1005tapsHussey: Moore minimizes harmonic effects, vibrations and shocks by coordinating FSP 300x HMCs and their controls
Like most worm gear parts, the supercharger is a 100% five-axis machined workpiece without any straight or pure arc machining. The profile wheel is generally conical, with a large number of airfoil blades radiating from the hub and starting to spiral along the axis of the cone. At each machining instant during the speed increaser machining, the cutting path varies along all of the machining axes, so each axis is always in an acceleration or deceleration mode, which results in severe gravitational acceleration.
At the heart of Taps, the heavy-duty 5-axis supercharger is machined by four FSP models 300x high-speed machining centers, which are products of Bridgeport, Conn's Moore Tool Co. The most striking aspect of this machine is that the horizontal spindle of the fixed position can only move along the X and Y axes. Only limiting the movement of the main shaft in the horizontal direction does not change the elongation of the main shaft, which can increase the rigidity and increase the vibration damping at the time of large inertia force, and large inertia force is very common in the processing of the supercharger.
The table-on-table rotation design of the workpiece table avoids the center of gravity shift of the hinge shaft during the complex contour cutting of Taps, improving the response and accuracy of the cutting path. With a horizontal spindle, chips can be removed faster, without double cuts.
The large, cast iron and three-point horizontal box-in-box construction enhances stability and vibration absorption. The machining contour feed rate can reach 787 ipm, the speed can reach 1,181 ipm, and the acceleration can reach 653 in./sec2 or 1.7 G in five-axis mode.
The FSP 300s also incorporates a high-gain, closed-loop digital servo system for fast positioning, high feed rates and rapid acceleration on all axes. Moore's advantage is that it captures the essence of machine design and minimizes the effects of harmonic effects, vibrations and shocks by coordinating machine and control systems, and keeps the machine's Siemens Sinumerik 840D control system at a normal working level. Moore's manager Rob Smith said, "When a low-rigidity machine runs at Taps speed, at such high gains, the control system must become dynamically unstable."
Turbocam Parts: When machining impellers from solid aluminum, MooreFSP 300x HMCs are used to remove more than 50% of the weight in the automated production system of Taps, and the impeller is processed in approximately 1 hour while maintaining a volumetric error of 0.001 inches. Within the scope.
He said that Siemens' control system can provide high processing and processing speeds as well as true five-axis machining. Moreover, it is not necessary to stop any of the axes during the machining process, and the stopping of the shaft can greatly reduce the machining speed in the complicated contour processing.
The 840D control system can control 10 channels, 10 mode groups, and 31 axes. To meet the high demands of the axes and channels, the computing power and storage area of ​​the NCU can be extended and combined. This allows the 840D to connect 248 axes and spindles on a single CNC.
The first FSP 300 to be used in Taps is now processing prototypes and machined parts that are one of the company's largest parts, a 4-inch supercharger cut from 2618 aluminum. Using Moore's reciprocating feed, the machine can be operated unattended, cutting 50% of the weight in one hour and completing the press, with a volumetric error of 0.001 inches.
Taps validates the quality of the machine by machining a 10-inch supercharger that requires 7 contour cuts and 7 tool changes from the start of the machine.
The FSP 300 was finished in three hours and all surfaces met the size and finish requirements. For this cut, the feed rate is between 190 and 282 sfpm, while the spindle speed is in the range of 24,000 to 40,000 rpm.
1005TAPSactivearea: Moore FSP 300x HMCs The table-on-table rotary design of the workpiece table avoids the center of gravity shift of the hinge during the complex contour cutting of Taps, improving the response and accuracy of the cutting path.
Taps Engineering Manager Andrew Hussey said: "In any way, this is the fastest five-axis machining profile. The FSP 300x performance is comparable to the best five-axis machining center in Europe, better than any US we have seen. Manufactured CNC."
Due to the success of the first FSP 300, the factory purchased three more for the same turbocharger processing. The processing effect is very good, only two employees can manually trim the products that are produced around the clock.
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