The aim of the thesis is focused on the proposal of a new technological procedure of the blade carrier for use in its own production. Currently, the carrier is manufactured by the German company B.Maier Zerkleinerungstechnik GmbH. The work includes several parts. The first part deals with the component itself, its function and importance, as well as its function in the assembly and the whole machine. In the next part the technological procedure of the blade carrier production is created. Fleet of machines including the necessary tools is also designed. In a separate chapter there is an economic evaluation of the proposed solution in two different variants, a subsequent evaluation and a proposal for implementation.

This diploma thesis is elaborated on the specific assignment of AB Komponenty Ltd. The core of this thesis features the technology of manufacturing of component BASE CROSSBAR of aluminium alloy EN AW 2017 on the vertical machining center. CNC control program for the suggested technology is developed in the CAM software PowerMill 2010th. To complete the work it also includes a brief introduction to the issues and analysis of aluminum, aluminum alloys and coatings. From the perspective of the practice is probably the most beneficial and interesting final technical economic evaluation of selected solution of the given problem. The suggested technology can be a significant saving in production costs.

This thesis will focus on a design of multifunctional machining center. The work is created in cooperation with two colleagues. Michal Kunorza will design a rotary table and Tomáš Grëtz will design a machine spindle with automatic tool exchange. My part of the work will focus on design of linear tool axis. The result of this cooperation should be machining center for rotary and non-rotary workpieces.

La réalisation de formes complexes comme les moules ou les prothèses médicales nécessite l’utilisation d’opérations de super finition pour obtenir de faibles défauts géométriques, pouvant aller jusqu’au poli-miroir. Ces opérations de pré-polissage et de polissage sont encore régulièrement réalisées manuellement. En effet, malgré des avantages en termes de répétabilité, de productivité et de qualité géométrique, les méthodes de polissage automatique sont peu utilisées car elles nécessitent une mise au point importante. Les travaux de recherche présentés participent à la maîtrise du procédé de polissage automatique tout en contrôlant la qualité géométrique des pièces. Pour parvenir à cette maîtrise, un outil de simulation de l’enlèvement de matière est mis en place. Cet outil permet de simuler l’enlèvement de matière au cours d’une opération de prépolissage réalisée sur centre d’usinage 5 axes. Il se base sur un modèle du contact obtenu entre l’outil de pré-polissage et la pièce, ainsi que sur un modèle du pouvoir abrasif intégrant l’usure et l’encrassement du disque. Cette simulation permet de vérifier la régularité de l’abrasion sur une surface et d’identifier les zones pouvant faire apparaitre des défauts macro-géométriques importants. Une méthode est également proposée pour compenser les variations du pouvoir abrasif au cours du temps. La compensation s’effectue en optimisant les consignes de vitesse d’avance et/ou de fréquence de broche le long de la trajectoire. Cette méthode de pilotage permet d’obtenir un taux d’enlèvement de matière plus constant et ainsi de réduire les défauts géométriques générés pendant une opération de prépolissage. / Complex shapes such as medical implants or injection molds require the use of super-finishing operations to minimize geometrical defects, down to mirror effect finish. These pre-polishing and polishing operations are still regularly performed manually by skilled workers. In spite of advantages in terms of repeatability, productivity and geometrical quality, automatic polishing methods are not widely used because they require systematic and significant developments. The present work contributes to enhance the automatic polishing process compared to the geometric quality of the parts. To achieve this control, a numerical simulation of material removal is implemented. This software simulates the material removal during a pre-polishing operation performed on 5-axis machining center. It is based on a contact model obtained between the pre-polishing tool and the part, as well as an abrasive model including wear of the disc. This simulation allows to check the uniformity of the material removal on the surface and to identify potential areas where macro-geometric defects appear. A method is also proposed to balance variations of the abrasive efficiency. The correction is performed by optimizing the federate and/or the spindle speed along the tool path. This method provides a constant material removal and reduces the geometrical deviations generated during pre-polishing operations.

Esta tese teve por objetivo desenvolver um algoritmo preciso e robusto capaz de compensar os erros térmicos volumétricos de um centro de usinagem 5 eixos em diferentes condições operacionais. O comportamento térmico da máquina foi modelado usando técnicas do método dos elementos finitos (MEF) com base na teoria do calor de atrito e calor de convecção, e validadas através dos vários campos de temperatura obtidos experimentalmente usando termopares e imagens térmicas. Os principais subsistemas da máquina foram inicialmente modelados, como o conjunto de fusos de esferas, guias lineares e motofuso, o que permitiu posteriormente a validação do comportamento termoelástico da máquina completa para onze ciclos de trabalho em vazio, seis ciclos de usinagem, nove ciclos de posicionamento e dois ciclos com temperatura ambiente variando, obtendo erros máximos inferiores a 9%, ao comparar os resultados numéricos com os resultados experimentais. A validação do modelo em elementos finitos permitiu usar os resultados obtidos para treinar e validar uma rede neural artificial (RNA) para prever os erros térmicos do centro de usinagem. Os desvios entre os erros térmicos previstos pela RNA e os calculados pelo MEF foram inferiores a 5%. Baseado nos resultados obtidos pelas medições das peças de trabalho usinadas foi possível formular e implementar um modelo de compensação dos erros térmicos no CNC do centro de usinagem, que obteve uma redução dos erros entre 62% e 100% nas peças usinadas com compensação. Foi também proposto um algoritmo de previsão e compensação dos erros térmicos para o centro de usinagem, baseado em todos os ciclos e simulações realizadas, e que se comparando com os resultados experimentais mostrou-se capaz de reduzir os erros térmicos entre 50% e 95%. Após sua validação, foi possível concluir que o algoritmo desenvolvido é uma ferramenta precisa e robusta para compensar os erros térmicos da máquina para várias condições de trabalho, podendo compensá-los mesmo com esta movendo-se a diferentes velocidades, em usinagem ou mesmo operando em temperatura ambiente variável. / This thesis aims to develop an accurate and robust algorithm capable of compensating the volumetric thermal errors of a 5-axis machining center under different operating conditions. The thermal behavior of the machine was first modeled using finite element method (FEM) techniques based on theory of friction heat and convection heat, and validated with the various experimentally raised temperature fields using thermocouples and thermal imaging. The main machine subsystems were initially modeled, such as the ball screw system, linear guides and spindle, which allowed for validating of the thermoelastic behavior of the entire machine for eleven no load duty cycles, six cycles of machining, nine cycles of positioning and two cycles with varying ambient temperature, obtaining errors lower than 9%, when comparing the numerical results with the experimental results. The validation of the finite element model allowed for the use of the results obtained to train and validate an artificial neural network (ANN) for predicting the thermal errors of the machining center. The deviations between the thermal errors predicted by ANN and the FEM simulation results were less than 5%. Based on the results obtained by the measurements of the machined workpieces, it was possible to formulate and implement a model of compensation of the thermal errors in the CNC of the machining center, which obtained a reduction of errors of 62% and 100% of the machined parts with compensation. It was also proposed a thermal error prediction and compensation algorithm for the machining center, based on all cycles and simulations performed, and that, comparing with the experimental results, it was able to reduce the thermal errors between 50% and 95%. After its validation, it was possible to conclude that the developed algorithm is an accurate and robust tool to compensate the thermal errors of the machine for various duty conditions, being able to compensate the errors even when it is moving at different speeds, in machining process or even operating in variable ambient temperature.

Esta tese teve por objetivo desenvolver um algoritmo preciso e robusto capaz de compensar os erros térmicos volumétricos de um centro de usinagem 5 eixos em diferentes condições operacionais. O comportamento térmico da máquina foi modelado usando técnicas do método dos elementos finitos (MEF) com base na teoria do calor de atrito e calor de convecção, e validadas através dos vários campos de temperatura obtidos experimentalmente usando termopares e imagens térmicas. Os principais subsistemas da máquina foram inicialmente modelados, como o conjunto de fusos de esferas, guias lineares e motofuso, o que permitiu posteriormente a validação do comportamento termoelástico da máquina completa para onze ciclos de trabalho em vazio, seis ciclos de usinagem, nove ciclos de posicionamento e dois ciclos com temperatura ambiente variando, obtendo erros máximos inferiores a 9%, ao comparar os resultados numéricos com os resultados experimentais. A validação do modelo em elementos finitos permitiu usar os resultados obtidos para treinar e validar uma rede neural artificial (RNA) para prever os erros térmicos do centro de usinagem. Os desvios entre os erros térmicos previstos pela RNA e os calculados pelo MEF foram inferiores a 5%. Baseado nos resultados obtidos pelas medições das peças de trabalho usinadas foi possível formular e implementar um modelo de compensação dos erros térmicos no CNC do centro de usinagem, que obteve uma redução dos erros entre 62% e 100% nas peças usinadas com compensação. Foi também proposto um algoritmo de previsão e compensação dos erros térmicos para o centro de usinagem, baseado em todos os ciclos e simulações realizadas, e que se comparando com os resultados experimentais mostrou-se capaz de reduzir os erros térmicos entre 50% e 95%. Após sua validação, foi possível concluir que o algoritmo desenvolvido é uma ferramenta precisa e robusta para compensar os erros térmicos da máquina para várias condições de trabalho, podendo compensá-los mesmo com esta movendo-se a diferentes velocidades, em usinagem ou mesmo operando em temperatura ambiente variável. / This thesis aims to develop an accurate and robust algorithm capable of compensating the volumetric thermal errors of a 5-axis machining center under different operating conditions. The thermal behavior of the machine was first modeled using finite element method (FEM) techniques based on theory of friction heat and convection heat, and validated with the various experimentally raised temperature fields using thermocouples and thermal imaging. The main machine subsystems were initially modeled, such as the ball screw system, linear guides and spindle, which allowed for validating of the thermoelastic behavior of the entire machine for eleven no load duty cycles, six cycles of machining, nine cycles of positioning and two cycles with varying ambient temperature, obtaining errors lower than 9%, when comparing the numerical results with the experimental results. The validation of the finite element model allowed for the use of the results obtained to train and validate an artificial neural network (ANN) for predicting the thermal errors of the machining center. The deviations between the thermal errors predicted by ANN and the FEM simulation results were less than 5%. Based on the results obtained by the measurements of the machined workpieces, it was possible to formulate and implement a model of compensation of the thermal errors in the CNC of the machining center, which obtained a reduction of errors of 62% and 100% of the machined parts with compensation. It was also proposed a thermal error prediction and compensation algorithm for the machining center, based on all cycles and simulations performed, and that, comparing with the experimental results, it was able to reduce the thermal errors between 50% and 95%. After its validation, it was possible to conclude that the developed algorithm is an accurate and robust tool to compensate the thermal errors of the machine for various duty conditions, being able to compensate the errors even when it is moving at different speeds, in machining process or even operating in variable ambient temperature.

This master‘s thesis deals with the suggestion of suitable tools for milling aluminum alloys profiles for the construction of aperture fillings and their aplication to a CNC machining center for increasing the efficiency of the cutting process. The first part of the thesis is focused on the description of the company and the workplace of production of aluminum alloys constructions. The following pages contain description of standardized products, which are used to identify the test profile that is part of the experimental verification. Next part of this thesis is characteristic of aluminum alloys and tool materials suitable for their machining. Second part of this work contains an analysis of the current state, suggestion of new cutting tools and their application to the production proces. At the end of this thesis there is the technical-economic evaluation that deals with the time and economic savings of the applied design.

The Master's thesis deals with the safety of operator activities at the BASICTURN vertical turning center. The first part is focused on the requirements arising from the directives of the European Parliament and the Council in relevant areas and a system analysis of the issue. The second part is a risk analysis related to operator activities on the operated machine.

The diploma thesis deals with legislative purposes for the operation of machinery in the Czech Republic and the European Union. It deals with the analysis of technical standards of machinery, specific machining centers. The analysis of the risky machining center NHX 5500 DMG Mori is based on this. The result of the work is the minimization of ongoing risks and meeting the legal requirements of the state of the operated machining center.

This thesis describes the complete technology solution of front driving axle console production by machining. The console is part of the self-supporting structure of the tractor and is produced under conditions of large engineering company. Introduction describes the prduction technology of component. The main part is devoted to the technological process of production and selection of appropriate cutting tools. Technical and economical evaluation of machined part is mentioned in the conclusion of thesis.