ME 6303 COMPUTER AIDED MANUFACTURING

ASSIGNMENT NO 01
Submitted to the
DEPARTMENT OF MECHANICAL AND MANUFACTURING ENGINEERING

FACULTY OF ENGINEEING

UNIVERSITY OF RUHUNA

GROUP MEMBERS:
EG/2014/2357 AFSAL S.L.M
EG/2014/2358 AHMAD RILA A.R
EG/2014/2362 ARIYARATHNA W.A.D.T
EG/2014/2378 CHATHURANGA W.D.B
EG/2014/2401 FERNANDO W.L.R
EG/2014/2435 JAYATHUNGA R.D.S
EG/2014/2447 KULARATHNA K.G.T.C.L
EG/2014/2530 SANDUNIKA W.G.C
EG/2014/2554 THINESH K
EG/2014/2555 THISANTHAN S
EG/2014/2565 WEERASINGHA M.J.D
ABSTRACT
ACKNOWLEDGEMENT
First and foremost, we would like to forward our sincere gratitude to Dr. Muditha Dassanayake
senior lecturer, faculty of engineering, University of Ruhuna for giving this valuable opportunity to get
more knowledge under ME6303 Computer Aided Manufacturing module. Also we wish to express our
gratitude for his guidance. And we like to give our special thanks to our colleagues who are giving
their support to success this task.
Table of Contents
1 The Mechanisms Used in the Rotary Tables in Five Axis Machines...................................5

1.1 Feed mechanisms of the rotary tilting table in the 5 axis machining centers...........5

1.1.1 Feed mechanism with gears..............................................................................5

1.2 Hydraulic positioning, clamping and supporting.......................................................8

1.2.1 Time gain and accuracy.....................................................................................8

1.2.2 Basic principles..................................................................................................8

1.2.3 The correct choice.............................................................................................9

2 Conclusion......................................................................................................................11

3 References......................................................................................................................12
1 The Mechanisms Used in the Rotary Tables in Five Axis Machines
1.1 Feed mechanisms of the rotary tilting table in the 5 axis machining centers
There are two types of advance mechanisms of the rotary tilting tables,
1. Feed mechanisms with gears, provided with various solutions to remove the backlash.
This mechanism consist of duplex worm gears which has a high operating accuracy
even under a considerably lower reliability. And also it has a lower cost.

2. Torque, or built-in motor mechanisms, which do not have gears, the motor casing being
in the frame of the rotary table. This is a direct drive solution with built-in motors. This
mechanism has good functionality and reliability. But its cost is higher.

When comparing performance and cost of those mechanisms rotary feed mechanism is a better
solution due to its functionality and the associated cost.
1.1.1 Feed mechanism with gears
To ensure a balanced load of the rotary feed mechanisms, two synchronously operated worm
gears were used.

While the table is rotated due to use of a gear provided with worm wheel and diametrically opposite
wheels to ensure the movement, the wheels will rotate in the opposite direction. By using spur gear and
a transmission with a toothed belt above mentioned process can be done. But removing the backlash
when changing the direction in the case of the spur gear is difficult and expensive. Therefore driving
the two worm gears with a single tooth belt is better.

Let’s consider 5 axis machining centers with the possibility of processing sculptural profiles. Following
characteristics can be used for a rotary tilting table.
  Table diameter - 250 (mm)
 Maximum shelf rotation speed - 75 (rot/min)
 Maximum torque at the worm gear - 420 (Nm)
 Positive tilt angle - 135°
 Negative tilt angle - 10°

To increase the tilt angle of lo height table servo motor (SMAB) can be adopted, placed coaxially
with the tilt axis (B). Following schematic diagram shows the arrangement of rotary table with servo
motor.

 SMAA servo motor – the circular tilting movement is taken from this motor through a
synchronous belt, and it is transmitted to the couple of worm gears.
 SMAB servo motor – it generates a continuous rotary movement of the rotary tilting table.
 Duplex worm gear with following characteristics can be chosen for above discussed rotary tilting
table.

Worm gear Worm wheel

Size 40 40
Distance between axes 104 104
Gear ratio 1 : 40 1 : 40
Direction Right Right
Pitch diameter 48 160
Number of teeth 1 40
Diametral coefficient 12 12
Module 4 4
Large step of worm screw 12,816 12,816
Small step of worm crew 12,315 12,315

1.2 Hydraulic positioning, clamping and supporting.

Reduction of downtime is an important factor in increasing productivity and maximizing capacity
utilization. Positional accuracy and the repeatability of clamping force also make an essential
contribution to efficiency and quality improvement. Flexible machining centers aim to reduce
production cycle times. The placing and clamping of several components on one fixture, and later
removing them, is often a major time factor in the process. In order to be productive and efficient, it is
important that procedures such as positioning, clamping, support and release be rapid, straight forward
and safe. This is more important for larger work pieces with relatively brief processing intervals
making semi-automatic or fully automatic clamping in one fixture a profitable option. Hydraulic
positioning and clamping is an extremely reliable and efficient technique.
1.2.1 Time gain and accuracy
The major benefit of hydraulic work holding is the enormous time saved in clamping and
unclamping the components. When we compare the time required for hydraulic clamping with that
required for manual clamping the gain is no less than 90 to 95%. The use of Enerpac hydraulic work
holding products reduces cycle times thereby increasing manufacturing capacity significantly and
reducing costs. Equally as important as the time advantage is the positional accuracy of hydraulic
clamping systems. The clamping forces are constant resulting in very precise positioning and clamping.
This ensures identical processing procedures and guaranteed quality. Rejection rates due to distortion
will be insignificant. A third advantage offered by hydraulic clamping is optimum use of clamping
space due to compact standard components and the ability to clamp in manually inaccessible areas.
This can increase the number of components that can be clamped and processed simultaneously on one
fixture.
1.2.2 Basic principles
The basic design of any fixture using manual or hydraulic clamps is the same. The structure of
the fixture must be sufficiently rigid and heavy to avoid deformities and vibrations due to machine
movements and clamping forces. The unprocessed component must initially be positioned, supported
and clamped only at three fixed points. When the work piece is clamped on these three fixed points it’s
position is statically determined. We can compare this with the stability of a table with three legs.
Three functions
Any work holding fixture must fulfil three basic functions:
a) Position the component accurately.
b) Support the component adequately.
c) Clamp the component securely for machining.

During positioning, the work piece is pressed onto fixed limit points and support surfaces. The work
piece must then be clamped in this position so that the cutting forces cannot displace it during
machining. The work piece may also need to be supported at other points to overcome distortion,
vibration and torque. These forces can deform the work piece and influence the accuracy of processing.
To overcome these forces the work piece will be engaged by support cylinders with a light spring
pressure, after which they will be locked hydraulically. This will create support tailored to the work
piece. The three functions must be carried out in the proper sequence. This means that the appropriate
cylinders will have to be activated at the correct times (sequentially). Normally this is achieved with
mechanical sequence valves or solenoid operated directional valves fitted into the hydraulic system.
Hydraulic pressure may be provided by a variety of pumps, such as manual pumps, air-hydraulic
pumps and electro-hydraulic pumps.
1.2.3 The correct choice
When designing a hydraulic work holding system the correct choice of components is very important.
Examples of things to consider: Is there enough space, is clamping along the edge appropriate or
should it be internally? This requires each design to be considered on a case-by-case basis and there are
times when the solution will involve a system with special components. This will also naturally lead
you to question whether hydraulic clamping is justifiable. Enerpac has developed a software program
specifically for this purpose that provides clear insight into the advantages and profit in a quantitative
fashion. When a decision is made to develop a hydraulic clamping system a logical plan will provide
the best chance of success. The plan should include the following choices.
1) The clamping force and the clamping stroke of the cylinders;
2) The power source;
3) The control of the clamping system (accessories and valves)

The choice of clamp tooling as a function of the processing sequence in particular is extremely
critical. The size and shape of the work piece determine the various clamping points and hence the
clamp selection.
There are many significant benefits with hydraulic clamping systems. The major advantage of
hydraulic clamping is that it significantly reduces the load and unload times compared to conventional
manual clamping. This results in higher capacity utilization on all types of machines. Hydraulic
clamping also offers improved quality due to consistent and repeatable clamping forces being applied.
Totally automatic operation is also possible with hydraulic clamping.

2 Conclusion
3 References

[1] "Quality Transmission Components - Catalog Q410," [Online]. Available:

http://www.qtcgears.com/Q410/Q410Cat.htm. [Accessed 05 08 2017].
[2] R. Utpal, M. Cargian, S. Dunstall and A. Wirth, Systems Techniques and Computational Methods,
Cornelius Leondes, 2001.
[3] J. Reddonot, M. Rubio and F. Monies, Optimising Tool Positioning for End-Mill Machining of
Free-Form Surfaces on 5-Axis Machines for both Semi-Finishing and Finishing, Springer: Int J
Adv Manuf Technol, 2000.
[4] "GSA-Product CNC TILTING Rotary Table," [Online]. Available:
HTTP://WWW.GSAPLUS.COM. [Accessed 10 08 2017].