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Customer project - table layshaft wheel (Machining of the friction welding seam)

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Because of rising quantities the company Daimler AG is going to invest in a new machine tool for machining the table layshaft wheel. Currently the components are ... – PowerPoint PPT presentation

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Title: Customer project - table layshaft wheel (Machining of the friction welding seam)


1
Customer project - table layshaft wheel
(Machining of the friction welding seam)
  • Because of rising quantities the company
    Daimler AG is going to invest in a new machine
    tool for machining the table layshaft wheel.
  • Currently the components are machined on a lathe
    with a driven unit.
  • But in the rough turning prozess they have
    problems with the friction
  • welding seam. During the machining a hard and
    solid ring springs up, which could damage insert
    and tool holder.

Material 25MoCr4
2
Customer project - table layshaft wheel
(Machining of the friction welding seam)
Goal
  • The goal of this project was
  • presenting the Daimler AG a
  • concept to machine the
  • friction welding seam with high
  • reliability and productivity.

Solution
  • Best possible solution
  • Turn-milling
  • Alternative solution
  • Slitting and turning

Slitting and Turning
Material 25MoCr4
3
Customer project - table layshaft wheel
(Starting situation)
During the rough turning prozess a hard and
solid ring springs up, which could damage insert
and tool holder. Because of the ring chips also
could not drop down and get caught up in the tool
holder.
Cutting speed. 300 m/min Feed per
tooth (radial). 0,15 mm Feed per tooth
(axial). 0,3 mm Cutting depth ap
3 mm
4
Customer project - table layshaft wheel (Best
possible solution - turn-milling)
  • For machining the friction welding seam on
    Mulit-Task-Machines, turn-milling
  • is the best possible solution.

- no ring is bulid up - short machining time
(30 s) - high reliabilty (insert break, chips) -
only one tool necessary
5
Customer project - table layshaft wheel
(Alternative solution - slitting and turning)
  • For machining the table layshaft wheel on a
    lathe with driven unit, slitting and
  • turning of the weldseam is an alternative
    solution. On big advantage is, that you
  • do not need such a solid milling unit.
  • But this version has two big disadvantages

- 33 longer machining time (42 s) - two tools
are needed
6
Customer project - table layshaft wheel
7
Turn-milling with Coromill R390(two cuts)
tool R390-044C4-11MO60 insert R390-11T308M-PM dept
h of cut ap 2 1,5 mm cutting speed vc 235
m/min R.P.M n 1700 min-1
Radial feed feed per tooth fz 0,09 mm feed
rate vf 600 mm/min
Axial feed feed per tooth fz 0,16 mm feed
rate vf 1100 mm/min
8
Turn-milling with Coromill R390(two cuts)
Process reliability good Process time T
49s Chip control perfect Power consumption Pe7,1
KW
9
Turn-milling with Coromill R390(one hit
operation)
tool R390-044C4-11MO60 insert R390-11T308M-PM dept
h of cut ap 3,5 mm cutting speed vc 235 m/min
R.P.M n 1700 min-1
Radial feed feed per tooth fz 0,09 mm feed
rate vf 600 mm/min
Axial feed feed per tooth fz 0,16 mm feed
rate vf 1100 mm/min
10
Turn-milling with Coromill R390(one hit
operation)
Process reliability good Process time T
30s Chip control perfect Power consumption Pe12
KW
11
Sloting of the welded seam and turning
milling tool R300-020A25L-10L diameter Dc 20
mm number of tooth Z 2 milling
insert R300-1032M-PM 1030 depth of cut ap 3,5
mm cutting speed vc 200 m/min feed per tooth
(radial) fz 0,04 mm feed per tooth (axial) fz
0,16 mm
turning tool N176.39-2525-12 turning
insert RCMT-10T3M0-4225 depth of cut ap 3
mm cutting speed vc 300 m/min feed (radial) fn
0,15 mm feed (axial) fn 0,3 mm
12
Sloting of the welded seam and turning
Process reliability good Process time T
42s Chip control good Power consumption Pe3,1
KW Pe12 KW
13
Summary
The most effective solution is turn-milling as a
one hit operation on a stable multi task turn
milling machine.
  • shortest process time
  • high process reliability
  • one tool for the roughing process

If a classical lathe should be used for the
operation slotting with a driven unit and then
classical turning offers a reliable process too.
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