Next generation spindles for micromilling.

There exists a wide variety of important applications for micro- and meso-scale mechanical systems in the commercial and defense sectors, which require high-strength materials and complex geometries that cannot be produced using current MEMS fabrication technologies. Micromilling has great potential to fill this void in MEMS technology by adding the capability of free form machining of complex 3D shapes from a wide variety and combination of traditional, well-understood engineering alloys, glasses and ceramics. Inefficiencies in micromilling result from the relationships between a cutting tool's breaking strength, the applied cutting force, and the metal removal rate. Because machining times in mesofeatures scale inversely to the part size, a feature 1/10th as large will take 10 times as long to machine. Also, required chip sizes of 1 m or less are cut with tools having edge radius of 2-3 m, the cutting edge effectively has a highly negative rake angle, cutting forces are increased significantly causing chip loads to be further reduced and the machining takes even longer than predicted above. However, cutting forces do not increase with cutting speed, so faster spindles with reduced tool runout are the path to achieve efficient mesoscale milling. This research explored the development of new ultra-high speed micromilling spindles. A novel air-bearing spindle design is discussed that will run at very high speeds (450,000 rpm) and provide very minimal runout allowing the best use of micromilling cutters and reducing overall machining time drastically. Two generations of this spindle design were completed; one with an air bearing supported tool shaft and one with a novel rolling element bearing supported tool shaft. Both designs utilized friction-drive systems that relied on diameter differences between the drive wheel (operating at speeds up to 90,000 rpm) and the tool shaft to achieve high rotational tool speeds. Runout, stiffness, and machining tests were conducted with the spindle designs and though they both showed promise for ultra-high speed machining, runout issues in the friction drive and in the stock tools kept the system from achieving sustained machining capability

Design of ultraprecision machine tools with application to manufacturing of miniature and micro components

Currently the underlying necessities for predictability, producibility and productivity remain big issues in ultraprecision machining of miniature/microproducts. The demand on rapid and economic fabrication of miniature/microproducts with complex shapes has also made new challenges for ultraprecision machine tool design. In this paper the design for an ultraprecision machine tool is introduced by describing its key machine elements and machine tool design procedures. The focus is on the review and assessment of the state-of-the-art ultraprecision machining tools. It also illustrates the application promise of miniature/microproducts. The trends on machine tool development, tooling, workpiece material and machining processes are pointed out

Optical machine tool alignment indicator Patent

Optical gauging system for monitoring machine tool alignmen

Application of Mineral Casting for Machine Tools Beds.

The article provides state of the art and the latest development trends in the manufacturing of machine tool beds. The emphasis is placed on modern materials whose mechanical and dynamical properties may prove to be a breakthrough in the field of machine tool design

A particle swarm optimisation-based Grey prediction model for thermal error compensation on CNC machine tools

Thermal errors can have a significant effect on CNC machine tool accuracy. The thermal error compensation system has become a cost-effective method of improving machine tool accuracy in recent years. In the presented paper, the Grey relational analysis (GRA) was employed to obtain the similarity degrees between fixed temperature sensors and the thermal response of the CNC machine tool structure. Subsequently, a new Grey model with convolution integral GMC(1, N) is used to design a thermal prediction model. To improve the accuracy of the proposed model, the generation coefficients of GMC(1, N) are calibrated using an adaptive Particle Swarm Optimisation (PSO) algorithm. The results demonstrate good agreement between the experimental and predicted thermal error. Finally, the capabilities and the limitations of the model for thermal error compensation have been discussed. Keywords: CNC machine tool, Thermal error modelling, ANFIS, Fuzzy logic, Grey system theory

Innovative Service-Based Business Concepts for the Machine Tool Building Industry

Organised by: Cranfield UniversityDuring the last decade, machine tool building companies have been forced to put innovative offers on the market. Due to the technical features of their products and the prevailing organizational structures in this sector, especially product-service systems are a promising way of creating a unique selling point. In this paper, potential new business concepts for machine tool builders will be presented which aim at fulfilling basic customer needs like the increase in quality, flexibility, productivity and the reduction of lead times, costs and risks. For the implementation of these product-service systems, practical examples are given.Mori Seiki – The Machine Tool Compan

Representing the Process of Machine Tool Calibration in First-order Logic

Machine tool calibration requires a wide range of measurement techniques that can be carried out in many different sequences. Planning a machine tool calibration is typically performed by a subject expert with a great understanding of International standards and industrial best-practice guides. However, it is often the case that the planned sequence of measurements is not the optimal. Therefore, in an attempt to improve the process, intelligent computing methods can be designed for plan suggestion. As a starting point, this paper presents a way of converting expert knowledge into first-order logic that can be expressed in the PROLOG language. It then shows how queries can be executed against the logic to construct a knowledge-base of all the different measurements that can be performed during machine tool calibration