This software also facilitates faster processing speeds, meaning less lag time and quicker feedback for machine operators while they work. Multi-axis machine tools are more efficient, but they also come at a higher risk for collision as multiple parts work at once. Advanced software cuts down on this risk, in turn cutting downtime and lost materials. The machine tools of the future are smarter, more easily networked, and less prone to error.
As time goes on, automation will become easier and more efficient through the use of machine tools guided by AI and advanced software. Operators will be able to control their machines via computer interface more easily and make parts with fewer errors. Networking advancements will make smart factories and warehouses easier to achieve.
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To achieve this goal we work on innovation in various aspects of machining processes and in the development of new machining systems to enhance the capabilities of conventional processes, ultimately seeks to improve the performance of processes. The use of materials of high hardness is indicated for high performance components running under high loads, in which the finishing process influences very significantly in the functional behavior; for this reason, the finish must provide high quality components, both from the point of view of material thermomechanical properties of finishing and surface integrity achieved.
The finishing processes must ensure that the material maintains its mechanical properties to support the loads in use, and at the same time not affect the integrity that could lead to the emergence of problems of fatigue or corrosion. The growing use of materials of high-performance, such as hardened steels and carbides cementados hard metal , has raised the need to find new manufacturing processes, to improve those used habitually.
The main problem in the manufacture of components of certain hardness materials focuses on the finishing processes that are usually performed through operations slow and expensive as through grinding and EDM processes. As an alternative to these, in recent years he has worked in the development of processes for milling and turning hard to transform materials of high hardness above 55 HRC obtaining surface finishes and tolerances required, with reductions in time in relationship 1 to 3, and costs of machinery 3 times lower face grinding and EDM processes.
Machining centers can empower the process of greater flexibility in relation to the capacity to develop multiple operations, without the restrictions imposed by another type of machines as the grinding or wire EDM. In addition, the possibility of using machining strategies in dry reduces the use of lubricants getting an environmental improvement of the process. The problems that arise in the machining of materials of high hardness and high mechanical properties, focus on the material of the tool, the required surface finish and productivity.
Recent achievements in the development of materials of Court provide sufficiently rigid tools for cutting hardened materials, and at the same time enough tenacity to withstand high mechanical loading of the process. On the other hand, taking into account the nature of the type of materials to transform, these tools must provide sufficient capacity to withstand the wear and high temperatures that arise in this process.
In the case of turning hard problems tend to be related to the achievement of the quality and surface integrity required that are primarily associated with the tool wear, vibration and the rigidity of the machine.
For the correct development of a process of turning hard is necessary the use of a proper machine, mainly of high rigidity and power, but commonly used available machines therefore improve the performance of the process through properly select other aspects such as the tools and conditions for court. Tekniker work done in recent years has been directed to the correct selection and optimization of PCBN tools and machining conditions, given that a good choice for both allows you to control the process of formation of chipto reduce the trend of vibration and deformation, control surface finish and increase the life of the tools.
There are several aspects to consider: tool, tools, conditions of cutting and lubrication; cited in the sequence appropriate to the proper definition of the overall process. As already indicated above, in addition to the improvement of the performance of the process, surface integrity and the microstructure of the material are of great importance.
These aspects are related to high temperatures and mechanical loads that occur in the cutting area. In the case of steels, turning hard affects the surface microstructure by the generation of residual stresses and hardened areas on the surface, also known as white layers. Normally, these layers are followed by a zone softened at greater depth. Occasionally, depending on the workloads of the piece, the hardened surface layers may be the origin of cracks which limit life fatigue of the component.
In Tekniker working on the definition of hard machining processes dealing with the selection tool, tools, and conditions of machining for the increase in the performance of the process by ensuring the surface integrity of the component. From an industrial point of view or implementing the goal of improving all mechanical manufacturing process seeks to three aspects, on the one hand to the improvement of technological aspects precision, quality , on the other to the improvement of the economic aspects of the processes times , costs… , and a third are environmental and working conditions.
Machining processes are a productive activity and it is governed primarily by economic criteria and competitiveness, so that the optimization of the processes is mainly aimed at the improvement of the technological and economic aspects.
The optimization of machining processes in general becomes a problem complicated by the existence of a large number of aspects to consider and the existence of psychic phenomena of different nature materials, mechanics, Tribology, chemistry … with interactions between them.
These difficulties are increased by the ignorance of the basic mechanisms that govern the process, and the extreme conditions in which is the process that does not occur in any other process manufacturing high temperatures and thermal gradients , large plastic deformation at high speeds of deformation, dimensional and temporal scale varied in the process In these circumstances, it is normal conduct the optimization of the process through trials of prueba-error looking for new conditions based in part on the experience and the capacity and time available for testing.
Before these problems in all fields of technology are emerging techniques of modelled and simulation that are presented as tools key in support of manufacturing in the 21st century. No other technology offers greater potential for the improvement of products, the improvement of processes, reduction of the departure time to market and lower manufacturing costs. The modelizado and the simulation through the development of predictive models is presented as an alternative to experimental trials in the form of industrial decision tools.
Objectives are in the machining processes are the improvement of cutting tools, the structures of the machines, drives and the engineering of manufacturing processes.
Most of the developed models focus on the study of one or several of the aspects involved in the cutting process, the complexity of the global study of it. In this regard Tekniker works with two types of models that allow information of different nature: numerical models based on finite element and semiempirical models or mechanistic. Numerical models based on the finite element method are focused on the study of the area near the cutting edge where there is contact between the piece, the chip and the tool.
This type of models allow the acquisition of the distribution of stresses, deformations and temperatures in the cutting area, forces of court, the form of chips or residual stresses.
In Tekniker used for the following activities:. This type of models are based on the assumption that shear forces are proportional to the thickness of chip without cutting, which is basically a relationship of the Court, the geometry of the process and other variables of the same conditions.
These relationships are obtained empirically and therefore, each operation is studied separately still required experimentation to obtain specific court coefficients that relate the different magnitudes and measured parameters.
The reliable prediction of the value of the components of forces in machining operations is essential to determine power requirements, geometric errors in the machined components, the characteristics of the vibrations, the requirements of resistance of cutting toolstooling design and the sizing of own machines for machining, either directly or indirectly so they are a necessary intermediate step for the calculation of many aspects in machining processes. Figure 20 shows an example of redesign of the geometry of the cutting edge chamfer in a PCBN tool for the machining of steel of 53 HRC.
Figure 21 shows the use of numerical models for the design of a rompevirutas for the turning of aluminum with plates of PCD polycrystalline diamond , the machining of the rompevirutas has been in Tekniker using the technique of the micromecanizado laser. The objective here is the fragmentation of the chip for its proper evacuation of the cutting area.
Figure 22 shows a case of milling of thin-walled in which only existed two cutting speeds between 12, and 18, rpm producing a stable machining in the entire wall. The use of the mechanistic models allow the identification of the stable Court conditions to ensure a good surface finish in the operation. The use of external energy sources such as assistance to machining processes is presented as a possibility of improving machining processes.
In this aspect in Tekniker is working on the development of machining processes assisted by ultrasound in operations of turning and drilling. The application of the ultrasound is the introduction of a vibration of between Micron 20 kHz superimposed on the action of Court of the process. The work includes the development of the systems necessary for the realization of machining operations and the assessment of the capabilities of assisted processes. As regards assisted turning objectives are the fragmentation of chips to prevent the buildup in the area of work and the reduction of forces of court.
While in the case of the drilling seeks to break the chip to facilitate the evacuation through the hole, reduce shear forces and improve the accuracy of the hole.
The machining industry has been rapidly expanding in scientific knowledge for a long time. Advanced materials, tooling and equipment are being used to make components. One can take implants in the medical field as merely one noteworthy example, including the use of advanced computers to create five-axis tool paths or models through sophisticated scanning.
This is being done by machinists who have specialized. Can you call them tradespeople anymore? The machinist of today is a computer programmer, a metallurgist, a process improver, a quality control technician and much more. This is not just about cutting metal anymore. Machinists of today need to have more than one skill. I believe that the machinist of yesteryear is now called an operator in most shops.
The reason I am going through the struggle of figuring out the answer to the question above has to do with the connotations of the terms involved. Most people who think of machining as a trade also believe that being a machinist is to have a second-class job. If you cannot make it to Rocket Science School, your fallback is a trade. That really bothers me in light of what I have said about the transformation of machining and the machinist.
Machining and machinists ride the crest of the technological wave. As I see it, this field is advancing faster than other fields and is becoming somewhat immune from technological disruption precisely because it is in the forefront. I can see many highly coveted jobs being disrupted in the coming years. Many doctors may be replaced by artificial intelligence. Can you imagine an AI replacing engineers by being able to design things like buildings more quickly and accurately than their human counterparts?
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