Machining

Machining

The aim is to develop and optimise the removal of machined material in order to obtain greater productivity and/or quality of the machined part. To this end, the process is tackled from various perspectives: the cutting tool itself, refrigeration/lubrication, the machine-tool, cutting conditions, the machining strategy and the material being machined. The process was studied experimentally as well as through modelling and simulation.

Machining is an established technology. Nevertheless, the ongoing evolution of the industry often involves the use of new materials or more exigent quality and environmental requirements. To meet these new challenges, TEKNIKER has embarked on experimentation, modelling and simulation, as well as on the implementation of other technologies to complement or enhance the process.

Some machining processes in which research has been undertaken are:

  • Ecological machining (dry, MQL, cold air, cryogenic fluids: CO2 and  liquid nitrogen
  • Hard machining (hardened steels ~58HRc, hard metal, and so on)
  • Aeronautics materials (Inconel 718, Ti6Al4V, gTiAl, etc.)
  • Emerging materials (Mg, hybrids, ADIs, MMC, and so on)
  • Assisted processes (ultrasounds, high pressure refrigerant, laser, cryogenic refrigerant, etc.)
  • In situ dimensional control

For the optimisation of machining it is necessary to control the variables of the process and know the loads to which the machine is being subjected in the cutting process. IK4-TEKNIKER has wide experience in the use of different means of monitoring, in carrying out the analysis of the machining process (measuring forces, power values, vibrations, temperature, generation of scarf, tool wear and tear, and so on).

Besides experimental characterisation, TEKNIKER uses machining simulation models, both in-house and commercial ones, for enhancing working conditions, cutting strategies and the cutting tool design. The simulation of the process enables forecasting the results prior to implementing the means of production, thus appreciably reducing experimental work.

Related contents

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    The aim is to develop and optimise the removal of machined material in order to obtain greater productivity and/or quality of the machined part. To this end, the process is tackled from various perspectives: the cutting tool itself, refrigeration/lubrication, the machine-tool, cutting conditions, the machining strategy and the material being machined. The process was studied experimentally as well as through modelling and simulation.

    [fase_1] => [fase_2] => [fase_3] => [fase_4] => [texto_2] =>

    Machining is an established technology. Nevertheless, the ongoing evolution of the industry often involves the use of new materials or more exigent quality and environmental requirements. To meet these new challenges, TEKNIKER has embarked on experimentation, modelling and simulation, as well as on the implementation of other technologies to complement or enhance the process.

    Some machining processes in which research has been undertaken are:

    • Ecological machining (dry, MQL, cold air, cryogenic fluids: CO2 and  liquid nitrogen
    • Hard machining (hardened steels ~58HRc, hard metal, and so on)
    • Aeronautics materials (Inconel 718, Ti6Al4V, gTiAl, etc.)
    • Emerging materials (Mg, hybrids, ADIs, MMC, and so on)
    • Assisted processes (ultrasounds, high pressure refrigerant, laser, cryogenic refrigerant, etc.)
    • In situ dimensional control

    For the optimisation of machining it is necessary to control the variables of the process and know the loads to which the machine is being subjected in the cutting process. IK4-TEKNIKER has wide experience in the use of different means of monitoring, in carrying out the analysis of the machining process (measuring forces, power values, vibrations, temperature, generation of scarf, tool wear and tear, and so on).

    Besides experimental characterisation, TEKNIKER uses machining simulation models, both in-house and commercial ones, for enhancing working conditions, cutting strategies and the cutting tool design. The simulation of the process enables forecasting the results prior to implementing the means of production, thus appreciably reducing experimental work.

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    CHARACTERISTICS OF THE EQUIPMENT

    • Ø630 table with A and C axes
    • Travel: X 700 mm; Y 600 mm; Z 500 mm; A -35º/+125º; C 360º
    • Head: HSK63A; 18.000 RPM; 20 kW; 110 Nm
    • MQL Lubrix 750 system (Minimum Quantity of Lubricant)
    • Siemens 840Dsl Control

    EXPERTISE

    • 3- and 5-axes machining of all types of materials
    • Adaptive control for Siemens control based on power readings
    • Studies of machinability with different systems of refrigeration
    ) [1] => Array ( [id] => 19 [titulo] => 5-axes machining – Deckel-Maho DMU 100T [imagen] => Mecanizado_5_Ejes_Deckel_Maho_DMU_100_T1.jpg [texto] =>

    CHARACTERISTICS OF THE EQUIPMENT

    • Table: 1500 mm x 795 mm with C axis / Ø800 without C axis
    • Travel: X 1060 mm; Y 710 mm; Z 710 mm; B -27º/+91º; C 360º
    • Head: SK40; 18.000 RPM; 35 kW; 119 Nm
    • Refrigerant pressure 40 bar
    • Heidenhain Control

    EXPERTISE

    • 3- and 5-axes machining of all types of materials
    • Control-based power monitoring
    • Studies of machinability
    ) [2] => Array ( [id] => 45 [titulo] => 3-axes machining – Kondia Maxim [imagen] => Mecanizado_3_ejes_Kondia_Maxim.jpg [texto] =>

    CHARACTERISTICS OF THE EQUIPMENT

    • Travel: X 750 mm; Y 1000 mm; Z 500 mm
    • Head: HSK63A; 24.000 RPM; 15 kW
    • Linear motors
    • Especially designed for the machining of Mg alloys (fire extinguishing system with argon)
    • Conventional refrigeration and MQL (Vogel)
    • Renishaw OMP400 measurement probe
    • Fanuc control

    EXPERTISE

    • 3-axes machining  of all types of materials
    • Ecological machining of alloys of magnesium and hybrids
    • Monitoring of deflection and vibration of the tool in machining tests, thanks to Y axis on the work table
    • Possibility of using various MQL systems, standard drill and high pressure
    • Dimensional control in situ. Possibility of carrying out complex measurements with PowerInspect OMV
    ) [3] => Array ( [id] => 46 [titulo] => High-pressure coolant pump, up to 140 bars (Chipblaster) [imagen] => ES_Bomba_Taladrina_Alta_Presion_140_Bares.jpg [texto] =>

    CHARACTERISTICS OF THE EQUIPMENT

    • Independent equipment that can be coupled to any machine
    • Coolant pressure between 17 and 140 bars

    EXPERTISE 

    • Turning and milling operations for alloys in aeronautics, stainless steel, etc.
    • Fragmentation and evacuation of scarf in machining processes
    ) [4] => Array ( [id] => 47 [titulo] => Monitoring of the machining process [imagen] => Monitorizacion_Mecanizado.jpg [texto] =>

    CHARACTERISTICS OF THE EQUIPMENT

    • Keyence contact microscope
    • Kistler Dynamometer
    • Thermographic camera
    • Laser displacement sensors without Keyence contact
    • High-speed digital video cameras
    • Mitutoyo portable roughness tester

    EXPERTISE

    • Monitoring cutting forces, tool wear, scarf formation, surface roughness, vibrations and stability, and so on.
    ) [5] => Array ( [id] => 94 [titulo] => CNC lathe – various systems for the refrigeration/lubrication of the cutting [imagen] => Torno_CNC_Diferentes_Sistemas_Refrigeracion.JPG [texto] =>

    CHARACTERISTICS OF THE EQUIPMENT

    • Distance between points: 738 mm
    • Maximum millable diameter: 430 mm
    • Head: 5000 RPM; 8 kW; 159 Nm
    • Motorised tool:  4000 RPM; 2.8 kW; 37 Nm
    • Standard drill and high pressure
    • MQL (Minimum Quantity of Lubricant) system
    • Cryogenic refrigeration with liquid nitrogen and CO2

    EXPERTISE

    • Hard milling with ceramic and diamond cutting tip tool
    • Ecological milling with MQL, liquid nitrogen, CO2 and cold air
    • Optimisation of the machining of materials for various sectors: aeronautic, automobile, turning, and so on…
    ) ) )

Industrial sectors

Aeronautics and space

Automotive

Renewable energy

Machine tools and manufacturing