Transcript Vordergelegedopprelrad-eng

Customer project - table layshaft wheel
(Machining of the friction welding seam)
• Because of rising quantities the
company Daimler AG is going to invest
in a new machine tool for machining the
table layshaft wheel.
• Currently the components are machined
on a lathe with a driven unit.
• But in the rough turning prozess they
Material: 25MoCr4
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have problems with the friction
welding seam. During the machining a
hard and solid ring springs up, which
could damage insert and tool holder.
Customer project - table layshaft wheel
(Machining of the friction welding seam)
Goal:
• The goal of this project was
presenting the Daimler AG a
concept to machine the
friction welding seam with high
reliability and productivity.
Solution:
• Best possible solution:
» Slitting and Turning
Material: 25MoCr4
Turn-milling
• Alternative solution:
Slitting and turning
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Customer project - table layshaft wheel
(Starting situation)
Cutting speed.:
Feed per tooth (radial).:
Feed per tooth (axial).:
Cutting depth ap:
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300 m/min
0,15 mm
0,3 mm
3 mm
During the rough turning prozess a hard
and solid ring springs up, which could
damage insert and tool holder. Because of
the ring chips also could not drop down and
get caught up in the tool holder.
Customer project - table layshaft wheel
(Best possible solution - turn-milling)
• For machining the friction welding seam on Mulit-Task-Machines, turn-milling
is the best possible solution.
- no „ring“ is bulid up
- short machining time (30 s)
- high reliabilty (insert break, chips)
- only one tool necessary
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Customer project - table layshaft wheel
(Alternative solution - slitting and turning)
• For machining the table layshaft wheel on a lathe with driven unit, slitting and
turning of the weldseam is an alternative solution. On big advantage is, that you
do not need such a solid milling unit.
But this version has two big disadvantages:
- 33% longer machining time (42 s)
- two tools are needed
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Customer project - table layshaft wheel
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Turn-milling with Coromill R390
(two cuts)
tool
insert
depth of cut
R390-044C4-11MO60
R390-11T308M-PM
ap= 2 + 1,5 mm
cutting speed vc= 235 m/min
R.P.M
n = 1700 min-1
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Radial feed:
feed per tooth fz= 0,09 mm
feed rate
vf= 600 mm/min
Axial feed:
feed per tooth fz= 0,16 mm
feed rate
vf= 1100 mm/min
Turn-milling with Coromill R390
(two cuts)
Process reliability
good
Process time
T = 49s
Chip control
perfect
Power consumption Pe=7,1 KW
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Sloting of the welded seam and turning
milling tool
diameter
number of tooth
milling insert
depth of cut
cutting speed
feed per tooth (radial)
feed per tooth (axial)
turning tool
turning insert
depth of cut
cutting speed
feed (radial)
feed (axial)
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N176.39-2525-12
RCMT-10T3M0-4225
ap= 3 mm
vc= 300 m/min
fn= 0,15 mm
fn= 0,3 mm
R300-020A25L-10L
Dc= 20 mm
Z= 2
R300-1032M-PM 1030
ap= 3,5 mm
vc= 200 m/min
fz= 0,04 mm
fz= 0,16 mm
Summary
The most effective solution is turn-milling as a one hit operation on a
stable multi task turn milling machine.
• shortest process time
• high process reliability
• one tool for the roughing process
If a classical lathe should be used for the operation slotting with a driven
unit and then classical turning offers a reliable process too.
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