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    Machining

    NILES-SIMMONS close the door on downtime

    • By MTDCNC
    • July 16, 2020
    • 4 minute read

    NILES-SIMMONS developed the ‘Closed-Door Machining’ concept to meet the ever-increasing requirements of manufacturing complex, high-precision parts for the aviation industry. The complete machining concept allows machining in one continuous process within one machine without operator intervention is available from McDowell Machining Technologies.

    It is applicable for various parts that were historically made in several process steps on different machines. Some machine tool manufacturers may be thinking ‘we do that’, but do you really?

    When using the ‘Closed-Door Machining’ concept, a raw part is clamped in the machine and after several fully-automatic re-clamping and re-chucking procedures, it can be removed as a finished part. Machining runs entirely uninterrupted and depending on complexity, shifts can be overlapped several times throughout the cycle as the process runs fully automated. The time associated with part-handling procedures and moving parts between several machines is removed. Similarly, the tasks for operators are also reduced, as fewer machines are required and less operator intervention is necessary.

    By integrating all the technology into one machine, such as turning, milling, drilling, deep-hole drilling, boring, bottle boring thread cutting, gear hobbing, power skiving and grinding; there is no need to use ‘process-specific’ machines. In the long term, this considerably contributes to much more cost-efficient production.

    For the implementation of the concept, NILES-SIMMONS introduced several new machining and measuring technologies. In doing so, it is now possible to achieve extraordinarily high accuracies of <5µm in a process-reliable way by the use of scanned part measuring through a RENISHAW Sprint measuring sensor and automatic tool compensation after the measurement cut. As well as Sprint, there is also another various touch measuring sensors such as RMP60 or RMP600 fitted to carry out other measurement tasks.

    At the same time, the measurement of all necessary tools also takes place, again fully automated within the machine using a touch probe measuring system for fixed tools and an optic measuring system (laser) for rotationally symmetric tools.

    To accommodate a large number of tools, it is possible to configure two tool magazines on the headstock and tailstock side with a capacity of up to 144 tools each to service the multi-axes turning-milling unit. Alternatively, for specific machining tasks an additional magazine can be applied for the counter spindle or tailstock sided boring bar slide. This long tool magazine has a maximum of 16 positions for long tool cartridges with up to two meters in length these can be operated with high coolant-pressure up to 300 bar and respectively with a high flow rate of up to 150 l/min. Consequently, any deep-hole drilling requirement can be achieved as part of an extremely stable and reliable process.

    For surface optimisation, it is also possible to integrate grinding operations. The grinding wheel can be exchanged, measured and dressed – all fully automatically. For sparking, there are also sensors available. The coolant that needs to be positioned close to the part is controlled and positioned by a separate, programmable NC-axis.

    The highest equipped machine with a turning/milling unit, boring bar slide, turret (bottom), main and counter spindle, as well as steady rests and tool change units, can be configured with up to 32 NC-axes. Due to this complexity, a CAD/ CAM system with integrated post-processors is essential.

    Furthermore, a liquid-cooled concrete machine bed is used to achieve higher temperature stability and to ensure the requested accuracies despite temperature variation. The machining centres are also equipped with damping and vibration-reducing components such as FEM optimised slide-geometry, hydraulic clamped components of the part-axes, damping surfaces in machining direction and roller guides of the machining axes in size 45/55.

    To ensure a clear and easy operation a Siemens OP 19 panel is used with additional touchscreen for process monitoring.

    The process security within the Closed-Door-Machining’ concept is significantly enhanced through Niles Simmons comprehensive software modules driven by Industry 4.0, such as Volumetric Compensation Software, spindle modulation, axis compensation, tool breakage and drive monitoring. This concept and the respective solutions have been operational worldwide for over a decade among innovative manufacturing businesses with significant success.

    https://cdn.mtdcnc.global/cnc/wp-content/uploads/2020/07/16173617/38-Renishaw-Sprint-measuring-sensor-scaled.jpg

    NILES-SIMMONS close the door on downtime

    NILES-SIMMONS developed the ‘Closed-Door Machining’ concept to meet the ever-increasing requirements of manufacturing complex, high-precision parts for the aviation industry. The complete machining concept allows machining in one continuous process within one machine without operator intervention is available from McDowell Machining Technologies.

    It is applicable for various parts that were historically made in several process steps on different machines. Some machine tool manufacturers may be thinking ‘we do that’, but do you really?

    When using the ‘Closed-Door Machining’ concept, a raw part is clamped in the machine and after several fully-automatic re-clamping and re-chucking procedures, it can be removed as a finished part. Machining runs entirely uninterrupted and depending on complexity, shifts can be overlapped several times throughout the cycle as the process runs fully automated. The time associated with part-handling procedures and moving parts between several machines is removed. Similarly, the tasks for operators are also reduced, as fewer machines are required and less operator intervention is necessary.

    By integrating all the technology into one machine, such as turning, milling, drilling, deep-hole drilling, boring, bottle boring thread cutting, gear hobbing, power skiving and grinding; there is no need to use ‘process-specific’ machines. In the long term, this considerably contributes to much more cost-efficient production.

    For the implementation of the concept, NILES-SIMMONS introduced several new machining and measuring technologies. In doing so, it is now possible to achieve extraordinarily high accuracies of <5µm in a process-reliable way by the use of scanned part measuring through a RENISHAW Sprint measuring sensor and automatic tool compensation after the measurement cut. As well as Sprint, there is also another various touch measuring sensors such as RMP60 or RMP600 fitted to carry out other measurement tasks.

    At the same time, the measurement of all necessary tools also takes place, again fully automated within the machine using a touch probe measuring system for fixed tools and an optic measuring system (laser) for rotationally symmetric tools.

    To accommodate a large number of tools, it is possible to configure two tool magazines on the headstock and tailstock side with a capacity of up to 144 tools each to service the multi-axes turning-milling unit. Alternatively, for specific machining tasks an additional magazine can be applied for the counter spindle or tailstock sided boring bar slide. This long tool magazine has a maximum of 16 positions for long tool cartridges with up to two meters in length these can be operated with high coolant-pressure up to 300 bar and respectively with a high flow rate of up to 150 l/min. Consequently, any deep-hole drilling requirement can be achieved as part of an extremely stable and reliable process.

    For surface optimisation, it is also possible to integrate grinding operations. The grinding wheel can be exchanged, measured and dressed – all fully automatically. For sparking, there are also sensors available. The coolant that needs to be positioned close to the part is controlled and positioned by a separate, programmable NC-axis.

    The highest equipped machine with a turning/milling unit, boring bar slide, turret (bottom), main and counter spindle, as well as steady rests and tool change units, can be configured with up to 32 NC-axes. Due to this complexity, a CAD/ CAM system with integrated post-processors is essential.

    Furthermore, a liquid-cooled concrete machine bed is used to achieve higher temperature stability and to ensure the requested accuracies despite temperature variation. The machining centres are also equipped with damping and vibration-reducing components such as FEM optimised slide-geometry, hydraulic clamped components of the part-axes, damping surfaces in machining direction and roller guides of the machining axes in size 45/55.

    To ensure a clear and easy operation a Siemens OP 19 panel is used with additional touchscreen for process monitoring.

    The process security within the Closed-Door-Machining’ concept is significantly enhanced through Niles Simmons comprehensive software modules driven by Industry 4.0, such as Volumetric Compensation Software, spindle modulation, axis compensation, tool breakage and drive monitoring. This concept and the respective solutions have been operational worldwide for over a decade among innovative manufacturing businesses with significant success.