GF Machining Solutions New Milling Magic...New Milling Magic GF Machining Solutions Gisbert Ledvon...

New Milling MagicGF Machining Solutions

Gisbert LedvonDirector of Business DevelopmentGary MichalekCEO, GAM EnterprisesDr. Arno WoernHead of R&D, Jakob Antriebstechnik

New Milling Magic

GF Machining Solutions

Gisbert Ledvon Director of Business DevelopmentINTEC AWARD Leipzig 2015

MM AWARD Stuttgart 2010

PRODEX AWARD Basel 2014

Machine and Spindle

Protection (MSP)

What does „collision“ mean?

Z

Y

X

Crash

A collision is the unplanned impact of at least two physical mass with each other at high kinetic energy (Collision speed v >> 0).

Machine tool crash Collision of mass

Collision speed vcoll

MSP - Presentation IMTS 2016 | 9-14-2016 | Gisbert Ledvon, Gary Michalek, Dr. Arno Woern

Crash

High impact force up to 10 tons Reaction time for numerical control is <5 ms

Collision force path

Col

lisio

n fo

rce

F col

l,z[k

N]

Time [s]0.194 0.198 0.2020

200

400

600

800

1000

1200

Col

lisio

n fo

rce

F col

l,z[k

N]

Collision speed vcoll,z [m/s]

vcoll,z

Fcoll,z


Harmful crash force tip

What happens during a „collision“?

Frequency- Die & Mold: 0-15/month

Cause and Error- Operator: Tool, clamping

- Programming: Zero-point

Effect and Damage- Tool deformation & crack

- Bearing & slide deformation

- Marks on Periphery & work piece

- Machine geometry misaligned

Most collisions are generated by human error!

Why do most crashes happen?

MSP - Presentation IMTS 2016 | 9-14-2016 | Gisbert Ledvon, Gary Michalek, Dr. Arno Woern | Source: www.kobasis.de

What happens to the motor spindle?

60 % of motor spindle failures are crash related Exchange spindle amounts up to 80% of original price

Housing and shaft: deformations

Tool interface:crack of driving pin

Clamping system:damage of collet

Ball bearing:marks in bearing ring

Motor spindleCrash

MSP - Presentation IMTS 2016 | 9-14-2016 | Gisbert Ledvon, Gary Michalek, Dr. Arno Woern | Source: Korff, D.: Schutzmechanismen…, Shaker 2016

How complex is the repair of a crashed motor spindle?

7.Shipment

1.Check in

2.Dis-

assemble

3.Inspection

4.Repair & part replacement

5.Re-

Assemble

6.Test run

About 3 days of repair time

Cost of repair amounts up to 70% of new spindle priceMSP - Presentation IMTS 2016 | 9-14-2016 | Gisbert Ledvon, Gary Michalek, Dr. Arno Woern

Crash

The crash protection has got a high priority for users

Model Invoice Fatal collision of spindle & workpiece

Motor spindle repairOn side assembly of spindle $ 5.000Repair of motor spindle $ 18.000Cost for shipment $ 2.000

Sum for repair $ 25.000

Machine breakdownDown time (3 days) $ 5.000

Total average cost $ 30.000

How much does a spindle crash cost?


How much are the total repair cost during life time of a machine tool?

$ 1.520k

14 %

16 %6 %

18 %

5 %

25 %

16 %

Initial Invest

$ 500k

*downtime related repairs

Example

Maintenance,Inspection

Repairs* Basearea

Electrical energy

Compressed air

Cooling lubricant

Others Total

Period under review 10 years

Total = 3 x Initial Invest

75 % of Initial Invest


A fatal crash means….

Motor spindle damaged

Machine geometry misaligned

Machine downtime

Huge costs!MSP - Presentation IMTS 2016 | 9-14-2016 | Gisbert Ledvon, Gary Michalek, Dr. Arno Woern

GF Machining Solutions

offers a new smart machine tool feature named…

Machine andSpindleProtection

in all directions MSPMSP - Presentation IMTS 2016 | 9-14-2016 | Gisbert Ledvon, Gary Michalek, Dr. Arno Woern

What is different?

Machines equipped with MSP spindle and machine protection have a key to switch the machine into a safe mode.

And an integrated mechanical protection unit


Safe Mode

In safe mode the feed rate in the linear axes are adjusted to max 12m/min (470 ipm)

For the C-axis it is 3150°/min (8.75rpm) and A-axis it is 2250°/min (6.25rpm)


Time [s]0.194 0.198 0.2020

200

400

600

800

1000

1200

-90%

Col

lisio

n fo

rce

F col

l,z[k

N]

Protection unit cuts harmful force transmission Provides reaction time & path for safe machine stop

How does MSP protect the spindle?

Harmful crash force tip

Excessive load zone

MSP


How does the MSP work?


Movie

How does MSP perform in action?


MSP provides high stiffness & well-defined force break!

disp

lace

men

tin

µmdi

spla

cem

enti

n µm

force in kN

moment of tilt in kNm

time in s

time in s

colli

sion

forc

e in

kN

colli

sion

forc

e in

kN

disp

lace

men

tin

µmdi

spla

cem

enti

n µm

actuation moment 2,3 kNm

actuation force 18 kN

tcoll

treact

tcoll

treact

axia

l loa

dra

dial

load

static test dynamic test (collision with v = 20 m/min)

disengaging

acceleration of the inertialmass of the spindle

What happens after a crash with MSP? Retract the tool Remove the damaged tool from the

spindle Check the machine geometry for

example: Kinematic opt Proceed working with a new tool

As easy as that!


On which machines is the smartmachine tool feature MSP available?

Mill P 800 U


Can you believe this part was machined after more than 200 crashes? –Same spindle – no repairs –no adjustments

Bild Teil


With this surface quality?

After 200 Crashes!


With this surface quality?


Yes! With the New Milling Magic from

GF Mikron


Learn more about spindle protection

Visit GAM online: www.gamweb.com/spindle-safety-system-main.html


Location South Hall Booth S8754


Visit our websiteGFMS.COM/US

Gisbert LedvonPhone: +01 847 955 [email protected]


GF Machining Solutions New Milling Magic...New Milling Magic GF Machining Solutions Gisbert Ledvon...

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