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A Technology Roadmap for the Machine Tool Industry

Prepared by the Technology Issues Committee of AMT – The Association For Manufacturing Technology

Flexibility

Accuracy Capability

Production Rate

Delivery Cycle

Reliability/Maintainability

Safety, Ergonomics, and Environmental Response

User Friendliness

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Qua

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FORMING

ASSEMBLY

JOINING

INSPECTION

FINISHING

WORKHOLDING

CONTROLS

DRIVES

MACHINING

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7901 Westpark Drive, McLean, Virginia 22102-4206

2002 EDITION

Over 100 Years of Building Global Productivity

AMTThe Association ForManufacturing Technology

REGISTERED DOCUMENT

A Technology Roadmap

for the

Machine Tool Industry

2002 Edition

Prepared by the Technology Issues Committee

of AMT – The Association For Manufacturing Technology

REGISTERED DOCUMENT NUMBER______________________

This registered study, containing copyrighted material, has been prepared for your company’s sole use and is being provided to you with the expectation that it will help further advance the global competitiveness of your company and thereby the U.S. manufacturing technology industry as well. Copies of this study should not be given or otherwise revealed to third parties. If you believe that another organization or individual, whose interests are supportive of our own U.S. industry, would benefit from receiving its own registered copy, please contact AMT – The Association For Manufacturing Technology. AMT will promptly respond to all such requests.

Published by: AMT - The Association For Manufacturing Technology 7901 Westpark Drive, McLean, VA 22102 Printed in the United States of America 1996, 2002 by AMT - The Association For Manufacturing Technology. All rights reserved. No part of this publication may be reproduced in any form, in an electronic retrieval system or otherwise, without prior written permission of the publisher.

FOREWORD TO THE READER We welcome participation from all members of industry, government, and academia in refining and implementing this technology roadmap. It should be noted that issues are not always addressed in only one area or under one heading or topic. Various aspects of an issue may be discussed in different portions of the roadmap. It should also be noted that the background information collected in this document represents the ideas and thoughts expressed by participants in the development of the roadmap. This information, whether complete or incomplete, has been incorporated here for future reference. In some cases, the reader will notice that further data and comment would be helpful.

DISCLAIMER Statements of facts and opinions in this publication are those of providers of information to this document alone and do not necessarily reflect the views of AMT membership, officers, directors or staff.

1996, 2002 by AMT - The Association For Manufacturing Technology iii

ACKNOWLEDGMENTS

TECHNOLOGY ISSUES COMMITTEE AMT would like to thank the members of its Technology Issues Committee for their participation and comments in the development of this technology roadmap.

Ralph Resnick, Committee Chairman, Extrude Hone Corporation

Peter Beecherl, UMT - Lamb Technicon Body & Assembly Op.

Richard Curless, Cincinnati Machine

Stephen Fedor, Masco Machine, Inc.

Patrick Harrington, CNC Engineering, Inc.

Richard Heitkamp, Remmele-Micro Machining Division

Scott Hibbard, Bosch Rexroth – Electric Drives & Controls

Milton Hoff, Master Chemical Corporation

Mark Huston, Kennametal Inc.-World Headquarters

Thomas Kuhnell, Siemens Energy & Automation-Lebanon, OH

Mahendra Patel, Hardinge Inc.

Anthony Romero, The Torrington Company

Craig Ronald, The Gleason Works

Andrew Scholeck, Eitel Presses, Inc.

William Silberhorn, Elk Rapids Engineering, Star Cutter Company

SUPPORTING ORGANIZATIONS A special thanks is given to the following organizations for their assistance in the preparation of workshops held and the development of this document.

Massachusetts Manufacturing Extension Partnership

National Tooling and Machining Association (NTMA)

1996, 2002 by AMT - The Association For Manufacturing Technology iv

SUPPORTING COMPANIES The Association expresses sincere thanks and appreciation to the organizations that have offered personnel time to participate in workshops and interviews. Their efforts have helped the machine tool industry acquire knowledge about what is required in the future and what technologies will help us develop the products needed. This will improve the effectiveness and productivity of manufacturing facilities in the future.

American Axle and Manufacturing Bawden Industries, Inc.

Carlson Tool & Manufacturing Corp. Dana Corporation

D&H Manufacturing Company DOE Nuclear Weapons Complex, Y-12, Oak Ridge

GKN Aerospace Service, St. Louis Haig Precision

Halwest Technologies, Inc. Karlson Machine Works

Kinefac Corporation Maine Machine Products Company

Mission Tool and Manufacturing Co., Inc. Patriot Machine, Inc.

PDI SMT

Saint-Gobain Abrasives, Inc. Spicer Driveshaft, Inc. - Dana Corporation

Stonebridge Thayer Aerospace

T-K & Associates, Inc. Thorsen

Trimac Mfg. Inc. The Boeing Company

The Torrington Company

1996, 2002 by AMT - The Association For Manufacturing Technology v

AMT STAFF - A Technology Roadmap for the Machine Tool Industry Charles F. Carter, Jr. -- Vice President-Technology

Paul R. Warndorf -- Director-Technology

Sheila C. Kaplan, Assistant to Vice President-Technology

1996, 2002 by AMT - The Association For Manufacturing Technology vi

TABLE OF CONTENTS

FOREWORD ................................................................................................ III ACKNOWLEDGMENTS............................................................................... IV

INTRODUCTION ........................................................................................VIII EXECUTIVE SUMMARY...............................................................................X

PART 1 - MATERIAL REMOVAL .............................................................. 1-1 Flexibility ..............................................................................................................1-2 Accuracy Capability..............................................................................................1-9 Production Rate .................................................................................................1-18 Delivery Cycle ....................................................................................................1-25 Reliability/Maintainability ....................................................................................1-31 Safety, Ergonomics, and Environmental Response ...........................................1-37 User Friendliness ...............................................................................................1-42

PART 2 - CNC CONTROLS....................................................................... 2-1

PART 3 - FIRST PART CORRECT............................................................ 3-1 Explanation of Terms Used in the Pareto Charts .................................................3-3 Summary of Comments .......................................................................................3-4

1996, 2002 by AMT - The Association For Manufacturing Technology vii

INTRODUCTION

The first edition of A Technology Roadmap for the Machine Tool Industry was published in 1996. The trends described in that edition have continued to develop. Many of the needs expressed then by machine tool users are now being met. However, in too many cases, users continue to express the same needs now that were expressed in 1996. Comparisons to the first edition will be noted under the appropriate attribute heading in this edition. Work remains to be done. The first edition contained a section on metal cutting, and a section on forming. This edition omits forming which will be covered at a later date. However, this edition has two added sections that were created because of the large number of comments relating to each. One new section is devoted to CNC controls, and the other presents information on the subject of First Part Correct.

About Roadmaps A Technology Roadmap is a means to identify user problems and needs that can be satisfied by features added to product designs. In some cases, advances in technology will be required to implement a feature. It is the role of a roadmap to point out those technology advances. It is not always obvious how to fulfill a need. It is up to the reader to infer appropriate solutions to expressed needs. The needs should be viewed as opportunities for product development by the new product planner. This Roadmap points out where gains have been made since the first edition, and suggests directions for improvement based on reasonable expectations for technology advances.

How the Roadmap Was Developed Input for the Roadmap was gathered through a series of workshops of about a five-hour duration with typically no more than seven or eight participants. In order to provide structure to the discussions, each participant was provided with a list of machine attributes in advance of the workshop. Participants were asked to come prepared to make comments under each attribute. The attributes are:

• Flexibility • Reliability/Maintainability

• Accuracy Capability • Safety, Ergonomics, and Environmental Response

• Production Rate • User Friendliness

• Delivery Cycle

Workshops were held on the West Coast, in the Midwest and on the East Coast. A total of 53 people participated, representing 38 different companies or organizations.

Trends Underway In response to the need to reduce setup time and eliminate workpiece moves, machines that combine operations are becoming well established. Even grinding is being incorporated with metal cutting operations. High speed spindles have become more reliable since the Roadmap’s first edition, and now 10,000 rpm is becoming more of a standard rather than the traditional 6,000 rpm.

1996, 2002 by AMT - The Association For Manufacturing Technology viii

Linear motor drives continue to be incorporated on new designs. Cost is the primary factor inhibiting wider use. Since the first edition was published, linear motors have become the drive of choice for all ultra precise machines. CNC controls continue to become more open and user friendly. Users look for this trend to continue, and for the cost of upgrades to come down. CNC-PC interoperability, either as PC front-end or embedded in the control, will become norm rather than an option as the shop floor operations and control continue to be integrated seamlessly, both locally and remotely, with the up-front engineering, planning and programming, and the back-end analysis, service and business functions using LANs, WANs and Internet. Where regenerative chatter occurs, the existence of zones of stability between unstable lobes on the stability diagram has been known for over half a century. Until recently, spindle speeds could not be easily and continuously varied to find a stable zone. Now that almost all spindles are variable speed, techniques to find a chatter-free speed are more straightforward.

Trends to Watch The continued miniaturization of components used in medical and electronic applications has motivated the development of machines that are less than desktop in size. Machines that would fit inside an 8-inch cube are in the prototype stage. Friction stir welding will displace the use of rivets and other fasteners where smooth surfaces are a requirement. New applications for this process are still being explored. The building of parts by stereolithograpy and similar additive techniques is a growing field. Continued new developments make the process worthy of monitoring. Variations of the process allowing for expanded workpiece material selection contribute to the growth.

Two New Sections Since many workshop participants brought up problems encountered in making a First Part Correct, a section devoted to that subject has been added. This is the first time that a Pareto chart will have been presented anywhere that depicts the relative importance of the problem’s sources. Controls are a strong factor in many of the improvements requested by users. For that reason, participants were asked to comment on a list of attributes related to CNC controls. The results appear in the CNC section.

1996, 2002 by AMT - The Association For Manufacturing Technology ix

EXECUTIVE SUMMARY Challenges To Global Competitiveness The ever-changing competitive climate of the world continues to bring increasing demands to almost every sector of the manufacturing community to improve and go beyond where it is today. These demands require products to be engineered and produced in a continuing cost-effective manner, to more stringent quality standards, and within shorter time spans. This climate is causing customers of machine tool builders to demand manufacturing capabilities that meet or surpass increasing global standards. As a result, machine tool producers must adapt quickly to these changing needs by providing improved products addressing the following attributes:

► Flexibility The ability of machine tools to address a wide range of

different workpieces and workpiece specifications with minimum downtime for change.

► Accuracy Capability

The capability of a machine to meet the accuracy and repeatability specification of the workpiece, with minimum impact on productivity.

► Production Rate

The rate at which workpieces are produced over a short period of time (cycle time).

► Delivery Cycle The time from the order of a piece of equipment to its successful production of specified work.

► Reliability/ Maintainability

Reliability is the capability to produce without having a machine tool failure. Maintainability is the ease in maintaining the integrity of a machine tool (working condition) as well as its repair.

► Safety, Ergonomics, and Environmental Response

Safety is the condition of being safe as measured by the number of accidents requiring doctor attention or causing lost time per 200,000 person hours of operation.

Ergonomics is the degree to which a piece of equipment meets the physical capabilities of individuals.

Environmental Response is the ability to meet or exceed established environmental standards and regulations.

► User Friendliness

Ease of operation and maintainability of a machine tool including consideration given to ergonomics and the degree of training and retraining required to become proficient in these functions.

1996, 2002 by AMT - The Association For Manufacturing Technology x

Common Needs and Opportunities When the attributes above were discussed, it became apparent that a number of topics could be characterized as common to the various industries that participated in the development of this document. These topics may be considered as general areas of major importance to both users and builders of machine tools and related products. It should be noted that the topics, almost in total, are the same as identified in the 1996 Roadmap.

Reduction of Non-Value-Added Time

The most commonly mentioned need throughout this program remains to be the reduction of non-value-added time. Many participants felt that there was more to be gained from reductions in this area than from increasing the speed of a machine tool. A major topic discussed was the development of aids to reduce part setup time. This is largely due to customers buying parts with multiple deliveries and the increased inability to recoup setup costs.

It is customary to consider the time a machine is not actually processing parts (altering the shape of the workpiece) as “Non-Value-Added.” However, the time a machine spends in changing pallets or dies or tooling is also an essential function of the machine, and it is somewhat of a misnomer to call that time non-value-added. During these changeovers and during processing times, the machine may be in a wait mode for various reasons -- this wait time is certainly non-value-added. Since the goal of machine productivity improvement is to keep the machine in a processing mode a high percentage of total time, we in this document will consider any nonprocessing time as non-value-added.

First Part Correct

Associated with the reduction of non-value-added time is the time required to prove out a first part on a machine. Whether this requires the debugging of a part program or the testing of new tooling, dies or fixturing, the goal of industry is to minimize or eliminate these needs. First Part Correct was mentioned so frequently that separate discussions were encouraged on that issue. A section of this 2nd edition of the Roadmap summarizes the comments received during those discussions.

Control Related Approaches to Machine Improvements With increased attention being placed on the capability of manufacturing equipment to maintain processing consistency (repeatability), improved techniques are required to monitor, diagnose, and adjust for causes of inaccuracy. These compensation and diagnostic features are viewed as an integral part of meeting increased process capability requirements. These compensation and diagnostic features must not only address equipment-related variances, but must also adjust for deviations brought about by the process itself. In addition to monitoring the process, techniques are also required to monitor the health of the machine and ancillary equipment, and to provide for the early detection or prediction of component failures.

1996, 2002 by AMT - The Association For Manufacturing Technology xi

With the implementation of such monitoring, compensation, and diagnostic features comes the need for an integrated approach (systems view) to addressing concepts like process control, real-time error compensation, and preventive maintenance. In fact, so many advances in machine capability are based on control features, a CNC section has been added to this edition of the Roadmap.

Systems Approach to Machine Purchases Throughout the workshops it continued to be apparent that users are placing more requirements on builders to take a systems approach to machine deliveries. That is, an approach which places more responsibility on the builder to work with the user in supplying not only a machine tool, but also the ancillary equipment, tooling, fixturing/dies, safety equipment, training materials, etc. needed to deliver a manufacturing process, not just the manufacturing equipment. Many times this will place builders in the position of having to master unfamiliar technologies or acquire processing knowledge they may not have been required to address in the past. Coupled with this is the pressure for improved delivery schedules aligned to reduce customer product development cycles--deliveries which are being redefined as complete once the equipment is operating at production rates as opposed to being accepted upon a successful installation. Most importantly, discussions emphasized the critical need for builders to meet quoted delivery schedules.

1996, 2002 by AMT - The Association For Manufacturing Technology xii

Material Removal Goals and Thrust Areas

Listed below are the identified goals determined most important at this point in time to bring about a competitive advantage to material removal machine tool builders. These goals, derived from user needs, provide the basis for establishment of the primary thrust areas identified underneath each listed attribute.

■ Reduction in machine tool non-value-added time

■ Highly predictable machine tools

■ Highly reliable and maintainable machine tools

■ Reduced time to deliver, install, and produce first production part

Goals

Primary Thrust Areas Accuracy Capability

•Integrated approach to machine error compensation •Systems oriented approach to process monitoring and compensation •Improved tool holder accuracies and retention techniques •Reduced thermal distortion •Constant tool tip monitoring •Attention to surface texture

Production Rate

•Reduce lost time caused by machining cycle process inefficiencies •Development of computer models for predicting machining processes •Improved chip and coolant delivery and removal systems •Increase spindle HP commensurate with speed

Delivery Cycle

•Reduction in machine, fixture, tooling, etc. delivery, installation, and startup/ rampup times •Improved ability to provide quoted production rates and capabilities at machine delivery •Required need to meet promised delivery date

Reliability and Maintainability

•Development of collision protection capabilities •Improved reliability of machine components •Improved diagnostic features on machines

User Friendliness

•Improved training techniques •Common controller interfaces, features, and operator controls •Customize operator interface

Safety, Ergonomics, and Environmental •Improvement in noise reduction and air quality •Attention to improved ergonomics

Flexibility

•Reduce time to changeover from one part type to a second •Development of techniques to eliminate first part proveout •Improved machine mobility and reduced need for foundations •Standards to reduce tool holder type and enable part loading •Improved machine versatility

1996, 2002 by AMT - The Association For Manufacturing Technology xiii

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1996, 2002 by AMT - The Association For Manufacturing Technology xiv

Material Removal

PART 1 - MATERIAL REMOVAL This part of the technology roadmap addresses the material removal technical division of the machine tool industry. The types of equipment being addressed include, but are not limited to:

Machining centers ■ turning centers ■ grinders ■ milling machines ■ machining systems ■ station type machines ■ electro discharge machines (EDM) ■ lasers ■ water jet machines ■ other non-traditional machinery ■ gear cutters ■ broaches ■ etc.

Information presented in this section is organized by the following attributes:

Flexibility Accuracy Capability Production Rate Delivery Cycle Reliability & Maintainability Safety, Ergonomics, and Environmental Response User Friendliness

Information was collected from the following sources. The indicated reference numbers are used in the Summary of Information Sources table located at the end of each attribute section.

Reference Number Information Source

1992

1 AMT Research Agenda

1996 Edition

2 User questionnaire response

3 Builder questionnaire response

4 Powertrain

5 Jobshop

6 Offroad

7 Propulsion

8 Airframe

2002 Edition

9 Technology Issues Committee Comments

10 Department of Energy, Y-12

11 Aerospace, Boeing – St. Louis

12 Bearing Industry

13 Jobshop

14 Automotive Tiers

1996, 2002 by AMT - The Association For Manufacturing Technology 1-1

Material Removal

Flexibility Figures of Merit The figures of merit determined to be important in addressing flexibility are:

Product Changeover Time The time between the completion of the manufacturing of one product part number to the acceptance of a second part number of similar part types.

Machine Mobility The ease in moving a machine from one location on the shop floor to a second.

Cell Reconfiguration The ability to quickly modify a machining cell from one configuration to a second.

To address these figures of merit, the recommended target values for the rate of change required in each area are:

Figures of Merit Metric 2002 2007 2012 Product Changeover Time

- Flexible Machines

- Dedicated

- Standard

time x

(6 hrs)

(30 min)

.5x

(3 hrs)

(15 min)

.2x

(1 hr)

(5 min)

Machine Mobility time

1 week

3 days

(8 hrs)

Cell Reconfiguration time

1 month

2 weeks

4 days

1-2 1996, 2002 by AMT - The Association For Manufacturing Technology

Material Removal

Flexibility (Continued) Technology Issues/Needs Although user requests were generally similar to those made for the first edition, several changes are worth noting. Off-line NC program tryout is now an integral part of programming and has now matured to the point where it no longer appears on a wish list. Comments in this area now relate to errors in translation when multiple CAD systems must be used as input. The increased use of high speed spindles has prompted expressed concern about multiple tool holder types and standards. However, high speed machining itself has appeared to mature to where it is no longer a pressing development need. The importance of setup and part changeover time is still a concern of low volume manufacturers, but is now becoming an important point for higher volume manufacturers. They must make shorter runs to accommodate customers wanting JIT delivery. The emphasis on machine versatility has shifted from the idea of a design that allows reconfiguration to one that allows multiple processes in one part clamping. Users see that even grinding can be included with turning and milling. Consensus of Issues/Needs There were several recurring comment areas that appeared during the information-gathering workshops. Further explanation will be given here. The comments are all aimed at impediments to flexibility or ways to improve flexibility.

Standards Participants mentioned standards from two points-of-view: too many standards, and not enough standards. In the area of too many standards, tool holders seem to be the prime offender. Even among the basic types (standard taper and HSK) there are subsets beyond requirements based on spindle size. The proliferation of tool holders, and spindles to accept them, inhibits the ability to move jobs quickly from one machine type to another. On the other hand, standards are needed in the area of part load/unload height (automotive), workholding pallets and tombstones, and service connection (air, electric, data) points and type.

Setup Time The subject of setup time enters the discussion under several machine attributes, not just under Flexibility. The question for the machine builder becomes: What features can be incorporated in the design that relates to setup? Job shops have traditionally been the source of most concern about setup time. Now, even the shops enjoying higher volumes per part find that multiple setups are required due to customer requests for spaced deliveries based on JIT manufacturing. High volume manufacturers are faced with shorter runs. They are looking for a one-hour changeover where part families are in the order of 500,000 per year, and 10-minute changeover where part family


Material Removal

Flexibility (Continued) demand is 10,000 per year. High volume manufacturers also need to make samples on high volume equipment. A recurring issue that prompts requests for setup aids is the growing shortage of skills. Participants from all industries asked for more setup aids to be provided in the machine and control. The presentation of data from previous setups, and the easy entry of cutter compensation were common requests.

Machine Mobility The request for 3-point support continues. Participants recognize that machine range is a governing factor. However, the requirement for a foundation inhibits the flexibility of cell formation and change. The goal is to have machines up to 80,000 lbs. on 3-point support. Connections for services such as air and electric should be easy to change.

Machine Versatility Participants from all industry groups requested machines that can handle more operations (mill, turn, grind, etc.) in one clamping. In addition, they requested the ability to do a wider variety of parts on these same machines. The ability to switch quickly from one material to another was frequently expressed as a need. The primary enabler here relates to spindle torque and speed. The need is for spindles with a wider range of capability, or quick-change spindles. This, in turn, raises the question about standards for spindle mounting and techniques for chip management. Greater machine range provides for more flexibility and part selection, but usually brings a compromise on accuracy for small parts due to thermal distortion. Also, on 5-axis machines it was suggested that locking two axes for roughing could allow higher rigidity. Then, use 5-axes for finishing.

First Part Correct Contributing to the attribute of Flexibility is the capability to make a first part correctly. Discussion of first part correct is usually coupled with requests for more capability in software proveout at the machine – a CNC related issue. Also, there was the request for the ability to recall data at the machine from previous experience on the same or similar parts. Primary Thrust Areas and Objectives

Primary Thrust Area Desired Change Time Frame Reduce part changeover time

(setup time)

50% Reduction in time 5 yrs

Improve machine mobility

Reduce need for foundation

Three point support up to 80,000 lbs.

5 yrs

Develop techniques to bring about first part correct First Part Correct 75% of the time

5 yrs

Continue to improve machine versatility (combine operations) for all sizes

Available in all size ranges 5 yrs


Material Removal

Flexibility (Continued)

Background Information Listed here are the comments that formed the basis for the program suggestions in the previous section. Discussion Summary

TECHNOLOGY ISSUES COMMITTEE MEETING (9) Consideration should be given to reconfigurable machines and machines that combine processes or are

multi purpose. There is an increased importance being placed on the ability to reconfigure a cell or machine tool in

shorter time periods. Mill-turn type machines represent a trend towards reduced configuration times since the machine can

process different part configurations even without the need for fixtures since the spindle chuck becomes a universal type fixture. According to NTMA, the current issue is throughput time or “Zero Volume Manufacturing.” The area of “first part correct” is really a broader issue than one that a builder can fully address,

however, some consideration should be given to the time it takes to make the first part correct. The use of software for part prove out should be given consideration.

DEPARTMENT OF ENERGY (10) Looking for machines that can handle a wider variety of parts (combined operations). With shrinking skilled labor force, need more intelligent machines (especially machines with capability to

assist operators in part setup). Need standards to assist in flexibility, like standards on interchangeable workholding. Eliminate the need for foundations by use of a 3-point support. Standardization of service points and connections (electrical, air, etc.) to improve mobility and

installation of machinery. Improve ability to operate equipment from a control room minimizing the number of people on the floor.

AEROSPACE (11) Improve setup tools to provide capabilities that minimize operator input and measurement requirements. Issue that cutter compensation has to be in the part program to be active. Be able to economically switch materials during changeover (e.g. go from hard material to soft material

at appropriate rates). Have ability to switch from 3-axes for roughing to 5-axes for finishing. Would like a common spindle that can do all (high and low speeds). More modularly designed machines.

BEARING INDUSTRY (12) We would like flexibility with simplicity. Even though we do a lot of high volume, we make a lot of

samples and low volume also. A range of parts on a less dedicated machine would be helpful. Rigidity helps more than speed.


Material Removal

Flexibility (Continued) Background Information (Continued)

Discussion Summary (Continued)

JOBSHOP (13) Would like more ability of machines to meet size/range flexibility (i.e. a large machine that can

economically machine small parts and still provide efficient setup capability). Machines that cover a larger part spectrum. Need standard 5-axis laser machining capability. Trying to get the first part correct remains a big issue. Would like more intelligence in machine control to help set adjustments for setup (help achieve first part

correct). Setup is a cost that customers do not want to pay for. With the move towards concepts like “Lean

Manufacturing,” and customers buying larger quantities with multiple deliveries, the cost for repeated setups becomes difficult to recoup. Need aids to reduce setup costs. Simplicity in design and control systems, especially with automated equipment. Proliferation of tool holder standards is a problem.

AUTOMOTIVE TIERS (14) Need quick changeover from one part to another. Changeover is becoming more of a factor, therefore, line setting time is a factor and needs to be

reduced. Looking for times to be less than one hour for high volume (500,000/yr.) production and less than 10 minutes for low volume (10,000/yr.) production. Need ability to change from one material to another quickly. Need tools to help in the justification of the higher cost of flexible lines. Need a standardized part load/unload height industry wide. Need smaller machine widths to better accommodate cell configurations.


Material Removal

Flexibility (Continued) Background Information (Continued)

Summary of Information Sources

1992 1996 Source 2002 Source

Factors Technology Issues/Needs 1 2 3 4 5 6 7 8 9 10

11

12

13

14

Product Changeover Time

• Setup techniques and procedures (machine intelligence)

• Spindle changeout - Common spindle

• Turret changeout • Multipurpose tooling • Fixturing

- Advancements (e.g. flexible fixturing) - Alignment techniques - Standardization

• Multiple process capability • Reduction or elimination of first part tryout

time (e.g. tape, tooling, and fixturing proveout)

• Surface sensing to determine material thickness for first cut

• Material changeover • Greater size/range flexibility

X

X

X

X

X

X

X

X

X X

X

X

X

X

X

X X

X

X

X

X

X

X X

X

X X

X

X

X

X

X

X

X

X

X

X

X

Machine Mobility

• Self leveling • 3-point support • Rigid structures • Better damping (e.g. vibration damping) • Reduced weight • Reduced size • Elimination of need for foundations • Single location service point and

standardized connections (e.g. electrical)

X

X X X

X X

X

X

X

X

X

X

X

X X

X X

X

Machine Reconfiguration

• Modular designs • Universal designs • Non-complex designs • Multi purpose machine designs

X X X

X

X

X X

X

X

X

X

X

X

X X

Cell Reconfiguration

• Modular designs • Part changeover time • Reduced machine width

X X X X X X X


Material Removal

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Material Removal

Accuracy Capability Figures of Merit The figures of merit determined to be important in addressing accuracy capability are:

Volumetric Accuracy The accuracy of a machine at any point within

its cutting range.

Variability (Repeatability) The ability to manufacture given workpiece features repeatedly as measured by defective parts produced or by capability (e.g. Cp, Cpk).

Tooling/Workholding Accuracy The accuracy of tooling, tool holders, workholding, and interface surfaces.

Measuring Device Accuracy The accuracy and measurement capability of gages, instruments, etc. (Gage R&R)

Surface Texture Quality of a surface with respect to smoothness, finish, edge condition, etc.


Figures of Merit Metric 2002 2007 2012

Volumetric Accuracy µ in/ cubic ft

x

(200 - 600)

.5x

(100 - 300)

.2x

(50 - 200)

Variability/Repeatability Cpk* 1.33 1.33 1.33

Tooling/Workholding Accuracy

inches x .25x .2x

Measuring Device Accuracy inches .5x .25x .2x

Surface Texture µ inches x .5x .3x

*The reader is to be cautioned that Cpk alone does not establish the accuracy of a machine tool since it is a ratio dependent on part tolerance objectives. As workpiece tolerances become tighter, machine tool accuracy must improve to maintain a constant Cpk. Refer to AMT’s “A Guide to Using Cpk” for further explanation.

Note: “A Guide to Using Cpk” can be downloaded from AMT’s Web site: www.amtonline.org


Material Removal

Accuracy Capability (Continued) Technology Issues/Needs Accuracy and repeatability issues have remained essentially the same as reported in the Roadmap first edition. However, technology changes are bringing about changes in emphasis. Acceleration and deceleration rates are becoming less of a constraint as ball screws can take on higher values. Linear motor drives have become more accepted, and are proving to enhance accuracy and finish. Linear scale feedback applications are moving to lower cost machines where they overcome ball screw thermal and pitch error problems. Balance is emerging as a greater problem as higher spindle speeds gain wider usage. Higher speeds also continue the focus on tool holders as a source of error. The increasing use of Cpk as a capability index has brought about more realistic goals. More knowledge of Cpk as a statistic has focused more attention on the importance of measuring methods and gauge certification. Consensus of Issues/Needs Workshop participants reported on the continued movement to tighter tolerances. It is now common to see high volume applications requiring ± 0.0001" on diameter. Comments made by workshop participants can be grouped under several headings for the purpose of reporting results.

Thermal Distortion All participants confirmed that thermal distortion remains as the largest single contributor to inaccuracy or loss of repeatability. Machine warm-up and/or temperature control are still required to stabilize thermal distortion. The actual and accurate position of the tool tip is not known in real time. Although the use of thermocouples combined with measurements to obtain a machine “thumbprint” has been demonstrated to compensate for thermal distortion, it is only in limited use. The use of linear scales for position feedback is on the increase. This eliminates errors associated with ball screws. However, temperature differences or machine motions, creating an Abbe offset error remain a significant error source.

Process Related Decisions made during process planning have an impact on final part accuracy. In addition to knowledge about machine parameters, knowledge must be applied relating to part and workholding rigidity, ratio of rough to finish cut, workpiece heating, tool wear, and distribution of initial stock – to mention a few. In-process monitoring can improve the process in real time and/or provide data for future process improvement.


Material Removal

Accuracy Capability (Continued)

Gauging As part tolerances are reduced and machine accuracies are improved, the instruments and methods of measurement become more important. The traditional ratio of 10:1 for artifact tolerance to gauge accuracy becomes commercially impractical as artifacts fall into the 0.000050" tolerance range. Users say measurement capability is not keeping up with demand for tighter tolerances. Many of the comments relative to gauging refer to the use of the machine as a measuring device. Users want to verify critical dimensions while the workpiece is still on the machine. A technique to determine the true position of the tool tip is required. Users also want historical data about machine accuracy and repeatability so that changes can be analyzed. A wider selection of an improved non-contact gauging method was also a request.

The current benchmark for meeting customer tolerance requirements is Cpk = 1.33. At this level it is important to agree on measurement methods and gauge R&R.

Tools This general category covers topics such as tools, tool holders, and workholding. Tool holders continue to be mentioned as a source of inaccuracy. Repeatability is the primary offender. Users have not collected detailed data on the problem source that could be the holder, the spindle, or the draw bar. Repeatability of workholding also comes in for comment. In the workholding area, the holding of thin parts during hard turning was mentioned as limiting the elimination of grinding by hard turning. The relative poor repeatability of turrets forces users to use gang tooling for high precision turning work. The improved monitoring of tools would allow for better accuracy and more effective tool management.

Other Factors Surface finish was frequently mentioned as a parameter of accuracy. Surface texture and the influence of chatter are important considerations. The user needs more knowledge of machine dynamics – and system dynamics including tooling – in order to predict final surface finish. The growing requirement to deal with harder materials coupled with high speed machining raises two issues. Greater forces make rigidity and resulting deflection more of an accuracy problem. Higher feed rate puts greater demand on contouring accuracy. The consistency of dynamic and static rigidity among machines of the same model becomes important (and noticeable) if users move a job from one machine to another. Differences are currently noted causing part inaccuracies. In spite of CNC compensation, backlash is still a problem.


Material Removal

Accuracy Capability (Continued) Primary Thrust Areas and Objectives

Primary Thrust Areas Desired Change Time Frame Integrated approach to machine error compensation

40% Improvement in volumetric accuracy

5 yrs

Systems oriented approach to process monitoring and compensation--includes the ability to self correct “in-process” errors

30% Improvement in process capability to correct in-process errors

5 yrs

Improved tool holder accuracies and retention techniques

50% Improvement in tool holder accuracies

5 yrs


Material Removal

Accuracy Capability (Continued) Background Information Listed here are the comments that formed the basis for the program suggestions in the previous section.

Discussion Summary

TECHNOLOGY ISSUES COMMITTEE MEETING (9) There is a need for more features on size such as in die mold parts. Surface finish needs more definition. Perhaps the use of such terms as texture or surface characteristic

should be used. Consider volumetric accuracy in contouring. The sensitivity to dynamics should be raised when discussing variability (repeatability). There should be more emphasis on thermal stability. There is an overall reliance on proper process planning. There is a growing requirement to deal with harder materials being machined at higher rates and the

need to maintain path accuracies at those rates. Need to better address the elimination or control of chatter in machining parts. There needs to be improvement in the capability for in-process monitoring.

DEPARTMENT OF ENERGY (10) Tool holders need to be more accurate. Need system approach to be able to accurately perform measurements on machine tools. Accuracy of

the machine is important for inspection and still needs improvement. Improved process monitoring capability to collect and analyze inspection data on machines. Depending upon the application, surface finish is critical and needs to be controlled. Raise the knowledge base on the interrelationships of processes that when combined create an end

product.

AEROSPACE (11) Improved tool holder designs Improved consistency in machine dynamics. Difficult to move a part from one machine to another (same

make and model), because of differences in the performance of the machines. Improve cutting performance at the tool tip to be consistent across machines. Ability to verify part features for part acceptance. Improved ability and ease at recalibrating machines for accuracy. Sensors and gages to monitor repeatability of machines and automatically report deterioration or

discrepancies.

BEARING INDUSTRY (12) Thermals are still the big problem in accuracy. In hard turning the difficulty is in holding form. Also in hard turning there is a difficulty of chucking thin

parts. We require an air purge on feedback scales. Backlash is still a problem with encoders and ball screws. A warm-up time is still required. We have not used a “thumb print” of the machine in combination with thermocouples in order to

compensate for thermal distortion. We don’t need an accuracy better than ABEC 9. The problem is price and delivery. Surface finish is a component of accuracy.


Material Removal

Accuracy Capability (Continued) Background Information (Continued)

Discussion Summary (Continued)

JOBSHOP (13) Need to improve in-process gaging techniques. The trend in customer requirements is towards greater accuracies. Part complexity is also increasing. Objectives for Quality Control need to be set higher than before since customers have greater

expectations. More attention needs to be given to the ability to measure part parameters. With the drive towards

tighter tolerances the ability to accurately measure those parameters is increasing. The accuracy of gaging and advances in measuring technology is not keeping up with the higher accuracy requirements. Need improved non-contact gaging technologies. Now need to know the application of the part being manufactured to understand critical part

relationships. Need improvements in the ability to measure the part on the machine or during machining operations. Need ability to obtain better finishes, tolerances on turned parts to reduce or eliminate grinding. Need accuracy at the tool tip. Manufacturers of laser equipment need to incorporate look-ahead features in their machines to improve

ability to go around corners. Thermals remain a problem. Repeatability of turrets is a problem.

AUTOMOTIVE TIERS (14) Tolerances are getting tighter. Commonly now see ±0.0001” on diameters. Automatic thermal compensation is becoming more important. Workholding is becoming more of an issue when trying to achieve tighter tolerances. Need improved tool monitoring devices especially since the cost of tooling and tool holders is increasing. Need automatic chatter control. Measurement (gages) technology has not kept up with the capability of machines. Gage R&R is an

issue. Improved chatter control.

Benchmark Cpk is 1.33


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1992

1996 Source 2002 Source


11

12

13

14

Volumetric Accuracy Measurement

• Cost-effective and easy to use measuring techniques and devices

• Dynamic measuring techniques • Contouring measurement • Improve machine accuracy for

measurements • Thermal Effects

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

Accuracy - Tooling - Workholding - Measuring Devices

• Tool Interface • Tool holders and tool retention techniques

- Increased accuracy of tool holders • Advanced tool designs

- Increased accuracy of tooling

• Chucking thin parts • Increased accuracy

• Gage capability/accuracy • On machine measurement

X

X

X

X X

X

X

X

X

X

X

X

X

X

X

X X

X

X

Surface Texture • Contaminants in spindle oil • Elimination of post finishing • Chatter control

X X

X X

X

X


Material Removal


Summary of Information Sources (Continued)



11

12

13

14

Variability/ Repeatability

• Sensing and compensation - Controls, sensors, etc. for compensating

dynamics/mechanics/thermals - Compensation techniques, thermally stable

materials, etc. - Compensation for ambient temperature

changes - Highly sensitive torque/HP spindle monitor - Wireless sensors (for rotating/moving parts) - Sensing and controlling temperature of

coolant and fluids • Process monitoring and compensation - Robust compensation methodology to

adapt to production changes - Real-time sensing/monitoring,

measurement, and correction for part size/surface/geometry

- In-process inspection and probing capabilities and techniques

- Improved process controls and compensation (e.g. adaptive control)

- Low-cost, high accuracy tool compensation scheme

- Access to process control information and data

- Tool monitoring technology

X

X

X

X X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X • Dynamic balancing of machine components

and workpieces • Improved positioning accuracy - More accurate actuators - Improved servo control and acc and dec

capability - Reduced backlash

• Damping for spindles • Improved cutter technology • Improved methods of removing coolant

collecting on tool tapers and spindle-tool interface

• Guarantee process at tool tip not at machine face

• Address dynamic characteristics of machining

• Improved repeatability of feature size

X

X

X

X X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X


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Material Removal

Production Rate Figures of Merit The figures of merit determined to be important in addressing production rate are:

Value Added Time The amount of time a machine is adding value to a product (altering its shape).

Material Removal Rate: - Spindle Speed - Traverse Rate

Rate material is removed--primarily determined by spindle and traverse rates in conventional machining--measured as cubic inches per minute.

Part Load/Unload Time The time required to load/unload parts into and out of a machine.

Tool Load/Unload Time The time required to load/unload tools into and out of a machine or spindle.

Index Time The time required between the initiation of a defined pallet or table index move to its completion.

Probing Time The time between the start of a defined probing cycle to the completion of that cycle.

Chip Management Means for controlling and removing chips from the work area and machine.

Coolant Management Delivery of coolant to the work zone plus other aspects such as cleanliness and useful life.

The recommended target values for the rate of change required in each area are:

Figures of Merit Metric 2002 2007 2012 Value Added Time

cut time total

cycle time

40 - 50% 50 - 70% 70 - 90%

Material Removal Rate volumetime x 1.5x 4x

- Spindle Speed RPM x 2x 3x

- Traverse Rate g force x 1.5x 2x

Part Load/Unload Time time x .6x .4x

Tool Load/Unload Time time x .6x .4x

Index Time time Values not established during discussions

Probing Time time Values not established during discussions

Chip Management volumetime x 1.5x 4x

Coolant Management volumetime x .6x .4x


Material Removal

Production Rate (Continued) Technology Issues/Needs Most of the details users mentioned in development of the first edition have not changed for the second edition except for some notable changes outlined below. This round of workshops showed increased sensitivity to value-added time. There is a call for more sensors to report machine status. With respect to sensors, there is increased demand for sensors to deal with process problems that are related to thermals, tooling, or workpiece variation. This would allow for more successful unattended operations. There is reduced request for improvement in acc and dec since advances have been made since the first edition. Requests for improved chip control methods continue as a high priority. Consensus of Issues/Needs Users are increasingly aware of the fact that total production rate will be influenced more by an increase in value-added time than by a reduction in machine cycle time. Since machine value-added time stands at about 30% (some high production operations may be 50%), users see that moving from 30% to 60% (by addressing non cutting activities) would be easier than cutting cycle time in half for the same improvement in production rate. User comments on production rate can be grouped under two headings: Value-added Time and Cycle Time.

Value-added Time Machine features should enable running unattended so that operation could be extended to at least 20 hours per day. In order to achieve this, improvements will be required in chip control – a frequent request. Also, users recognize that more machine intelligence and sensing will be needed to deal with thermals, tool problems, and material variations. Changing of tool sets is time consuming. Users are starting to be sensitive to such lost time through the use of equipment availability and OEE1 calculations. Control features should be added to report cumulative machine status. The control could request operator response if the machine is not running. The purpose would be to provide data for ways to improve.

1 See AMT’s “Production Equipment Availability” for details. This publication can be downloaded from AMT’s Web site: www.amtonline.org


Material Removal

Production Rate (Continued)

Cycle Times There were multiple requests for sensors and in-process monitoring with associated control capability for cycle optimization and a means to build a database for best practice. This data will reduce the dependency on personal memory and knowledge. The request is for increasing features without increasing apparent complexity. Machine features leading to shorter cycle capability include: greater rigidity, increased contouring speeds, innovation for load/unload, and more spindle horsepower at low speed.

Primary Thrust Areas and Objectives

Primary Thrust Areas Desired Change Time Frame Reduce lost time caused by machining cycle process inefficiencies

25% Improvement in value added time

5 yrs

Continued advancement in high speed machining technology

Increased spindle HP commensurate with speed

5 yrs

Development of computer models for predicting machining processes and behavior

Predict all process events and behavior

10 yrs

Improved chip and coolant delivery and removal systems

Avoid all chip related downtime

5 yrs


Material Removal

Production Rate (Continued) Background Information Listed here are the comments that formed the basis for the program suggestions in the previous section. Discussion Summary

TECHNOLOGY ISSUES COMMITTEE MEETING (9) There should be emphasis on the ability to run 20 hours per day. Perhaps thru-put is a better term than production rate. There should be more emphasis on in-process monitoring. The importance of coolant placement needs to be addressed. The use of oil that does not need to be dumped should be a consideration.

DEPARTMENT OF ENERGY (10) This attribute was not an issue due to low production rate requirements. Improved separation and recovery of materials. Changeover from one material to another needs to be made easier.

AEROSPACE (11) Improved chip removal technology. Currently takes a long time to switch from one material to another. Improved tool changing time. Need more spindle horsepower at low-end speeds. Drill pecking cycles are slow on some machines.

BEARING INDUSTRY (12) Want multi-surface finishing in one loading. We need speed without complexity. Frequently, process speed provides no advantage since other factors control total production. Can’t optimize the cycle because of control problems. Rigidity is as important as speed.

JOBSHOP (13) Intelligence in machine to aid in addressing process issues optimizing forces, dealing with thermals,

reducing tool wear, addressing vibrations, etc. Controls need a built-in process knowledge base to help move away from the dependency on people

controlling machining operations. Material handling is becoming an overall part of the production rate. Need to provide operators with a sense of the degree of productivity occurring at the machine. Cycle time not the biggest factor in total value-added time.

AUTOMOTIVE TIERS (14) Priority is how many parts can be produced per hour, then quality, then changeover time. Beginning to address non-value added time through the use of OEE calculations. If a machine is not operating the control should request a mandatory response from the operator to why

the machine is not cycling. Chip evacuation needs to be improved. Need improved coolant systems and guarding. Ability of control to detect and control chip breaking (process optimization). OEE needs to go from 50% to 95%.


Material Removal

Production Rate (Continued) Background Information (Continued)




11

12

13

14

Value Added Time per Total Machine Cycle

• Increased percent of total cut time per machining cycle time

• Multi-surface finishing • Greater speed • Automatic optimization of machining

operations/processes

X X X X X

X X

X

X

X

X

Material Removal Rate

• High speed gearing • Motor technology • Cooling effect • Computer models which reflect

machine features and dynamics to predict processes

• Modular spindle cartridges to allow upgrading to improved technology.

X X

X

X

X

X

X

X

X

- Spindle Speed

- Traverse Rate

• High Speed Spindles - Tool interface and work retention techniques in high speed applications

- Tool holders - High power tool changer/power draw bar

- Motor parts (rotors, bearings, etc.) - Coolant and hydraulic fluid delivery systems

• Dynamic balancing of spindles, tools, tool holders, etc.

• High acceleration/speed drives (e.g.

linear motors, advanced ballscrew designs, etc.)

• Non-conventional, lightweight structures

• Improved control algorithms

X X

X X

X X

X

X

X

X X

X

X X

X

X

X

X

X

X X

X

X X

X

X

X X X

X

X

X

X

X


Material Removal

Production Rate (Continued) Background Information (Continued)

Summary of Information Sources (Continued)



11

12

13

14

Part Load/Unload Time

• Part verification sensing • Adaptive/flexible fixturing • Adaptive work handling techniques • Work changing designs (e.g. on-the-fly

changing, better accessibility) • Material handling

X X X X

X

X

X

Tool Load/Unload Time

• Improved tool changing designs (e.g. on-the-fly)

• Tool verification sensing

X

X

X

X

X X

Index Time Improved indexing speed

X

Probing Time • Improved probing speed

X X

Chip Management

• Methods for improved removal and separation of chips, stringers, rings, etc.

• Improved machine designs to get chips into conveyor devices

• Universal chip breaking techniques • Improved methods of cleaning chips and

coolant from parts • Changeover from one material to another

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

Coolant Management

• Separation of oil and coolant • Higher through the spindle coolant

pressures • Improved coolant capacity, filtering,

recycling, and changeover • Longer coolant life (sump life) • Improved coolant placement

X X

X

X

X

X

X

X

X

X

X

Note: Refer to the first page of this section for source references.


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Material Removal

Delivery Cycle Figures of Merit The figures of merit determined to be important in addressing delivery cycle are:

Order to Delivery Time Time from when an order is placed for a machine tool until it is delivered at the customer’s site.

Installation Time from delivery of a machine tool at a customer site until the machine tool is operational.

Startup/Rampup Time from when a machine becomes operational until it can operate at the quoted production rate.


Figures of Merit Metric 2002 2007 2012 Order to Delivery Time

- Standard Machines time x

(1-2 mths)

.5x

(2-4 wks)

.2x

(1-3 wks)

- Special Designs

-- Modifications to Standard Machines

time

x

(3-6 mths)

.6x

(3-4 mths)

.4x

(1-3 mths)

-- Small Turnkey Systems

time x

(6 mths)

.8x

(5 mths)

.5x

(3 mths)

-- Large or complex turnkey systems and Automated Systems

time x

(10 mths)

.4x

(4 mths)

.3x

(3 mths)

Installation and Startup/Rampup*

time x .5x .25x

*Note: At this time installation and Startup/Rampup are combined as a figure of merit and may vary depending upon the complexity of the installation and turnkey program.


Material Removal

Delivery Cycle (Continued) Technology Issues/Needs All of the comments made for delivery cycle in the first edition are still valid. Delivery cycles continue to be reduced, with users of small, standard machines calling for deliveries to be quoted in days – not weeks. The growing importance of E-commerce is shown by its first mention here as important to coordinating and shortening the delivery of critical components. Consensus of Issues/Needs Delivery cycle is the total time from order placement to the successful operation of the machine in the customer’s plant. Although many issues are common, users agreed that different factors come into play depending on the nature of the machine. Three classes of machines are considered for comment: small machines delivered from stock, large machines usually built to order, and cells and systems.

General Comments The most frequent comment heard from users during discussion on delivery related to the failure of builders to meet a promised date. The date not only includes the machine being up and running, but also all documentation, spare parts list, and meeting agreed prove-out requirements. Materials such as operators’ manuals should be available prior to machine delivery. Foreign builders appear to be better at meeting a delivery promise. There is usually a window of opportunity for the customer to invest in a machine. This is an advantage of shorter delivery. There will be no letup in requests for shorter delivery. If training is part of the delivery cycle, training methods and schedule should be agreed upon well in advance.

Small Machines In addition to the comments made under the General Comments heading, users of small machines stress that delivery requirements are moving from weeks to days.

Large Machines and Cells and Systems Several suggestions were made that could enable shorter delivery cycles.

Use modular components with plug and play features. Use of E-commerce to shorten delivery of critical components Use of standard language for control logic Use of platform principle in design

It was recommended that tool life expectation should be provided for a turnkey system. Consideration should be given concerning ways to shorten assembly at the customer’s site. The location of connecting services is an issue. The need for a foundation continues to be a negative factor.


Material Removal

Delivery Cycle (Continued)


Primary Thrust Areas Desired Change Time Frame Reduction in machine, fixture, tooling, etc., delivery, installation, and startup/rampup times

50% Reduction in the time from order entry until machine startup

5 yrs

Improved ability to provide quoted production rates and capabilities at machine delivery

100% Improvement on meeting quoted production rates and capabilities

5 yrs


Material Removal

Delivery Cycle (Continued) Background Information Listed here are the comments that formed the basis for the program suggestions in the previous section. Discussion Summary

TECHNOLOGY ISSUES COMMITTEE MEETING (9) Need to add the consideration for turnkey and integration projects. Should reconsider whether or not there is a difference between a large machine and a small machine

relative to delivery. The delivery cycle of critical components is frequently the governing factor for the whole machine. Enabling technology for shorter delivery cycle:

- Plug and play - e-Commerce - Open Controls - Modular Components - Using the platform principal in product design - Lean Manufacturing Practices

Delivery of a turnkey process includes tool life expectations and data, gaging, process documentation, and training.

DEPARTMENT OF ENERGY (10) Delivery is important due to budget cycles and the need to receive purchases on time. Reduction in the time required for assembling machine at customer site. Provide a single location for connecting services to the machine.

AEROSPACE (11) For very large machines, builders could consider assembling subcomponents first and finish assembly

at the user site. Depends on site ready and runoff. Should split installation and startup into small machines, large machines, cells, etc. Material (i.e. operators manual) should be complete, user friendly, and available for review prior to

delivery. This will allow customer personnel to be better prepared for onsite training and installation.

BEARING INDUSTRY (12) Need shorter delivery time. Need to meet promise.

JOBSHOP (13) Need to meet quoted delivery dates, as well as reduce the time to delivery (from weeks to days). What is more important is how an issue is resolved, not usually what the issue is about. Reduce need for foundation.

AUTOMOTIVE TIERS (14) Need to meet quoted delivery dates. This includes documentation, spare parts lists, etc. Delivery is ended when all items are delivered, are up and running, and meet agreed upon prove out

requirements.


Material Removal

Delivery Cycle (Continued) Background Information (Continued)




11

12

13

14

Order to Delivery Time

• Improvement in machine tool delivery time as well as tooling, fixturing, and documentation

• Meeting quoted delivery date • Documentation completed

X X X X X

X

X

X

X

X

X

X

X X

Installation Time

• Better training prior to startup • Reduced time to assemble machinery • Provide service connections at one

point with common connectors

X X X

X

Startup Time

• Obtaining quoted production rates/ capabilities

X X X X


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Material Removal

Reliability/Maintainability Figures of Merit The figures of merit determined to be important in addressing reliability and maintainability are2:

Reliability The probability that machinery/equipment can

perform continuously, without failure, for a specified interval of time when operating under stated conditions.

Maintainability A characteristic of design, installation, and operation, usually expressed as the probability that a machine can be retained in, or restored to, specified operable condition within a specified interval of time when maintenance is performed in accordance with prescribed procedures.

Equipment Availability3

A measure of the degree to which machinery and equipment is in an operable and committable state at the point in time when it is needed.


Figures of Merit Metric 2002 2007 2012 Reliability MTBE

minimum

x

(100 -320 hrs)

1.5x

(150 - 480 hrs)

2x

(200 - 640 hrs)

Maintainability MTTR x

(1 - 4 hrs)

.5x

(.5 - 1 hr)

.25x

(12 - 48 min)

Equipment Availability % 92 95 98

2"Reliability and Maintainability Guideline for Manufacturing Machinery and Equipment," Society of Automotive Engineers, Inc. and National Center for Manufacturing Sciences, 1993. 3 “Production Equipment Availability – A Measurement Guideline, Third Edition,” AMT – The Association For Manufacturing Technology, 2002.


Material Removal

Reliability/Maintainability (Continued) Technology Issues/Needs All of the comments from the first edition remain valid. Advances in control technology can be inferred from user requests. For instance, in the first edition a request was for standardized error codes. Now, the request is for the elimination of codes, and the use of full text to explain a fault. The reliability of high speed spindles has improved, but remains an issue. Little headway has been made for crash protection. It remains a priority as does chip control. Consensus of Issues/Needs Users are calling for a standardized way of collecting and presenting data about machine reliability. As builders incorporate remote diagnostics capability and machine history data collection, users will need one system to handle multiple machine vendors. Requests continue for better and more complete documentation – preferably in electronic form. Components requiring frequent maintenance or checking by means of taking a reading should be placed for easy access and preferably in a single location. Comments regarding reliability and maintainability can be grouped into one of three categories: diagnostics, components, or maintenance.

Diagnostics Users want to see greater use of sensors to monitor and provide diagnostic information. The sensors should provide data that can be used to predict the need for maintenance. Greater explanation should be provided on the control screen such as complete text rather than codes. Consideration should be given to who is the user of the diagnostic screen. It could be an operator, maintenance person, or setup person. Remote help for diagnostics should continue to grow and be improved.

Components Components should be carefully selected and tested since it is the components that fail. Preference should be given to off-the-shelf components for easy availability. Also, the possibility of component obsolescence should be a factor in selection. Components requiring maintenance should be easily accessible. Consideration should also be given to the number of tools (i.e. wrench sizes) required for the mounting of components and tooling. In general, excessive component use should be designed out. Seals continue to be high maintenance items, as well as leaking guards.


Material Removal

Reliability/Maintainability (Continued)

Maintenance The CNC should provide reminders and procedures for preventive maintenance (PM). Builders should design out the need for PM or provide automated PM. There is a need for training on how to maintain the equipment. Chip build-up still creates maintenance problems and there is a need for better crash protection capabilities. Primary Thrust Areas and Objectives

Primary Thrust Areas Desired Change Time Frame Development of collision protection capabilities Incorporation of enhanced

collision protection capabilities into standard machine tool products

5 yrs

Improved reliability of machine components 100% Improvement in reliability

5 yrs

Improved maintenance and remote diagnostic features on machines

Incorporate control and design features addressing maintenance activity

5 yrs


Material Removal

Reliability/Maintainability (Continued) Background Information Listed here are the comments that formed the basis for the program suggestions in the previous section. Discussion Summary

TECHNOLOGY ISSUES COMMITTEE MEETING (9) Need to formalize thinking on how to record and analyze information relating to the reliability of

equipment.

DEPARTMENT OF ENERGY (10) Separate the machine tool from the work zone so that they can be readily maintained. Application of sensors to monitor health of equipment and provide diagnostic information.

AEROSPACE (11) Some machines are maintenance issues due to use of many different components (complexity). Need more self-diagnostic capability and data that something is going wrong so that it can be caught

early. The issue is trying first to find out what is wrong, then how to address it. Need recommended process/procedure in the CNC to lead personnel through preventive maintenance

steps. Need high speed machine designs that provide reliability. Need to look at ways to reduce or eliminate the need of servicing equipment.

BEARING INDUSTRY (12) We would like more data on preventive maintenance details. We would like better diagnostics with more verbiage presented on the screen. Items or components requiring maintenance should be easily accessible. Since components are the usual source of failure, off-the-shelf components should be used wherever

possible. Don’t use components soon to be made obsolete.

JOBSHOP (13) Find it difficult to have a service person come to the site in a timely manner. Need machines to have

ability to detect and determine issues prior to failures to minimize service requirements. Need better quality and more accurate documentation (e.g. manuals, drawings, etc.). More screen data on diagnostics. Need improved crash protection.

AUTOMOTIVE TIERS (14) Items requiring maintenance need to be located in the back (not along the sides) of cellular concept

machines. Need improvements in the reliability of spindles (seals), bearings, and other components. Would like more remote diagnostic capability. Eliminate error codes and place information on the control screen. Need better training on what is needed to maintain equipment. Reduce the number of components used on machines (i.e.. replacing over travel limit switches with

smart slides, reduce the number of different types of screws used on a machine).


Material Removal

Reliability/Maintainability (Continued) Background Information (Continued)




11

12

13

14

Reliability (MTBE)

• Life-long lube systems • Low cost, high-reliability way systems • Reliable I/O devices • Reduced machine complexity • Methods for getting/gathering data on

MTBE of components • Improve machine and component reliability • Improved ballscrew protection

X X

X X

X

X X

X

X

X

X

X

X

X

X

Maintainability (MTTR)

• Diagnostic systems to aid in trouble-shooting (e.g. on-line help, self-diagnostics, remote diagnostics, etc.)

• Reduced design complexity • Better repair instructions, drawings,

information, and training • Standardization of error codes • Controls which permit analysis of internal

(not-generally available) information, availability of data

• Availability of spare parts • Machines designed to metric standards • Ease in accessibility of components • Use of off-the-shelf components

X

X

X X

X X

X X

X

X

X

X

X X

X

X X

X

X X

X

X X X X X

X

X

X

X

X

Equipment Availability

• Predictive maintenance, total productive maintenance

• Better builder data (e.g. preventive maintenance schedules, procedures, and details)

• Improved crash protection

X

X

X

X X

X

X

X

X

X


Material Removal

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Material Removal

Safety, Ergonomics, and Environmental Response Figures of Merit The figures of merit determined to be important in addressing safety, ergonomics4, and environmental response are:

Waste Elimination The elimination of waste as measured by the

amount of material or fluids to be removed from a site or recycled (e.g. lubricants, chips, scrap, etc.).

Noise Quality The permissible level of noise as defined by government regulations.

Air Quality The permissible level of contaminants in the air as defined by government regulations.

Energy Efficiency The theoretical amount of energy required to convert material divided by the energy used.

Safety The condition of being safe as measured by the number of accidents requiring doctor attention or causing lost time per 200,000 person hours of operation.

Ergonomics The degree to which a piece of equipment meets the physical capabilities of individuals.


Figures of Merit Metric 2002 2007 2012 Waste Elimination $ Values not established during discussions.

Noise Quality db Meet or exceed government requirements.

Air Quality ppm Meet or exceed government requirements.

Energy Efficiency energy req. energy used x 1.2x 1.4x

Safety accident rate x .8x .6x

Ergonomics Values not established during discussions.

4 See ANSI B11.TR 1-1993, AMT - The Association For Manufacturing Technology, 1993.


Material Removal

Safety, Ergonomics, and Environmental Response (Continued) Technology Issues/Needs The primary changes in comparison to the first edition relate to increased use of high speed spindles. Increased energy (i.e. speeds, force, etc.) brings about the need for consideration of improved containment measures. Containment applies to both objects (tools) and added mist brought about by higher speeds. Consensus of Issues/Needs

Safety High feed rates and spindle speeds bring about increased need for protective design ideas. Through the use of sensors, there should be reduced need to observe the process with protective guards open. Improved sensing could reduce crashes caused, for example, by mis-loaded parts. Electrical circuits should be designed with common interfaces to easily accept the addition of safety devices.

Environmental All participants mentioned the increasing requirement to improve air quality. As spindle speeds increase, mist becomes more of a problem. Mist containment is a top priority. Also associated with coolants is the elimination of leaks around the guarding. Toxic fumes associated with laser cutting and dry machining were also raised as issues of concern. Closely following the mention of air quality is noise. Users want reduced noise.

Ergonomics A common layout for control panels would reduce chances for operator error. A touch screen that can be customized would appear to be a viable solution. Machine designers should be made more aware of required operator movements. Standards are needed in the area of part load/unload height (automotive), workholding pallets and tombstones, and service connection (air, electric, data) points and type.


Primary Thrust Areas Desired Change Time Frame Improvement in noise reduction and air quality Achieve or exceed

established standards at reduced cost

5 yrs

Attention to improved ergonomics Increased consideration of ergonomic requirements

5 yrs


Material Removal

Safety, Ergonomics, and Environmental Response (Continued) Background Information Listed here are the comments that formed the basis for the program suggestions in the previous section. Discussion Summary

TECHNOLOGY ISSUES COMMITTEE MEETING (9) Need to maintain increased attention to the design of higher velocity machines addressing safety, noise,

airborne particulates, and machining dynamics.

DEPARTMENT OF ENERGY (10) Need to expand the meaning of safety to include the long term effects associated with the manufacturing

process (e.g. coolants). Noise and air quality are of increasing importance.

AEROSPACE (11) Mist is becoming a growing issue.

BEARING INDUSTRY (12) Design to minimize carpal tunnel syndrome where manual loading is required. Integrate the operator movements. Why do we need to run with the door open? Wheel touch up and similar functions should be

accomplished with the aid of sensing. Most crashes are due to mis-loaded parts. Better sensing would be an improvement.

JOBSHOP (13) Need to pay more attention to noise quality.

AUTOMOTIVE TIERS (14) Need improvements in crash protection capability. Need a common layout for push button panels to help reduce errors. Ergonomics, air quality, and fluid control are increasing issues (i.e. eliminate leaks when using high

pressure coolants). Need improved coolant guarding.


Material Removal

Safety, Ergonomics, and Environmental Response (Continued) Background Information (Continued)




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12

13

14

Waste Elimination

• Leak-proof machines • Designs which keep coolant and oils

separated • Dry machining techniques

X X X

X

X

X X X

Noise Quality

• Sound absorbing materials that are resistant to coolants and oils

• Sealed enclosures • Reduced noise

X

X X

X

X

X

X

X

X

Air Quality • Built-in air cleaning and mist control • Sealed enclosures • Improved air quality systems

X X

X X

X X

X

X

X X

X

X

Energy Efficiency

• More efficient use of compressed air in designs

X X

Safety • Review of OSHA requirements for accessing machine tools

• Need different safety standards for CBN and composite tooling

• Eliminate/reduce need to open doors of machine

• Collision protection techniques

X

X

X

X

X

X

X

X

Ergonomics

• More attention needs to be paid to the ergonomics of machine tools

X X X X


Material Removal

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Material Removal

User Friendliness Figures of Merit The figures of merit determined to be important in addressing user friendliness are:

Training Time The time required to train or to retrain

personnel on the operation and maintenance of equipment.

Programming Time The time required to develop a program for, or to program, a machine tool.

Operator Interface

Ease of use

Help screens

The means an operator or maintenance personnel uses to interact with a machine tool.

Machine Complexity The apparent complexity of a machine tool from an operation and maintenance point of view.


Figures of Merit Metric 2002 2007 2012 Training Time time By 2012 on demand

Programming Time time By 2007 automated

Operator Interface

Ease of use

Help screens

CNC Screen

By 2007 able to customize

Machine Complexity CNC Screen

Instructions in full text and graphics


Material Removal

User Friendliness (Continued) Technology Issues/Needs Requests for improved user friendliness show little change from the first edition. The use of tools such as CD ROM and video for training and documentation are still requested. Several builders are now providing these tools, but the response is not universal. There was increased discussion of skill level for this edition. There was considerable comment on the lack of skill availability. There was also the request for documentation (electronic) to consider the different skill levels among operators and maintenance personnel. Consensus of Issues/Needs Comments by workshop participants relating to user friendliness may be grouped into two categories: skills & training, and online help.

Skills & Training Training tools should be made available that take into account changing personnel, session time available, and variation in skill level of the person to be trained. Interactive video is one possibility. Video built into the control would be useful for setup and troubleshooting. An explanation of operator control terms could also be given. Customization of the operator control would allow more flexibility in operator assignment. This would also provide local site control concerning the use of available options.

Online Help Builders should make use of more detailed help screens augmented with online capability to update files to assure the most current information. With online help enabled (direct connection to builder’s site), builders would have the capability to create a good database of problems being encountered in the field or through accessed help screens. Process information should also be available online from tooling suppliers as well as from in-plant historical data. A Windows-based look will make controls appear more universal.


Primary Thrust Areas Desired Change Time Frame Improved training techniques Better use of computer aided

training techniques 5 yrs

Customizable controller interfaces, features, and operator controls

Development of interface, etc., standards

5 yrs


Material Removal

User Friendliness (Continued) Background Information Listed here are the comments that formed the basis for the program suggestions in the previous section. Discussion Summary

TECHNOLOGY ISSUES COMMITTEE MEETING (9) The use of help screens should be emphasized. Improved on-line documentation and availability – process documentation also. Make training compatible with other “life experiences.” Designs that reduce the skill-set requirements. Improve ways of communicating with end users - solving process problems. Training tools need to be developed considering the time available for learning.

DEPARTMENT OF ENERGY (10) Consistency in the location of buttons on operator control stations and in the understanding of their use. Better definition and consistency of G-codes, and what they do, to aid in the operation of different

machines.

AEROSPACE (11) Flexibility of manpower is reduced by CNC control differences. Documentation needs to be well written and delivered in easy to use media (e.g. CD ROM). Should address interactive video training.

BEARING INDUSTRY (12) Provide more trouble shooting aids on the control. Use a built-in video for setup or troubleshooting. Minimize the number of wrenches required for adjustment. Inch/metric is still a problem not solved.

JOBSHOP (13) Workers are entering companies with reduced skill sets, but are required to operate sophisticated

equipment. Equipment, therefore, needs to be simple to learn, have common controls, and operate similarly. Improve ability to bring shop data down to the machine and merge it there with other data to improve

operator information.

AUTOMOTIVE TIERS (14) Looking for more Windows-based controls. If a machine is not operating, the control should request a mandatory response from the operator to why

the machine is not cycling.


Material Removal

User Friendliness (Continued) Background Information (Continued)




11

12

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14

Training Time • Help screens • Use of video technologies for training • Training simplification • Bulletin board for documentation updates • Easier to use manuals (different media)

X X

X

X

X

X

X

X

X

X

X

X

X

X

X

Programming Time

• Universal canned easy-to-use programming packages

• Ability to move part programs, developed on one machine, between different machines

• Ability to program in a background mode on a machine tool while machine is running

• Consistency in G-codes and use

X X

X

X

X

Operator Interface

• Common control and operator systems (standard interfaces, layouts, features, etc.)

• Improved troubleshooting aids on the control

• Improved operator information • Ability to communicate with end users

X X

X X

X X

X

X

X

X

X

Machine Complexity

• Add sophisticated features to designs without increasing the apparent "perceived" machine's complexity to the user

X X X


Material Removal

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CNC Controls

PART 2 - CNC CONTROLS Many of the needs discussed during workshops held to gather information for the Roadmap are related to controls. Issues such as the use of sensors, diagnostics, remote helplines, operator interface, and many more are based on control feature capability. Because of the importance of controls, specific discussions were devoted to the subject. Comments were made according to a list of control attributes, and are summarized here.

ATTRIBUTES RELATED ISSUES

Reliability & Maintainability Diagnostics

Supplier support

Failure rate

Continuously monitoring/diagnose/control the condition/health of the machining process

Self-calibration

User Friendliness Ease of training

Who is trained – operator, setup, maintenance

Customize operator interface (HMI)

Robust help files

HMI standards – OMAC HMI, OSACA, JOP Common Application Programming Interface (API)

Cost Acquisition cost

Cost of ownership includes expansion and replacement parts

Interoperability/Connectivity Ability to accept application software from various vendors

Ability to connect to various WANs LANs, and the Internet

Support of standards such as IEC 1131 and RS.274D

Connect to various drives and feedback devices

Validation of these attributes

New NC programming standards – feature-based

NC Programming Interface

OPEN Architecture NC – ability to add functions for specific technologies

Upgradability Add features and performance

Add 3rd party boards

Modularity

Safety Regulations & standards

Accuracy Appropriate data rates and data handling

CMM-like capability on the machine


CNC Controls

Control Needs Categorized According to Attributes

Reliability & Maintainability • Diagnostics need to be more complete and remotely accessible • Need to get in and out of cycle more easily • Need 24/7 support • Need standard communication interface • Need crash monitor • Need common look and feel – be able to customize HMI • Drop-down box explaining the feature • Don’t use error code – use explanation • Parts are expensive • Remote diagnostics is a requirement • Store machine usage information • Pager interface • Need more adaptive and knowledge-based capability • Sensors capable of self-testing and self-calibration • Build models – effective mathematical models and analytical tools to reliably forecast machine tool

health and condition-based maintenance requirements • Collect event data – alarm levels, control information, machine logs, failure history • Access to production data from a variety of devices and communicating the data up to monitoring

systems

Friendliness • Store more information in the control about control use • Help for each level of use – operator, maintenance, setup • Consistency of terms among control builders • Maintenance training more important than operator training • Need more ways to train – at machine or remotely using the Web • Customize HMI • More description on maintenance

Reminders on screen • Visible gauges on screen based on sensor input • Train on the system, and on error recovery • Provide machine simulation on the control • Codes need to be consistent • Customize the screen • How to know and utilize all control features • Use of COM (Component Object Model) Interfaces, OPC (Ole for Process Control), and Active X

Technology • Common development tools – Microsoft Visual Studio C++/Visual Basic • Need to be able to create new menus, screens, and graphics

Interoperability • Standard interface connections for drives and application software • Should be easy to upgrade and add macros • Need universal user port (UUP) • Idea of “front end” should go away – need unified system • More use of SERCOS and PROFIBUS • Need validation of applications • Need new standards for providing unambiguous computer interpretable product specification (geometry,

non-nominal data, part finish, etc.) with robust data exchange between CAD/CAM and CNC without post processing – Step-NC and beyond

• Real time Ethernet • Open Architecture – add special transformations and technological add-on functions into real time NC

software


CNC Controls

Cost • Builders offer limited choice of controls • Cost of training is high – need new approaches • Cost of memory upgrade is high • Cost of retraining • Components don’t comply with industry standards – therefore high cost

Upgradability • Need plug-and-play capability • Need ability to add third party board • Need to change look of HMI • Need to add new features

Safety

• Need zone of workpiece interference to reduce crashes • Sensor input for spindle balance, pallet seating, etc. • International icons for safety alarms

Accuracy • Monitor data rate • Control features to ensure constant chip per tooth • In-process on-machine probing • Corrections in real time • Provide trend data


CNC Controls

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First Part Correct

PART 3 - FIRST PART CORRECT

First Part Correct means producing a workpiece for the first time while meeting all tolerance and surface finish specifications within the planned cycle time. Workshop participants were asked to discuss the factors that contributed to an inability to produce the First Part Correct. Participant comments can be divided into two general categories. One relates to problems that can be traced to planning and communication issues. The other category relates to problems encountered during the machining process. Of course, problems are interrelated, but the two general groupings are valid for the purpose of looking for solutions. It is interesting to note that shops machining aluminum and other soft metals emphasized problems in the planning area, whereas shops machining cast iron and alloys tended to talk about process problems. Also cultural issues were discussed relating to general practices used in a shop (i.e. test parts used for debugging).

Planning and Communications Inadequate time for detailed process planning and limited knowledge of workpiece materials were frequent comments. Missing information in the communications chain from the designer (intent) to the planner to the operator accounted for problems. Correct translation of the CAD file (where multiple vendors are involved) and missing specifications were measurable problems.

Machining Workholding and fixtures come in for frequent comment. Tools and tool life were also prominent issues. As might be expected, thermal distortion shared the blame for not achieving specified tolerance in the time quoted. Participants noted that the ability to capture process data at the machine would be useful in future planning.


First Part Correct

Summary The frequency that given problems were mentioned plus statements from workshop participants about the priority of events were recorded. The results can best be interpreted by viewing the Pareto charts based on the recorded data.

Problems Associated With Machining

Initial stock

Tool life

Thermals

Toolsetting

Workholding

Relative Importance

Problems Associated With Planning

Incomplete specs

CAD translation

Communications

Programming errors

Inadequate process plan

Relative Importance


First Part Correct

Explanation of Terms Used in the Pareto Charts

Inadequate Process Plan Frequent comments were made relating to time pressures that prevented the completion of a detailed plan. In some cases errors could be traced to lack of planner experience, especially relating to new materials or complex parts.

Programming Errors Programming errors are usually found on complex parts. In cases where the programmer has also become the process planner, additional training and experience are required. In some cases, the CAD data is incorrectly interpreted by the programmer or the CAM system or is incomplete.

Communications In the communication chain from the part designer through planning and programming to the machine operator, critical information is lost or neglected. Sometimes it is helpful if the planner knows the intent of the design. The drawing (CAD file) may not convey information important to a successful process plan. The program may not warn the operator of important checkpoints.

CAD Translation In spite of advances made in transferring a CAD file from one vendor system to another, errors continue to occur.

Incomplete Specifications The part specification (CAD file) is unclear or missing a required explanation of an important part attribute.

Workholding Problems associated with workholding received frequent comment. Problems range from inadequate support to tool interference issues.

Tool Setting The failure to meet size tolerance can often be traced to errors in tool setting or improper offsets.

Thermals Thermal distortion has several sources. Even though the thermal movement of the machine may be understood, each new part introduces exposure to thermal distortion in the tooling, fixture, and the workpiece itself.

Tool Life Reasonable tool life must be achieved at the speeds and feeds specified to meet quoted cycle times. This becomes a problem when unfamiliar work materials are encountered. Also, feeds and speeds may be overly increased to achieve cycle time, due to the planner being too optimistic.

Initial Stock A process plan and program are based on initial stock specifications with respect to material hardness, size, roundness, and other factors that can affect the process. If the initial stock specifications are not met, the quoted time cannot be met.


First Part Correct

Summary of Comments How to capture (document) the process Thermals a problem Problem is incorrect interpretation of CAD data by programmer Thermals Tool setting and offsets Chatter – due to variable stock Insert variation Workholding and fixturing Job plan or process plan inadequate File conversion errors Not enough time to process plan NC programming errors Workholding CAD file not correct Incomplete part specification A “test part’ still consumes time Programmer as process planner needs training Can’t get accuracy in time quoted Unpredictable tool life on new alloys Tool life Need process index or characterization of workpiece to determine best feed and speed Hole size accuracy Knowledge of work material Communications – planner to operator


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