Improve metal cutting productivity with LMS Test.Lab
Based on the LMS test and test system, System3R has developed a new workpiece clamp chuck for reducing vibration in machining. In actual production operations, time is money, so mechanical efficiency becomes a decisive factor for manufacturers to make a profit. . This has prompted manufacturing companies to focus on leading suppliers of methods and tools that can provide them with increased productivity. Among them, Swedish processing tool supplier System3RInternationalAB has developed a workpiece clamping chuck that can reduce machining vibration. The new system not only improves metal cutting speed, but also improves accuracy and reduces wear on milling machines and other machining centers. In actual production operations, time is money, so mechanical efficiency becomes a decisive factor in whether manufacturers are profitable. This has prompted manufacturing companies to focus on leading suppliers of methods and tools that can provide them with increased productivity. Among them, Swedish processing tool supplier System3RInternationalAB has developed a workpiece clamping chuck that can reduce machining vibration. The new system not only improves metal cutting speed, but also improves accuracy and reduces wear on milling machines and other machining centers. Ordinary chucks do not fully control the vibration of the workpiece caused by the dynamic forces generated by the collision and rotation of the cutting tool. Therefore, in order to avoid instability in the machining process, the operator reduces the cutting speed so that the machined workpiece meets the required accuracy. However, even at low speeds, there are still some vibrations that cannot be eliminated, which can cause chiseling and wrinkles at the ends of the workpiece. Therefore, the workpiece requires a two-step or three-step process to eliminate defects and obtain a smooth end of the workpiece. Low speeds and additional machining not only extend the time of the entire machining process, but also accelerate the wear of the cutting tools, making them have to be replaced frequently.
The advantages of the damping chuck, the working speed and the machining quality of the machining system depend mainly on the dynamic stability between the three main components of the elastic system: machine tools, tools and workpiece clamping systems. The machine tool industry has long studied extensively how to improve the stability of cutting tools and machining centers. However, only a small amount of work has been done to study the dynamics of the workpiece clamping system. The workpiece clamping system is usually a rigid part. System3R spent many years researching the dynamics of the clamping system, pioneering the invention of the vibration-damping tray chuck (VDP) and applying for a patent. The new damper tray system blends viscoelastic polymer and metal backing within the structural stiffness to improve the vibration damping performance of the system. The new VDP absorbs workpiece vibrations and most of the cutting tool vibrations, thus improving the dynamics of the entire machining process, allowing the operator to run the machining center at higher speeds while reducing tool wear while improving machining accuracy. Part processing is therefore able to be done in one step, meeting both stringent dimensional tolerances and helping to reduce the end roughness to one micron. Due to the unique performance of VDP, many manufacturers favor this product, and companies that use VDP to manufacture precision parts have also benefited. Bojan Stefanov, general manager of Swedish auto parts supplier Liding Produktion AB, said that their five-axis milling machine uses VDP damping chucks, and now it is possible to achieve the required end surface smoothness in a single machining process for parts that previously required secondary machining. Not only that, they found that the speed of the machine tool is now doubled and the service life is twice as long. Similarly, the German Ingersoll cutting tool company uses VDP to manufacture titanium alloy aircraft parts, shortening the machining time by 32% and improving the surface end roughness by 72%. Portugal's MGM mold company uses VDP to reduce the processing time of copper electrodes by 40%. Japan's EpicYamada manufactures precision molds for semiconductors, using VDP to cut processing time by half and extending the life of tools used in machining. A Swiss company that manufactures high-speed milling machines has improved the milling process with VDP chucks. By cutting at 10,000 rpm, the cutting depth has been doubled, from 3 mm to 9 mm, which greatly increases metal processing speed.
The future business prospects of VDP are very optimistic. According to statistics from the Gardner Institute, the global investment in the machine tool industry increased by 70% since 2001, and the growth rate in 2006 exceeded 10%, reaching $59.6 billion. The continuous development of the machine tool industry will increase the sales of VDP in this industry, and many machine builders are very interested in integrating VDP into their products. The key role of vibration testing.
Dr. Amir Rashid, Manager of R&D at System3R, has led the team to design new products for the company and is also the principal responsible for VDP product development. In the VDP project, engineers adjusted the VDP by adjusting the thickness and shape and adjusting the preload of the damping component to reduce the predicted vibration load. It varies with the cutting of the workpiece material. “The designed structure has sufficient static stiffness and high dynamic stiffness to reduce machining vibrations in the expected frequency range while also clamping the workpiece in the correct position,†Rashid said. “The difficulty lies in how to accurately determine the magnitude of the damping required in the expected frequency range while maintaining sufficient stiffness. In our development process, LMSTest.Lab software plays a key role in effectively performing a large number of Vibration testing and rapid analysis of data.†The LMS test system used by System3R includes two LMSSCADASIII data acquisition front ends, each with eight data acquisition channels and built-in signal conditioning. Each front end is connected to LMSTest.Lab software for test control, measurement, results analysis, data management and report generation on a unified platform. Designing a flexible system, Rashid explained that at the beginning of the development process, vibration testing was performed on workpieces and machining centers without VDP. Engineers mount the accelerometers in different positions and use a hammer to strike the structure to determine their dynamic characteristics. Tests at various speeds in working conditions measure system vibration at different operating frequencies of the machine. Based on the data collected from these tests, LMSTest.Lab forms an animated modal shape and an operational deformation pattern (ODS) to show the deformation of the hardware. In addition, the vibration amplitude of the time domain is transformed into frequency domain analysis by Fourier transform, which can further study the response of the system at various frequencies. In these frequency plots, LMSTest.Lab uses a “column†color spike to clearly indicate the resonant frequency, eliminating the need to spend hours looking for resonance frequencies from the raw FRF data. The automation capabilities of LMSTest.Lab save a lot of time for this project and maintain data consistency while maintaining greater accuracy. The analysis function of the vibration data enables the engineer to calculate the energy transmitted through the component to determine the damping level required to design the contact surface of the clamping device. Based on previous practical experience, engineers understand the absorption properties of polymers, so they set the size of the contact surface to achieve the desired damping effect. Based on these specific requirements, the VDP physical prototype was constructed and the same structural modal test and working condition test were performed. The process was tested using LMSTest.Lab, which showed that the vibration amplitude measured by the workpiece on which the VDP system was installed was reduced. Comparison between the installation of VDP and test data without VDP measurement, through trial and error testing to adjust the design of the damping contact surface, to reduce vibration as much as possible, while maintaining the stability of the workpiece and meeting the assembly requirements of the clamping system . The advantages of the integrated test platform, "Because of the development of new product concepts, repeated vibration tests are required, LMSTest.Lab provides us with a unified test platform that allows us to increase the speed and accuracy of the test," Rashid said. “Previously, we needed a separate software for modal and conditional data acquisition, one software for modal analysis, and then a third software for generating processing test frequency maps.†He explained that because the system is between Independent of each other, different people use this software, which often causes delays in the regular development process. In addition, the exchange of data between different systems is also very time consuming and prone to errors, because in many cases the data cannot be completely converted and therefore has to be manually operated. “We needed a separate, integrated platform to help us perform vibration tests more quickly and more accurately. We needed to experiment quickly and get results at the same time, without having to switch between different systems. Use LMSTest .Lab, we are able to complete the test and analysis results in a matter of hours. The improvement of work efficiency is very important for us because we design various models to meet various machining applications and different workpiece sizes, including Some customers have special VDPs." Rashid believes that LMSTest.Lab's worksheets and templates are particularly useful for shortening the setup time of vibration tests. “LMSTest.Lab has a number of worksheets for feature functions such as modal testing, time domain data processing and signal testing,†he said. In addition, the template also has instrument sensitivity settings, and other automated implementations that no longer require manual setup by engineers. The System3R report indicates that the set time for the trial is reduced by at least 30%. “LMSTest.Lab enables us to perform various vibration tests faster and more accurately, avoiding time delays and reducing the probability of errors. From a business perspective, with the rapid development of global manufacturing, we only have to innovate. In order to stabilize the company's leading position in the global market, the LMS system is the best partner for our technological innovation."
Ultrasonic Flowmeter,Portable Flow Meter,Portable Ultrasonic Flow Meter,Ultrasonic Water Flow Meter
Wuxi Winsun Automation Instrument Co., Ltd , https://www.jswxwinsun.com