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Active alignment chuck for ultra precision machining
KTH, School of Industrial Engineering and Management (ITM), Production Engineering, Machine and Process Technology.ORCID iD: 0000-0003-2511-7267
KTH, School of Industrial Engineering and Management (ITM), Production Engineering, Machine and Process Technology.ORCID iD: 0000-0001-9185-4607
KTH, School of Industrial Engineering and Management (ITM), Production Engineering, Machine and Process Technology.ORCID iD: 0000-0002-5960-2159
KTH, School of Industrial Engineering and Management (ITM), Production Engineering, Machine and Process Technology.
2011 (English)In: Journal of Machine Engineering, ISSN 1895-7595, Vol. 11, no 4, 39-48 p.Article in journal (Refereed) Published
Abstract [en]

Ultraprecision (UP) components have become common in everyday life products such as mobile phones or compact high resolution digital cameras. Thus the need of producing such components with high accuracy and low production cost. UP machine tools are capable of extremely high accuracy in tool positioning but still today the workpiece is positioned by hand, hence the high production cost of UP components. A fully automated chain of production has been developed within the EU-IP project “Production 4 micro”. This paper describes the active alignment chuck for workholding in UP machining. The chuck has been provided with a high damping interface (HDI) and to evaluate its efficiency the chuck has undergone an experimental modal analysis (EMA) as well as machining tests. The chosen operation was grooving by fly cutting using a diamond tool. The EMA showed that the HDI was effective for those modes where there was relative displacement between one side and the other of the HDI. This result was confirmed by the machining tests as well. The HDI resulted being effective in damping high frequency modes (around 4 – 5 kHz), hence one expected benefit would be a longer tool life.

Place, publisher, year, edition, pages
Wroclaw, Poland: Drukarnia Oficyny Wydawniczej Politechniki Wroclawskiej , 2011. Vol. 11, no 4, 39-48 p.
Keyword [en]
Ultraprecision machining, high damping interface, active alignment
National Category
Engineering and Technology
Research subject
SRA - Production
Identifiers
URN: urn:nbn:se:kth:diva-49770OAI: oai:DiVA.org:kth-49770DiVA: diva2:460279
Conference
4th International Swedish production symposium. Lund, SWE. 3 - 5 May 2011
Projects
EU - Production for micro
Funder
XPRES - Initiative for excellence in production research
Note

QC 20111202

Available from: 2011-11-29 Created: 2011-11-29 Last updated: 2016-05-04Bibliographically approved
In thesis
1. Improving Machining System Performance through designed-in Damping: Modelling, Analysis and Design Solutions
Open this publication in new window or tab >>Improving Machining System Performance through designed-in Damping: Modelling, Analysis and Design Solutions
2012 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

With advances in material technology, allowing, for instance, engines to withstand higher combustion pressure and consequently improving performance, comes challenges to productivity. These materials are, in fact, more difficult to machine with regards to tool wear and especially machine tool stability. Machining vibrations have historically been one of the major limitations to productivity and product quality and the cost of machining vibration for cylinder head manufacturing has been estimated at 0.35 euro per part.

The literature review shows that most of the research on cutting stability has been concentrating on the use of the stability limits diagram (SLD), addressing the limitations of this approach. On the other hand, research dedicated to development of machine tool components designed for chatter avoidance has been concentrating solely on one component at the time.

This thesis proposes therefore to extend the stability limits of the machining system by enhancing the structure’s damping capability via a unified concept based on the distribution of damping within the machining system exploiting the joints composing the machine tool structure. The design solution proposed is based on the enhancement of damping of joint through the exploitation of viscoelastic polymers’ damping properties consciously designed as High Damping Interfaces (HDI).

The tool-turret joint and the turret-lathe joint have been analysed. The computational models for dimensioning the HDI’s within these joints are presented in the thesis and validated by the experiments. The models offer the possibility of consciously design damping in the machining system structure and balance it with regards to the needed stiffness.

These models and the experimental results demonstrate that the approach of enhancing joint damping is viable and effective. The unified concept of the full chain of redesigned components enables the generation of the lowest surface roughness over the whole range of tested cutting parameters. The improved machining system is not affected by instability at any of the tested cutting parameters and offers an outstanding surface quality.

The major scientific contribution of this thesis is therefore represented by the proposed unified concept for designing damping in a machining system alongside the models for computation and optimisation of the HDIs.

From the industrial application point of view, the presented approach allows the end user to select the most suitable parameters in terms of productivity as the enhanced machine tool system becomes less sensitive to stability issues provoked by difficult-to-machine materials or fluctuations of the work material properties that may occur in ordinary production processes.

Place, publisher, year, edition, pages
Stockholm: KTH Royal Institute of Technology, 2012. 79 p.
Series
Trita-IIP, ISSN 1650-1888 ; 12:05
Keyword
Machining performance, Cutting stability, Passive damping, High Damping Interface, Boring bar, Turret
National Category
Production Engineering, Human Work Science and Ergonomics
Research subject
SRA - Production
Identifiers
urn:nbn:se:kth:diva-93143 (URN)978-91-7501-328-2 (ISBN)
Public defence
2012-05-04, M311, Brinellvägen 68, KTH, Stockholm, 10:00 (English)
Opponent
Supervisors
Projects
DampComatProduction 4 microFFI Robust Machining
Funder
XPRES - Initiative for excellence in production research
Note

QC 20120413

Available from: 2012-04-13 Created: 2012-04-12 Last updated: 2013-04-19Bibliographically approved

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Daghini, LorenzoArchenti, AndreasRashid, Amir

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