Axes CNC Mutli Taper Turning SPM

Customer’s Initial Machining Process and problems faced:

• Used to outsource the job to a vendor.
• The vendor used hydro-copying attachment to make the tapers.
• The finish obtained was not good & buffing had to be done.
• The vendor was not able to cope up to the production requirement.
• The customer tried to turn on turning centre, but due to job not having centers, job clamping became difficult & each canned cycle would take around 20-30 minutes.

Feature’s and Specs:

• Lathe type configuration.
• Heavily ribbed, rigid, fabricated & stress relieved base.
• Carriage slide with a stroke of 500 mm.
• The carriage mounted on the horizontal slide consists of cross slide having stroke of 150 mm. A tool post is mounted on the cross slide.
• Both the cross slide & horizontal slide is driven by servo motor through Ball screw & ball nut arrangement for multi axes interpolation and for infinitely variable feed ranges.
• Head stock mounted on LH of the base is driven by motor through timer belt and timer pulley arrangement routed through Vector VFD for stepless speed variation from 750 to 1500 RPM.
• A hydraulically actuated precision self centering 3 jaw chuck is mounted for easy job clamping.
• Tail stock consists of pair of roller & hydraulic cylinder, so that when hydraulic cylinder is actuated and pressed down on the job, automatic centering is observed.
• Appropriate supports provided to avoid bend on job during cutting
• Power-pack of our own make.
• Chip Conveyor to facilitate easy chip disposal.
• Coolant System for heat dissipation & fine surface finish.
• Completely enclosed guard to protect from chips and coolant splash.

Sequence of Operation:

• Load job onto the chuck and press auto cycle.
• The 3 jaw chuck clamps and head stock turns on.
• The single point cutting tool rapid traverse from home to cutting position.
• The required tapers are turned on the job by 2 axis interpolation
• Job unclamps.
• Unload job.
• For describing the sequence of operation, the fixtures will be named as Fixture-1, Fixture-2, Fixture-3 & Fixture-4, in clockwise direction.
• Fixture-1 and Fixture-3 are 1st setup angle milling fixtures.
• Whereas Fixture-2 and Fixture-4 are 2nd setup angle milling fixtures.
• At the start of the cycle, Fixture-1 & Fixture-2 will be facing the operator. Fixture-3 & Fixture-4 will be under the milling heads.
• The operator has to load a fresh component on the Fixture-1 and transfer the component (1st side angle milled) from Fixture-1 to Fixture-2, for 2nd setup operation.
• When auto-cycle button is pressed, the rotary table, indexes by 180°.
• Now Fixture-1 comes under one milling head and Fixture-2 comes under the other milling head, while Fixture-3 and Fixture-4 face the operator.
• Now the vertical slides of both the milling head, position the milling head for the required depth of cut. Horizontal slides move the milling heads at the set feed to mill the components (1st setup and 2nd setup) simultaneously.
• Now, while milling is going on at Fixture-1 and Fixture-2, the operator, has to unload the component from Fixture-4(both sides milled), transfer the component from Fixture-3 (Single side milled) to Fixture-4 and load a fresh job onto Fixture-3.
• After milling, the slides return to home.
• Repeat the cycle.