Machining center with automatic tool change
Development of a small-size machining center having the abilities of an industrial milling machine presents a real alternative to the foreign products in the field of educational equipment. Such machining center enables to perform a great number of operations and the automatic change of tools after installing one blank without the intervention of an operator in order to improve accuracy of measurements, save time and serve as a visual aid in practical courses devoted to studying the equipment operation which reflects the maximum realistic conditions of manufacturing in full-size industrial solutions.
Machine tool building is a prospective and developing industry of the Russian Federation. Development of small-size and high-capacity milling machine with automatic change of tools and integrated 3D scanning technologies with laser engraving for digital production is the unique feature of the machining processing platform.
The working area exceeds the similar analogs on the Russian market though the overall dimensions, weight and machining accuracy are the same. It has contactless sensors to provide safe operation of the machine systems and exclude a probability of hazardous situations connected with the undesirable contacts between the working parts and power elements of the center.
The unique software customized for user needs and high efficiency of center operation. The machining center software coordinates operation of all center systems by tracing positioning and ensuring safety of the process.
Ability to change tools without intervention of the operator. This feature makes it possible to solve more problems using the machining center and to speed up the parts processing in order to exclude the human factor in the machining cycle. Automatic tools change permits to improve the accuracy of the machining at every tool change because the additional adjustment is not necessary.
Fitting up of the center with additional modules for laser engraving and 3D scanning considerably spreads the range of task solved during the design and prototyping.
Weight and dimensions of the center make it easy to transport and install the center inside small production space, training institutions and laboratories.
During the development of the machining center, preliminary design was carried out in the SolidWorks CAD system. This method allows of predicting the problems which may occur while assembling and testing of the machining center and determining the type and quantity of the necessary materials. Moreover, the important solutions of tools advance and fittings usage and configuration of mountings may be conveniently foreseen by application of the method mentioned above. Original developments connected with nano-positioning applied previously in operation of milling and engraving machines and probe microscopy were used for 3D manipulator development [1, 2].
Basic technical parameters of ATC machining center Industry 4.0 working prototype are:
overlap processing rate along the axis – at least 5.5 m/min;
positioning accuracy – 9 µ;
repeatable accuracy – 5 µ
Tool-to-tool changing time – 9 sec;
main spindle acceleration time from 0 to 24,000 r/min – 7.5 sec;
number of displacement axes: 3 linear axes with ability to add the additional 4th axis.
Basic technical parameters of 3D manipulator working prototype:
displacement accuracy within 1–10 nm;
extremely precise machining with resolution in a sample plane – 0.25 nm and perpendicular to a sample – 0.1 nm.
The milling machining center with automatic change of tools and 3D precise manipulator is intended for the individual usage, prototyping in factories and plants, construction departments and training facilities. The solutions proposed in this project enable to obtain the best possible technical parameters at relatively low cost which make the milling machining centers on a par with the mass-produced small-size CNC machines made by foreign manufacturers. Due to small-size, modular construction and multi-functionality these machining centers are especially required in general training facilities as interactive complexes for children . We efficiently used the ATC Industry 4.0 milling machining center to prepare parts of the scanning capillary microscope (flowing fluid cell, probe fastenings, electrode holds, etc.)
This center is the continuation of ATC family machine tools developed by such high-tech companies as Advanced Technologies Center and Energy Efficient Technologies together with specialists of the Physical and Chemical Departments of Lomonosov Moscow State University. Information of these developments is available free on www.ATCindustry.com and www.2ETechnologies.com. ATC family machines are widely used in the Centre for Youth Innovative Creativity "Nanotechnologies" (www.startinnovation.com) for training and production aims. ■
The works on manufacturing the machining center was accomplished with the support of the Fund for the Promotion of Innovation Contract No. 422GRNTIS5 / 44715. The manufacture of the capillary microscope parts and subsequent research using these parts was carried out with the financial support of the Russian Foundation for Basic Research in the framework of scientific project No. 17-52-560001.
The authors are sincerely grateful to the Department of Entrepreneurship and Innovative Development of the City of Moscow and the Ministry of Economic Development of the Russian Federation (agreement No. 8 / 3-63in-16 of 08.22.16) for their invaluable assistance.