Proses Permesinan

Kuliah # 2. Machine Tools

DIAN PRABOWO
 Machining System
 Machine Tool
 Cutting Tool
 Toolholder

Three types of machine tools

 Conventional machine tools

 Production machine tools
 CNC machine tools
History of Machine Tools
 Productivity
 High machining speed
 High feedrates
 Multiple cutting tools
 Stacking multiple parts
 Minimization of noncutting time
 Automatic feeding and tool changin mechanism
Machine tools constitute about 70% of the total operating production
machines in industry.
The successful design of machine tool requires the
following fundamental knowledge:
1. Mechanics of the machining processes to evaluate the magnitude
and direction and to control the cutting forces
2. The machinability of the different materials to be processed
3. The properties of the materials used to manufacture the different parts
of the machine tool
4. The manufacturing techniques that are used to produce each machine
tool part economically
5. The durability and capability of the different tool materials
6. The principles of engineering economy
Productivity levels can be enhanced using the following
methods:
1. Increasing the machine speeds and feed rates
2. Increasing the machine tool available power
3. Using several tools or several WPs machined simultaneously
4. Increasing the traverse speed of the operative units during the
nonmachining parts of the production time
5. Increasing the level of automation for the machine tool operative units
and their switchingelements
6. Adopting modern control techniques such as NC and CNC
7. Selecting the machining processes properly based on the machined
part material, shape complexity, accuracy, and surface integrity
8. Introducing jigs and fi xtures that locate and clamp the work parts in
the minimum possibletime
The machine tool should possess the following
general requirements:
1. High static stiffness of the different machine tool elements such
as structure, joints, and spindles
2. Avoidance of unacceptable natural frequencies that cause
resonance of the machine tool
3. Acceptable level of vibration
4. Adequate damping capacity
5. High speeds and feeds
6. Low rates of wear in the sliding parts
7. Low thermal distortion of the different machine tool elements
8. Low design, development, maintenance, repair, and
manufacturing cost
Machine tools are divided according to their
specialization into the following categories:
1. General-purpose (universal) machines, which are used to machine
a wide range of products
2. Special-purpose machines, which are used for machining articles
similar in shape but different in size
3. Limited-purpose machines, which perform a narrow range of
operations on a wide variety of products
Machine tools are divided according to their level of
accuracy into the following categories:
1. Normal-accuracy machine tools, which includes the majority of
general-purpose machines
2. Higher accuracy machine tools, which are capable of producing fi
ner tolerances and have more accurate assembly and adjustments
3. Machine tools of super-high accuracy, which are capable of
producing very accurate parts
Machine tools include the following elements:
1. A structure that is composed of bed, column, or frame
2. Slides and tool attachments
3. Spindles and spindle bearings
4. A drive system (power unit)
5. Work holding and tool holding elements
6. Control systems
7. A transmission linkage
Stresses produced during machining, which tend to
deform the machine tool or a WP, are usually
caused by one of the following factors:
1. Static loads that include the weight of the machine and its various
parts
2. Dynamic loads that are induced by the rotating or reciprocating
parts
3. Cutting forces generated by the material removal process
The main functions of the machine structure include
the following:
1. Ability of the structure or the bed to resist distortion caused by
static and dynamic loads
2. Stability and accuracy of the moving parts
3. Wear resistance of the guideway
4. Freedom from residual stresses
5. Damping of vibration
Machine tool structures are classifi ed by layouts into open (C-frames) and closed
frames. Open frames provide excellent accessibility to the tool and the WP. Typical
examples of open frames are found in turning, drilling, milling, shaping, grinding,
slotting, and boring machines. Closed frames fi nd application in planers, jig boring,
and double-spindle milling machines.
Machine tool frames can be produced as cast or welded construction. Welded
structures ensure great saving of the material and the pattern costs. A
cast iron (CI) structure ensures the following advantages:
•Better lubricating property (due to the presence of free graphite); most
suitable for beds inwhich rubbing is the main criterion
•High compressive strength
•Better damping capacity
•Easily cast and machined
LIGHT- AND HEAVY-WEIGHT CONSTRUCTIONS
MACHINE TOOL GUIDEWAYS
 Friction condition and, consequently, the wear of
the guideways are affected by
1. material properties of the fi xed and moving element,
2. surface dimensions of the guideways,
3. acting pressure, and
4. accumulation of dirt, chip, and wear debris.

Wear of guideways can be minimized by

1. minimizing the sliding surface roughness,
2. increasing the hardness of the sliding surfaces,
3. removing the abrasive wear particles from the guideways system,
and
4. reducing the pressure acting on the guiding surfaces.
 ROLLING FRICTION GUIDEWAYS

In rolling friction guideways, rollers, needles, or balls are inserted between the
moving parts to minimize the frictional resistance, which is kept constant
irrespective of the traveling speed.
MACHINE TOOL SPINDLES
Numerical Control and Computer Numerical Control Technology
NC can be used when
1.The tooling cost is high compared to the machining cost by
conventional method
2.The setup time is large in conventional machining
3.Frequent changes in tooling and machine setting are
required
4.Parts are produced intermittently
5.Complex-shaped components are needed
6.Expensive parts where human errors are costly
7.Design changes are frequent
8.100% inspection is required
MACHINE TOOL AXES FOR NC
 MACHINE MOVEMENTS IN NUMERICAL CONTROL SYSTEMS

Point-to-point (PTP) NC
Straight-cut NC:

This movement is used during the machining of successive shoulders in a

WP or cutting rectangular shapes on the milling machine. Such a system is
equipped to control the feed rate as the tool travels from one point to another.
Tool movements are restricted to lines parallel to the coordinate axes of the
machine or at 45° to the axes. NC machine tools are often equipped with PTP
systems in addition to the straight-cut movement that can be used for hole drilling
and simple milling operations.
Contouring (continuous-path) NC:
 CONTROL OF NUMERICAL CONTROL MACHINE TOOLS

Open-loop control system.

Closed-loop control system
The control of NC machine tools includes spindle rotation, slide movements,
tooling, work holding, and supplementary functions
 FEED AND SPINDLE SPEED CODING

FEED RATE CODING

SPINDLE SPEED CODING
Tugas #1