Hr. Lang

New machining
concepts and
technologies for
advanced metal
cutting

2010/12/14
Dr.-Ing. Heiner Lang
Global Chi f Technical Officer
Gl b l Chief T h i l Offi
MAG IAS

AGENDA - Process Integration and new
Technologies in Powertrain Applications

1. MAG - The Global Solutions Provider
2. Process Integration as Innovation driver
3. TurnMill & Hobbing – Complete Machining of Gears
(TrunMill Center with integrated hobbing unit – time study and practical example)

4.
4 Fine Boring and Honing on Machining Centers
(Roughing and finishing of cylinder blocks on one machine – practical examples and market introduction)

5. Free of Twist Turning
(Approach to significantly improve turning quality)

6. Combined Turning and Grinding
(Roughing and Finish Machining on one machine tool)

7. High Pressure Cooling
(Increase of tool life and cutting speed due to high pressure Cooling)

8. Cryogenic Machining
(Improve tool life and increase chip removal rate - first test results)

Heiner Lang Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 2

Milestones and Growth Strategies of MAG

04/2005 08/2007 - Cincinnati Machine
Cincinnati/Lamb MAG Russia - Lamb Technicon

10/2005 12/2007
ThyssenKrupp MetalCutting Kecskemét

- Cross Hüller
- Fadal
03/2006 09/2009
Ex-Cell-O MAG Brasil / Sao Paulo - Giddings & Lewis
New Sales & Service Facility - Hessapp
- Hüller Hille
01/2007 07/2010 - Witzig & Frank
MAG India MAG IAS GmbH

09/2010
MAG China / Changchun
01/2007 New Manufacturing Plant
Boehringer
10/2010
Samputensili, Chemnitz


MAG worldmap

3500 employees - world wide sales, engineering, production and service

Markets, Products, Applications

Industrial Equipment
Automotive Aerospace Renewable Energy
Rail, Construction, Power
OEMs, Truck
OEMs Truck, Commercial, Military, Space,
Commercial Military Space Wind, Solar
Generation,
Generation Oil & Gas,
Gas
Major Automotive Tier Helicopter Agriculture, General
Markets

Suppliers Machining, Marine
Machines and equipment
ations

Cylinder Heads & Blocks, Aluminum Structures, Large Frames, Bearings, Hubs, Solar Panels, Thin Film and C-
Cams, Cranks, Composite Structures, Planetary Carriers, Cases, Lift Si Solutions, Wind Blades and
Applica

Transmission, Chassis, Titanium Components, Arms, Wheel-Sets, Brake Root End Milling Machines
Wheels, Shafts, Engines, Landing Gear Disks, Drive & Chassis
Composite Panels Components, Engines, Shafts,
Pumps, Valves, Compressors




4.






The modular and communally building blocks are
developed,
developed used and expanded with CORCOM

CORCOM = Core Components
MAG in house technology

High communality/ Rotary tables for milling and
A-Axis turning operations
same and robust
product technology

Major advantages
j g
1. Flexibility / configuration
2. Cost-effective
3. Robust product design
B-Axis 4. Shortest delivery time B- on A-axis


Process Integration as Innovation Driver
- Customized Solutions -
Building Blocks
ard

Horizontal Vertical
B
Standa

Vertical Horizontal
Machining Machining
Turning Centers Turning Centers
Centers Centers

Turning Milling Hobbing Cold
Drilling Forming Laser Honing Grinding
hnologyy
odules
tomized Tech
Mo
d

Customized Solution
olution

- Base machine + standardized interfaces
- Configurable Technology/Softwaremodules
Cust
So

- U ifi d operator-, automation- and service
Unified t t ti d i
concept, similar parts



4.






Concept for Milling, Turning and Gearing (Modular
concept of base machine)

ƒ Vertical turning center as Base machine
g
- Modular expendable to 4ax (2 turrets)
- One or two turn tables
- 2ax milling spindle with tilting unit
- Vertikal RAM for heavy turning processes
- Hobbing unit for g
g gearing
g
ƒ Process integration
- Moduls for turning, milling, gearing, grinding

/
B/Y-axis
turret RAM spindle Hobbing


Technology Modules:
- 3-axis Swivel unit for gear milling operations
- Hobbing unit for gear manufacturing

Bi-functional Milling Spindel
Bi f ti l Milli S i d l Hobbing U it
H bbi Unit
Swivel Range: +/- 105 Swivel Range: +/- 30
Max. RPM: 5000 1/min Max. RPM: 600 1/min
Torque at 40%:
q ED 380 Nm Modul: bis 6 mm
Power at 40%: ED 36 kW Shifting Stroke: 200 mm


Concept for Milling, Turning and Hobbing in one
machine tool

Hobbing Unit (H400)
5ax Unit for: for Outside gearing
- Milling
- Drilling
- Winding
- Turning

Z- axis vertical 600mm
X- axis horizontal 300 mm
Y- axis shift 200 mm
A-
A axis vertikal 30
C- axis main spindle
Tool magazine

High precision
Table


Work piece data

Piece
MAG hobbing unit
Material 18CrNiMo6 H400

Normal modul 6
Work piece
Angle of profile 20 spur gear
Number of teeth 85
Pitch angle 18 right
clamping mandrel
Outside-‡ 548 mm Clamping ø 205 mm
Root-‡ 521 mm
Gear teeth width 85 mm


Complete process chain for cutting process
(Productivity comparison)

Single cut process Multi Task process
6 Machine tool : 3 1
6 Setting up: 30 min 10 min
6 L di / Rigging:
Loading Ri i 6 min
i 3 min
i
6 Process: 32.2 min 36.6 min
6 Unloading / Cleaning: 6 min 3 min

Cycle time first piece: 74.2 min 52.6 min
Cycle time following pieces: 44.2 min 42.6 min

Time reduction per piece: 1.6
1 6 min

ƒ Multi task process allows reducing of cycle time
g y
ƒ Productivity increasing result from minimized nonproductive times




4.






Definition Honing

TARGET: functionally optimized surface and geometry of bores
stroke
What is honing? Why honing?

Honing is a cutting method Higher lifetime at
for the correction of ƒ high power output
ƒ diameter ƒ less consumption
ƒ shape
h ƒ low emissions
ƒ surface ƒ less wear
ƒ positional tolerances of ƒ better emergency
bores running properties

Radial Rotational motion of
expansion of the tool
the honing
stones

The surface is characterized by its cross-hatch
structure.


Advantages by Honing on Horizontal Machining
Centre

Your B
Y Benefit
fit

ƒ Cost efficient solution compared to a separate, special honing machine
ƒ Less honing operations due to improved pre-machining
ƒ Less honing time due to reduction of stock and stock variation
ƒ One partner for the whole
production li
d ti line
ƒ Elimination of bottleneck
honing machine
ƒ Expandable honing tools
integrated in the standard
tool magazine
ƒ Automatic tool change
ƒ Scalability of the complete
production line matched to the
actual production volume


Draw Bar Spindle HSK100 GEN4

ƒ Synchronous-spindle HSK 100
ƒ 5000 1/min
ƒ 28 kW and 150 Nm
ƒ Integrated draw bar (
g (driven by
y
torquemotor and ball screw drive)
ƒ Highly dynamic feed system
Acceleration: 10 m/s² Speed:
10 m/min
ƒ Integrated channels for air gauging and
coolant through the spindle
ƒ Integrated axial force measurement


Results after Base Honing

Test results after base honing
ƒ Fax-Film (magnifaction 100-times) and surface


Results after Plateau Honing

Test results after plateau honing
ƒ Cylindricity: < 3,5 μm
ƒ Roundness: < 2 μm




4.






Drallfrei
Hart
Hart- und Weichdrehen auf einer VDF T


Grinding – Standard machining for finishing process

Advantages:
Ad t
ƒ Well known process, long life experience
ƒ High process quality and reliability
ƒ Good work piece surface and process
stability due to coolant use

Disadvantages:
Di d t
ƒ High investment cost – separate machine
ƒ Coolant required./ No dry machining
ƒ S f
Surface quality d
li depended on corn fi
d d finess
ƒ Real Free of Twist surface only achievable
when sparking out several times
ƒ LLong process / cycle ti
l time


New process: Free of Twist Turning

Underline:
2 1 Shaft
1a Machined Surface
2 Tool Holder
3 2a
2a Cutting Blade
D 3 Feed motion direction
7 Shaft rotation
10 Shaft axial axis
D Angle of Inclination
1a 1 Advantages:
ƒ Applicable on turning machines
ƒ Free of Twist surfaces
ƒ Typical Rz-value: 2-3 μm

Alternative to Hard Turning or Grinding
Much faster process / cycle time than Grinding
Longer Tool life than conventional carbide turning insert or grinding weel

Test result: Free of Twist Turning of sealing surface

Hard Turning
H dT i Free of Twist Turning
F fT i tT i Surface Topology of FoT Turning
S f T l fF TT i

CLA 19 μin CLA 10 μin


Comparison: Hard Turning vs. Free of Twist Turning

Hart Turning: Free of Twist Turning:

ƒ Parameters: ƒ Parameters:
– fz = 0,10 mm – fz = 0,50 mm
– r = 0,8 mm – fy = 0,08 mm
y
– ap = 0,15 mm – ap = 0,15 mm
– l = 165 mm – l = 165 mm

ƒ Result: ƒ Result:
– Roundness = 3,5 μm – Roundness = 3 μm
– t = 124 sec – t = 25 sec

Opportunities: Steering Knuckle Machining Results:
ƒ Performance increase: ƒ Free of Twist Turning of
Hart vs. FoT Turning 5 : 1 sealing surface
ƒ Longer Tool life 1 : 10 R 0 2 - 0 5 Pm
Ra 0,2 0,5
Rz d 2 Pm
ƒ Roundness of bearing
diameter d 3 Pm




4.






Combined Hard Turning and Grinding

Hardturning of face Finishgrinding f
Fi i h i di of
and shell surface bore hole

Finishgrinding of Measuring of
the keyway bore and keyway


Vertical turning machine for flange parts

Z-Slide ith t
Z Slid with turret for
tf
hard turning

Integrated measuring
probe for quality
check

Z-Slide with
Grinding Spindle Z-Slide with motorized
spindle to attach
crossheads for grinding
key ways or slots.
Y-axis integrated to
adjust feed
j
Workpiece table


Turret for Hard Turning

Z-Slide with turret for
hard turning


Spindle for cylindrical Grinding

Z-Slide ith
Z Slid with
Grinding Spindle


Spindle with attachment

Z Slide
Z-Slide with motorized
spindle to attach
crossheads for grinding
key ways or slots.
Y-axis i t
Y i integrated to
t dt
adjust feed




4.






High Pressure Cooling

Goals:
Increase Tool Life
Increase Cutting Parameters
Better Chip Formation
Intensive Cooling of tool and workpiece

Applkication Area:
Machining of materials with difficult cutting behavior


What is High Pressure Cooling

Effectiveness:
High Pressure Coolant flow between chip and tool
ÖPressure approx. 100 – 400 bar
ÖDue to high pressure the coolant gets closer to the tool
center point
ÖReduction of tool wear due to better friction behavior
ÖBetter cooling of tool and up to 50% lower temperature in
contact zone Span

Ö Better chip breakage and chip formation

Schneide


High Pressure Cooling

Results:
Increase of tool life up to 50%
Increase of cutting speed up to 50%
g p p
Chip formation

Low pressure

High pressure


Applications

Typical fields of application:
Mill-Turning of complex parts and materials
Increase of chip removal rate
Better chip evacuation

Industry sector:
Mainly Aerospace
Titanium and Alloys
Nickel based alloys
-- Inconel
-- Hastolloy

Other fields of application:
Low carbon steels due to better chip breakage
Al-alloys due to reduced adhesive wear and avoidance of build-up edge


MAG test machine for customer applications

Working room
g


Application: Titanium Cutting

Turning of Titanium: Tool Life
Conventional Cooling
Material:
Ti6AlV4 High Pressure Cooling
Cutting Parameters:
Vc=60m/min
ap=2,5mm
f=0,25mm/rot
f=0 25mm/rot
Vc [m/min]
Conventional Cooling High Pressure Cooling

After 2 min After 4 min


Customer Applications @ MAG

Industry Sector: Turbine Parts

8 CNC-Turning Machines for
Airplane Turbine Parts have
p
been delivered along with High
Pressure Cooling

Work Piece: Planet Carrier
Turning, Drilling, Milling on
MAG TurnMill Center




4.






Current Machining is Speed Limited

ƒ Machining generates heat at the
cutting edge due to friction,
shearing,
shearing and abrasion Rapid
Tool Wear
To Flank We (mm)

ƒ Once a critical speed is exceeded,
ear

Cutting
g
wear increases rapidly Speed Limit
ool

ƒ Occurs because conventional
coolants provide insufficient heat
removal to enable order-of-
magnitude i
it d increases i speed
in d


The Unique Application of MAG Cryogenic Venting

Conventional MAG
LN2 & CO2
Cryogenic
application
Vented,
Heat-sink
application

External only RAKE FACE
Cryogenic flow External Cryo
CHIP
&/or MQL Flow
FLOW

-321 F
321
SHEAR
PLANE
The MAG model plumbs the cooling
Prior nitrogen cooling applications flow through the insert to allow a
were all external, like conventional heat-sink effect rather than chip
coolants, aimed at the face of the zone cooling.
Heiner Langand chip.
insert Bewerken van “moeilijke” materialen MAG IAS GmbH 12/14/2010 43

Our Solution – MAG Cryogenic Technology

ƒ MAG Cryogenic Technology uses small flow rates of liquid nitrogen
(LN2) applied near the cutting edge (directly and indirectly) to maximize the
cooling effectiveness (~0.04 to 0.08 L/min/cutting edge)
ƒ MAG has licensed the Intellectual Property of cryogenic machining
ƒ Cryogenic processing replaces traditional cutting fluids with more
environmentally friendly cryogenic fluid that enables higher cutting speeds:
ƒ Environmental, Health & Safety Advantages:
– Nitrogen is an inert atmospheric gas which is
78% of the air we breath
– Very easily safeguarded with an Oxygen sensor
– LN2 is a non Greenhouse gas
– Safe non slip coolant system for large
walk-on machine t bl
lk hi tables
– Contamination free for Medical
machining requirements


Key Advantages – MAG Cryogenic Technology

ƒ Machining Performance
– 4X increase in processing speed for CGI
– 2-3X increase in processing speed for titanium
– 10X improvement in tool life for titanium 0.24 L/min of Liquid Nitrogen (ICS)
10

10X Improvement

min)
Tool Life (m
5X Improvement

1

15 L/min Flood Coolant

0.1
200 300 400 500

Surface Speed (ft/min)

40% Longer Cycle Time in
g y Dramatic Improvement in
Titanium for Flood Coolant Tool Life and Speed


MAG Cryogenic Performance Data - Titanium

Workpiece Material Operation Speed Results

300 SFPM (91 M/min.) 300 SFPM: 6 min. of in cut time (3 for flood) (2X)
Titanium Plunge Milling
400 SFPM (122 M/min.) 400 SFPM: 2 min. of in cut time (1 for flood) (2X)

Tool:
T l KMT 2 inch Pl
i h Plunge Mill with 5 Fl t
ith Flutes
Insert: SDCT120432ENLD2-KC725
Width of Cut: 0.875 inches
Plunge Depth: 1 inch Liquid Nitrogen
Stepover: 0.350 inches
CLPT: 0.00314 in/tooth
10
0.76 L/min of Liquid Nitrogen (ICS)
Tool Life (min)

2X Improvement
p Flood Coolant
L

35 L/min Flood Coolant 2X Improvement

1

200 300 400 500
00
[91 M/min] [122 M/min]
Surface Speed (ft/min)
Cryo Modified KMT 2 inch Plunge Mill

How Can You Get MAG Cryogenic Technology?

ƒ Portable Rotary Cryogenic Adapter (
y y g p (RCA) )
ƒ Test various materials, specific challenges, and
processing bottle necks without changing the machine
ƒ Evaluate MAG Cryogenic Technology
ƒ Cooperatively develop optimum machining parameters
ƒ Secure “Voice of the Customer” feedback and
sponsorship
hi


Technology, Speed, Flexibility & Service!


Hr. Lang

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