

Bustillo¹,

Oleaga

Zulaika

et al. 2014

International Journal of Computer Integrated Manufacturing

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“…Figure 3 illustrates most of these parameters, which define the cutting conditions in a drilling process that the process engineer can set before the cutting process begins. In this case, process variables such as vibrations cannot be easily measured, due to the greater rigidity of the milling machine head on the Z-Axis along which drilling usually takes place [8]. Therefore, real-time process monitoring measures the axial force of the milling machine.…”

Section: A U T H O R C O P Ymentioning

confidence: 99%

Interpreting tree-based prediction models and their data in machining processes

Bustillo

Grzenda

Macukow

2016

ICA

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Machine-learning techniques frequently predict the results of machining processes, based on predetermined cutting tool settings. By doing so, key parameters of a machined product can be predicted before production begins. Nevertheless, a prediction model cannot capture all the features of interest under real-life industrial conditions. Moreover, careful assessment of prediction credibility is necessary for accurate calibration; aspects that should be addressed through appropriate modeling and visualization techniques. A machine process test problem is proposed to analyze data-visualization techniques, in which a real data set is analyzed that describes deep-drilling under different cutting and cooling conditions. The main objective is the efficient fusion of visualization techniques with the knowledge of industrial engineers. Common modeling and visualization techniques were first surveyed, to contrast standard practice with our novel approach. A hybrid technique combining conditional inference trees with dimensionality reduction was then examined. The results show that a process engineer will be able to estimate overall model accuracy and to verify the extent to which accuracy depends on industrial process settings and the statistical significance of model predictions. Moreover, evaluation of the data set in terms of its sufficiency for modeling purposes will help assess the credibility of these decisions.

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“…This approach of designing prototype machines in software has been termed virtual prototyping. 24, 25 Bustillo et al 10 proposed a strategy to redesign and manufacture the milling head made of aluminum alloys, in which the metal tubular conduits were implemented by overcoming metal contraction during manufacturing process. As demonstrated in the experimental validation, the new prototype provides sufficient mechanical performance and reliability.…”

Section: Introductionmentioning

confidence: 99%

“…5,6 Based on this concept, different approaches were developed for machine manufacturer to follow to improve machine productivity and energy efficiency, including the new materials 7,8 and design methodologies. [9][10][11] Optimization criteria of the machine tool design have been carried out by incorporating the dynamics of machine tool with the consideration of machining stability in process. 11,12 The main components or key modulus as well as their properties affecting the static and dynamic characteristics of the milling tool system have been clarified, including the machine frame structure, linear components, feeding mechanism configuration, and spindle tool holder/tool modulus.…”

Section: Introductionmentioning

confidence: 99%

Design analysis of machine tool structure with artificial granite material

Chen

Hung

et al. 2016

Advances in Mechanical Engineering

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Artificial granite material has been used for construction of the high-precision machine due to superior damping ability. However, its lower material stiffness also lessens the application in fabrication of the machine tool. The purpose of this study was therefore aimed to verify the structure performance of the machine tool reformed with artificial granite material, instead of the casting iron. To gain insight into the optimized configuration of the vertical columns and spindle head stock, the static and dynamic characteristics of the machine models with cast iron and granite composites were predicted for comparison. With this, evaluations of the machine with different design were made to examine the experimental measurements on the prototype machine. According to the simulation results and experimental measurements, the static stiffness of the machine tool reformed with granite material is comparable to the original casting machine, differed by 8% approximately. However, granite machine shows superior dynamic stiffness, about 0.5-1.3 times of the conventional casting machine. This study verifies the feasibility and effectiveness in fabrication of the machine tool with the artificial composite material and provides the improvements for further fabrications.

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New strategy for the optimal design and manufacture of high performance milling heads

Cited by 7 publications

References 22 publications

New methodology for the design of ultra-light structural components for machine tools

New methodology for the design of ultra-light structural components for machine tools

Interpreting tree-based prediction models and their data in machining processes

Design analysis of machine tool structure with artificial granite material

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