Win the trend towards products 'high end' for maximum competitiveness

Machine tool manufacturers pay attention especially to the steps in the chain of processes before and after the chip startup. Present concrete solutions to reduce both downtime and secondary times. In addition, improved developments, apart from the increase in productivity, affecting positively mainly on the resistance to wear and tear of components in a machine-tool are still presenting. Manufacturers of precision tools offer optimized coating systems capable of better machining materials of high and very high resistance with a high thermal resistance. The sector of peripheral equipment, for its part, provides for cooling lubricants, media holding of high accuracy and appropriate control systems.

The processes of loading and unloading of a machine tool controlled by a CNC, which typically require long and only limited participate in the creation of value, especially for heavy parts, can shorten often using Automation.

For example, lathes of inclined bench equipped with a gateway to the area of working with an additional control. In this way, the robot provides access to the drive of spindle with the device of subject that is approaching him. On the one hand, this efficient use of the robot, which can equip cyclically, for example, three machine tool, allows you to minimize time stop and, on the other hand, it alleviates the task of the operator of the machine when handling heavy parts.

Another interesting solution is a Centre for milling and turning very compact dimensions that picks up the pieces automatically machining of a store with up to 20 pieces through a pick-up spindle vertical. Universal use calipers are responsible for the necessary centering of the piece for the subject. The shaft and optional with a distance of displacement of +/-90 mm allows the process of drilling and milling machining for complete parts. The pieces can have a length of between 5 and 210 mm and a diameter between 10 and 160 mm.

For the machining of finishing of large quantities of parts with small dimensions, automata multihusillo CNC offer the best solution. Some innovations are focused on modular construction and their different possibilities of machining. Up to 6 main spindles and contrahusillos allow machining with a maximum of 24 tools processes. In these cases, starting chips for the rear face of the piece by means of the contrahusillos is carried out at the same time as the machining of the expensive lead, so the machining time does not increase.

The large trees that are required, for example, for the energy sector or as components of large engines, can be machined completely through a few centres of milling and turning with the corresponding dimensions. As production times and costs for the piece are very high, applies the motto 'the first part is' a good part ('the first piece must be good'). A manufacturer already offers an anti-collision control in real time to prevent accidental collisions between the tool and the workpiece and thus also prevent the damage of the machine and tool during machining. A machine model in 3D that includes the corresponding models in 3D tools and fastening means allows to check through the theoretical values of position and speed if there is an imminent collision of the components in movement. Thanks to the control in certain intervals of cycle short, it is possible to stop the machine in time before there is a collision. The theoretical values of position and speed are applied at the core of real-time control of the machine, so you can see the current position of the tool and the State of machining of the part on the screen of the control unit.

The machining centers of simultaneous displacement in five axes that are used to manufacture complex surfaces of forming free, for example, matrices for the technique of formation, have been marked so far by its many possibilities of employment, in addition to their high costs of investment. They exist in the market centres of extremely dynamic simultaneous 5-axis machining with a position of horizontal spindle whose price is lower than the 250,000 euros. Tools table has the capacity to accommodate cubic components with a maximum weight up to 350 pounds and can be displaced to allow a machining over the head with an optimum fall of chips. The larger version of the tool changer allows host 221 tools. The spindle makes available a 39 kW power and a torque of 47 Nm at a maximum speed of 18,000 revolutions.

Manufacturers of tools have expanded the volume of their current ranges for to give the user of the tools appropriate for the different machining tasks with a provider only. Drilling tools, for example, are available with many different ratios between length and diameter. The tools of milling for the application HPC have adapted to the increased demands arising, for example, of a greater diameter of core, a greater number of edges and a few especially prepared sharp edges.

In this sense, fit to highlight current new and advanced developments in the field of machining from roughing. The use of trigonometric reversible cutting plates allows to speed up the process of grinding in rigid construction winches. On many occasions, it is possible to achieve progress up to 2,5 mm with a depth of cut to 2.5 mm. The low angle of adjustment which is the result of the conditions of gear and the form of the tool, gives rise to forces of progress relatively low and high passive forces that act in respect of the support of the insert of reversible Court.

The use of plates of trigonometric reversible cutting simple or doubles for the realization of high advances can also be applied to milling. The offer of a manufacturer includes strawberries of reversible cutting chips from a range of diameters between 50 and 125 mm, equipped with double reversible cutting plates of trigón. Equipped with six corners of edge tools allow progress of tooth of up to 3.5 mm and thus guarantee a high return. In comparison with the use of plates of court reversible rounded, obtained lower in axial aligning forces which, by the round shape of the reversible cutting plates, could lead to a deviation of the tool and a greater sensitivity of the process against the oscillations. In case of using reversible cutting plates of trigón doubles are introduced mechanized forces during immersion in the piece to mechanise axially in respect to the spindle. A machining with high advances employment often allows the use and utilization of all the leading and dynamic capacity of machine tools.

Although coating systems have experienced in the past a few substantial additions and improvements in this field are still potential not exploited at this time to increase the power. A coating is available in the market of the₂or₃ on the growth of crystals are influenced directly during the process of coating at the atomic level. Instead of the spontaneous and uncontrolled formation of crystals during the coating process, there is the possibility of aligning the crystalline structure and stop holding the growth of crystals in a controlled manner. On the surface of the coating is forming the lattice with a flat and regular hexagons which reduce the roughness and the formation of phyla of regrown during machining. Also reduce the points of attack for microfisuras causing landslides and, ultimately, the deterioration of the layer. In the case of the machining of stainless steel, a type of suitable coating selection allows achieve improvements of life corresponding to the four factor while maintaining the same court data.

Other manufacturers have also discovered the influence of the surface topography of the surfaces of the process of machining tools and offer some coatings of low friction in combination with a few sharp edges accordingly prepared for the process in question. A few developing countries-AlTiN correspondingly prepared coatings are suitable for materials with a burst of difficult chip as, for example, based on nickel alloys and titanium alloys. These show a high percentage of aluminium that controls the hardness of the coating. The structure nanocrystalline achieved a relatively high tenacity and at the same time you get a smooth surface. Depending on the application, there are available coatings with thicknesses between 1 and 5 micrometers.

Tools manufacturers face increasingly to the machining of materials with a difficult chip startup. On the one hand, it increasingly mechanized light materials such as titanium alloys or aluminitas of titanium, whose chip startup requires temperatures of process which lead to a very high wear. On the other hand, in the foreground are materials with a high hardness, such as, the types of high and very high strength steel or alloys based on nickel with ceramic reinforcements. These materials are intended to facilitate a thin dimensioning of components, allowing a corresponding reduction of weight or show a greater resistance to wear.

A manufacturer offers winches specially designed for the machining hard up to 65 HRC, whose frames shows a relatively high rigidity, thanks to a joint reinforcement of polymers. At the same time, thanks to strengthening Gets a best damping of oscillations that allows to achieve best qualities of surface during machining and to increase the useful life of the tools in up to 30%. To increase the precision during turning, is equipped with the spindle with a tweezers of subject that allows to hold the pieces very close to the lodging of the spindle. The spindle is characterized by its termosimétrico design. A slot between the casing of the spindle and the bearing construction allows air supply to provide cooling of the spindle. In addition, in this way the thermal expansion of the spindle unit does not carry any displacement of the axis of rotation of the spindle with respect to the coordinate system of the machine tool.

It can be the procedure of EDM for deep holes of different diameters in hard materials. A bidder has developed a drill of EDM of high-speed whose electrodes with its diameter of 0.1 to 3.0 millimeters are some holes with a depth of up to 800 mm in the material. Abrasion values are up to 65 mm per minute for stainless steels and reach up to 200 millimetres per minute in the case of aluminium. In specific cases they are even a few depths of 1,500 mm drilling. An application example is the realization of temperature in bladed regulatory holes. In this case, the approximation of the electrodes can be via a fourth and fifth axis optionally available.

A machine-tool guides are continuously exposed to environmental influences of machining, as shavings, dust or other accumulations. To increase the precision and durability, as well as to maintain the energy of movement required as reduced as possible, they can be assembled some units at the ends of guide carts that are removing the shavings and dust through a multi-layered structure. Also can be a more economic lubrication of guide through an ancillary unit. Instead of excessive lubrication by grease that adheres the shavings and dust particles to the tread of the Guide surfaces, lubrication unit applies only a thin film of oil when the surface of the Guide really need. The principle is based on the use of capillary forces generated between the lubrication film and guide unit.

The prototype of a system of subject adaptatrónico has already been submitted in respect of the subject media. This system continues to regulate the holding power during the machining process in order to keep it as constant as possible, using a strip of elongation measurement integrated on the plate of subjection that records the descent of the adhesive force during the machining processthat is due to the centrifugal force. Through a circuit of regulation, the subject cylinder is still adjusting to compensate for the loss of adhesive force.

There is also a hollow tensor of electric operation for lathes and grinders capable of opening and closing the plate of subject without resorting to the hydraulic system. The renunciation of a sophisticated hydraulic system involves several advantages: the constructive space that would be needed for hydraulic components and control valves can be used in another way. At the same time, prevents wear and tear on joints and potential losses of oil leakage. Rotation of the restraint system symmetrical construction allows even employment a greater number of revolutions. When the power is disconnected, the piece remains stretched by the automatic braking.

For the positioning and the subject of high precision of the pieces on the table of machine tools, is available a manual handling zero-point clamping system. The lower part of the system is set on the table of machine tools. In the interchangeable upper part is the subject of the piece. With a corresponding guide bushes and position cones containing balls of steel concealed in rubber, stands the piece held in the work with a precision of repetition less than 3 micrometers on the bottom. The system is manufactured with a material of daily fitness resistant to scratches that dampens fluctuations and it is not magnetic.

In the past it differed between non-mixable coolant lubricants with water-based oil or ester and refrigerant lubricants mixable with water, i.e., emulsions or solutions. A bidder's concepts of coolant lubricants provides a completely new group: water whose viscosity can be adapted individually to the requirements of the process. You can adjust any viscosity between 2 and 46 mm² /(s/40°C) to ensure not only the coolant effect but also the necessary lubrication effect. Advantages consist of a few larger volumes of chip startup time, which in turn have an impact on a few shorter machining times. The renunciation of the use of percentages of mineral oil has other positive features: do not form fog of oil, there is no danger of oil drag and its elimination is no problem, thanks to the high environmental compatibility.

A system of filter through a filter of electrostatic effect is able to evacuate effectively aerosols or smoke from the working area is available in the market in respect of the residual air filter systems. The elements in the field of tension of the filter unit have a coating which shows the 'lotus' effect. This does reduce the adherence of particles of lubricant coolant in the form of aerosols, oil mist or smoke particles. It also reduces the number of electrical discharges that reduce the power. In combination with the control of the tension of ionization, it is possible to keep the rate of almost constant filter.

Machine tool manufacturers and their suppliers are not subject only to the demands of its clients to develop a system of rapid and reliable machining to produce high quality products cheaply. The 'energy-using-products' (eup) directive, the EU's policy to also promote the development of machine tools and components able to provide the same performance but with a better energy efficiency. Thus, environmental burdens generated by production and their effects should be reduced.

Further, the EU intends to implement the framework directive of ecodesign not only consumer goods but also to equipment. One of the products actually affected in the near future could be machine tools.

It is clear that in the future it will have greater importance creating maximum value with minimum use of resources. And there is no way to avoid it! The necessary holistic perspective of environmental profiles and life cycles, the products will promote ecological design and ecological balance in the companies. Even before the entry into force of the EU directive, the machine tool industry is facing the challenge to quantify, visualize and avoid or, at least, reduce the consumption of energy and environmental burdens through the use of an intelligent production technique. To achieve this goal, proposed a number of performance improvements in energy conversion, a proper sizing and modularity of components, alternative technologies, as well as better information for developers, users and eliminators of a product.

Insistent form are warned that the improvement of energy efficiency in production is an issue of the future that has not already can separate from the technique of production. However, the experts discussed very variously on the objectives and measures appropriate to a technique of 'organic' production. Also, States and policy must create stimuli to make investments in this technique and encourage its use, that the use of appropriate and effective production concepts is often, in addition to a lower use of energy and the reduction of environmental loads, also the possibility of making potential of technology and reduction of costs.

In order to produce sustainably and with success in Europe, high-tech factories and a sophisticated strategy of production is required.

The strength of European manufacturers of machine tools should be offering their products specifically to each client and to have a range and adequate to each specific market products. It is very important to be technological precursor to offer customized solutions to clients in the 'premium' segment. However, standard machine tools for the middle segment of the market can also get good volumes.

For example, in Europe a company develops sophisticated technical solutions 'turn key' for the European and American market. They are members of different procedures in a machine-tool to solve a task of machining. Another bidder provides scalable systems to pursue different purposes: one, two and four spindles machines allow large quantities. Chained use of devices for changing parts and industrial robots allows to perform several of the processes carried out in a sequential manner so far in parallel to the main times. Another manufacturer uses flexible laser units for the integration of the coating and hardening processes on a machine tool. Thus, it is possible to link certain processes that so far have been carried out on additional machines in other departments of the company or even out of it, very close in time to the process of chip startup. Special controls allow monitoring of machining processes. With the help of a digital fingerprint of the machine tool which is made before the delivery, you can document the incidents that occur during the later use of the machine and plan maintenance work so effectively in time and from the technological point of view. A manufacturer of components supported the future developments of the manufacturers of machine tools by means of innovative guides and accommodation. For example, a combination of bearing and magnetic bearing gives rise to a longer life of the bearing with the same charge or allows a higher speed limit numbers as an alternative.

All the points of departure are based on reducing both the main times of the process and the side times, as also in the reduction of the work in relation to the previous and subsequent steps of the supply chain. The contemplation of the entire chain of value beyond mere chip startup becomes increasingly more important.

Summary of the present and future

Machine tools have been developed and put in the spotlight the starting points for the integration of procedures. The contemplation of the entire value creation chain allows to reach concepts flexible and personalized to the client as well as they can contribute to the reduction of times in passing and the costs of production of a product. He has been an impressive increase in power and a life also in the field of the precision tools, thanks to the use of innovative coating systems or designs of tool adapted to the task of machining. In the future it will become more important an efficient use of resources in energy and environment is concerned, maintaining the same productivity and the same performance.