In these days, on over the world, we ca find a huge CNC centres which are more and more often completely automatized. There is no necessity of human intervention to change or stock the machining tools. All these operations are made thanks of robots and manipulators to economize time and money. Target of this these is conception of the mobile storage stacker which can be made and then transported to the place of usage in a 40ft sea container. After transportation the stacker is completelly reade to use. Thanks of this concept, we gain universal storage stacker for differents conditions without necessity of new concepts and and solutions for each CNC centre.

This research is about a costly problem in the automotive industry due to tool fracture during the splines cold rolling of steel shafts. The objective is to study the cause of this failure and propose solutions that can be implemented in the workshop.The writing starts with a brief introduction of the companies involved in shafts production and problem solving. It introduces the cold rolling process and its advantages on splines manufacturing, and it goes through relevant material and process characteristics that help to determine the cause of tool fracture.In order to understand the process failure and production flow, it has been necessary to build up an Ishikawa diagram with possible tool fracture causes. After collecting and analysing the data about the machine tool, cold rolling process and work-piece and rolling tool materials, tests and experiments have been done.It has been considered that there is a rolling tool fatigue that causes tool fracture. Beside tool fracture, two more problems with production flow instability and the right side rolling tool have been detected. Testing the material hardness of the work-piece has shown continuous hardness fluctuations from the supplier. Rolling tool misalignment has been measured by using a vernier caliper measurement device. Rolling tools material hardness analysis shows that tool is very hard and it is possible to use a tougher material which responds better to cyclic loads.Leax has tried to solve the problem by testing another lubrication and tool coatings. A modal analysis test has been performed in order to find the natural frequency of the work-piece which possibly may lead to vibration and over loading one of the rolling tools.The conclusion that has been reached is that main cause of fracture is rolling tool fatigue due to cyclic loads and it is important to use other rolling tool material. The other two detected problems, production flow instability and rigth side rolling tool fracture, should be considered as a part of the problem in order to significantly increase tools life and stabilize production flow rate.

In this dissertation is presented the development of a new measurement method for the stiffness and damping characteristics of a joint in a parallel kinematic machine tool. The main contribution of this method is specially for applications, that demand accurate information about stiffness and damping parameters from assembled parts of machines tool. Methods for compensation of deformations in machines tool, that are carried out by control, belong to these applications. Another contribution of this work is the technical implementation of the proposed principle of the new method. At this point the focus of the work was devoted to signal processing, that differs in a certain degree from other types of signal processing methods, that are used in other dynamic measurements, e.g. modal analysis. One of the main requirements was the possibility to consider the nonlinear behavior of the measured structure. In another chapter the modified signal processing method was used for measuring a joint in a test rig. The results were compared with results from other measurement methods. On account of this comparison the statement was made that the new method can be used for measuring the stiffness and damping parameters of machine parts. Finally the new method was applied to measure the properties of a joint, which was built in a machine tool. Moreover, the problems, that appeared during the measurement, were also described.

The doctoral thesis deals with a position of a design process in machine tool life-cycle and with main design approaches. Main aim of the doctoral thesis is to bring System approach of machine tool development. This method follows design team experience with support by systematic methods and managing by product manager. Alongside this method respects System approach defined by Janicek. It is possible to achieve increasing of machine technical quality, reducing of final machine costs and reducing of time for machine tool creation by application of this method. System approach of machine tool development is focused on detailed outer and inner optimization of a machine structure from technical and economical point of view. This design approach is possible to apply in any production company because it is brought in intelligible way.

Machine tools need to be tested to check they behave correctly while machining. A bigger production (capacity), improving the accuracy in final products (quality) or reducing costs are some of the main goals. Reducing the maintenance of the machines, their nonproductive time and a higher quality of the final parts, have a strong influence in the costs. Even machines built to the same specification present different properties and behaviours, which leads into a reduction of the flexibility when it comes to move operations among them. This study is focused on the measurement and modelling of four machine tools (M1, M2, M3 and M4), with same specifications, from the static point of view. Methods used to measure all these properties are the circular tests under loaded conditions, with the device Loaded Double Ball Bar (LDBB), which measures positional accuracy and static stiffness. Different pressures (0.5, 1, 3, 5, 6, 7 bar) and locations for the LDBB have been used.   After the tests were performed, all the machines shown good properties with the detail of M4, which had a lower stiffness than the other three ones due to its table attachments. / Maskinverktyg måste testas för att kontrollera att de beter sig korrekt vid bearbetning. En större produktion (kapacitet), förbättra noggrannheten i slutprodukterna (kvalitet) eller sänka kostnaderna är några av huvudmålen. Att minska underhållet av maskinerna, deras icke-produktiva tid och en högre kvalitet på de slutliga delarna har ett starkt inflytande i kostnaderna. Även maskiner konstruerade för samma specifikation presenterar olika egenskaper och beteenden, vilket leder till en minskning av flexibiliteten när det gäller att flytta verksamheten bland dem. Denna studie är inriktad på mätning och modellering av fyra verktygsmaskiner (M1, M2, M3 och M4), med samma specifikationer, ur statisk synvinkel. Metoder som används för att mäta alla dessa egenskaper är de cirkulära testerna under laddade förhållanden, med enheten Loaded Double Ball Bar (LDBB), som mäter positionsnoggrannhet och statisk styvhet. Olika tryck (0,5, 1, 3, 5, 6, 7 bar) och platser för LDBB har använts.   Efter testerna visade alla maskiner goda egenskaper med detaljerna i M4, som hade en lägre styvhet än de andra tre på grund av dess bordsfästanordningar.

In modern manufacturing industries, many applications require precision motion control of multi-agent systems, like multi-joint robot arms and multi-axis machine tools. Cutter (end effector) should stay as close as possible to the reference trajectory to ensure the quality of the final products. In conventional computer numerical control (CNC), the control unit of each axis is independently designed to achieve the best individual tracking performance. However, this becomes less effective when dealing with multi-axis contour following tasks because of the lack of coordination among axes. This dissertation studies the control of multi-axis machine tools with focus on reducing the contour error. The proposed research explicitly addresses the minimization of contour error and treats the multi-axis machine tool as a multi-input-multi-output (MIMO) system instead of several decoupled single-input-single-output (SISO) systems. New control schemes are developed to achieve superior contour following performance even in the presence of disturbances. This study also extends the applications of the proposed control system from plane contours to regular contours in R3. The effectiveness of the developed control systems is experimentally verified on a micro milling machine.

This study explores the relationship between endmill tool dynamics and cutting parameters, emphasizing the impact of these factors on machining dynamics, surface finish, and dimensional control. It introduces a novel approach to analyze and optimize the overall performance of a solid carbide endmill, with a specific focus on machining Aluminum 6066-T6. By using stability lobes diagrams (SLD), stable conditions for cutting were chosen, and then surface roughness and tool and workpiece vibration analyses were performed to assess machining performance. This work aims to understand the effects of operating below the peaks and valleys, inherent in the shape of the SLD, using different RPMs. The study's methodology involves tap tests using CutPro - Tap Test Module and milling tests on a horizontal machining center. The surface roughness measurement was performed using an Alicona Infinite Focus confocal microscope and accelerometers were positioned on the spindle bearing housing and workpiece. The findings suggest that within the stable range below the stability lobe diagram's boundary, there is a significant difference in vibration resulting in variation in surface roughness corresponding to the peaks and valleys of the SLD. The variation of acceleration, and consequently vibration, was considerably higher when operating below valleys which negatively affected the surface roughness of the workpiece. The surface roughness plays a pivotal role in tool performance and subsequently influences metal removal rate and tool and spindle life. For conditions closer to instability, this is even more important. In conclusion, this research lays the foundation for a holistic approach to solid carbide endmill design and cutting parameter selection, showing that the machining process can be optimized in terms of the SLDs, even in regions far below the stability limit / Thesis / Master of Applied Science (MASc)

This diploma thesis deals with the construction proposal of a small multifunctional modeller CNC milling machine that enables milling of aluminium alloys and 3D printing using the FDM method. Based on the research, analyzes and defined entry requirements the construction proposal is created and verified by calculations. The thesis contains a description of all the construction parts including the printhead, the tool tray and the safety cover. The other part of the thesis describes the machine geometry adjustment and specifies the choice of control system. The thesis includes a 3D model and the drawing documentation of selected structural nodes.

The presented doctoral thesis is focused on environmental impact assessment of basic engineering materials used in a production machine construction. Ecological profile of the machine itself develops already in the phase of its design. It is not only about the choice of future machine parameters and materials that it is built from, but also about technologies used for its manufacture and operation conditions of the finished machine (consumption of energy and service fluids). The thesis occupies in detail with environmental impact analysis of the production machine design from the viewpoint of material production that mentioned machine consists of. The output from the performed analysis is methodology for evaluating of machine design from the viewpoint of greenhouse gas emissions. Created methodology enables evaluating of machine ecological profile and its possible adjustments even during pre-production stage. In the first part of the thesis the analysis of current legislation in the field of fighting against climate changes, reducing of products energy consumption and increasing of production machines energy efficiency is presented. Also in this part of the thesis description of methods that were used to achieve thesis goals is stated. Furthermore analysis of production machine as a system of structural components that fulfil the certain functions and description of used basic engineering materials are presented. The second part of the thesis is devoted to environmental impact analysis of the production machine design process. There the design process and environmental impact of machine design are described. This is followed by description of production machine life cycle and detailed analysis of undesirable substances emissions emitted during pre-production phases of machine life cycle (i.e. during the raw materials extraction and materials production). From this analysis the particular constituents’ pre-production phases which are sources of undesirable substances emissions (e.g. greenhouse gas emissions) were derived. The thesis also includes analysis of these constituents’ life cycles and description of electric power generation as a basic constituent of any phase of product life cycle. In this part of the thesis calculations of particular fuel type’s amounts that is required to produce 1 MWh of electric power and carbon dioxide amount produced during electric power generation are presented. The third part of the thesis contains created models of manufacturing processes of basic engineering materials and calculations of related emissions of selected greenhouse gases. The practical output from this part of the thesis is methodology that enables environmental impact assessment of machine design from the viewpoint of engineering materials used in its construction.

This study analyses the diffusion of numerically controlled machine tools in sixty Quebec and Ontario engineering and metalworking firms. Interviews with production management provide the data for a critical evaluation of labour process analysis and economic diffusion theory. Management decisions to adopt numerical control technology are found to be guided by technical criteria, contrary to labour process theory. However, economic diffusion theory is found to underestimate the extent of imperfections of knowledge of new technology in industry, the length and costs of learning to use new technology, the complexity of technological evolution, and the diversity of applications and methods of use of a particular technology.