This diploma thesis solves grinding box unit for vertical boring and turning machine for ČKD Blansko. For fixing is used standard fixing system used in ČKD Blansko. Spindle is drived by engine placed in slide ram. Engine can be also used for milling box unit. Grinding box unit must stand operating load. Using of automatic balancing system is also solved in this project.

This Master's thesis is focused on technical preparation of the MTB front wheel hub and application of SinuTrain 4.7 computer software. The thesis is divided into four thematic parts. The first part introduces the SinuTrain software and briefly describes the MTB wheel hub. The next section contains the hub design and selection of the suitable material for this component. The third part describes production technologies and selection of the turning machine with suitable tools. The last chapter deals with SinuTrain 4.7 software usage and also presents the results of the production simulations.

To remain competitive in today’s demanding economy, there is an increasing demand for improved productivity and scrap reduction in manufacturing. Traditional manufacturing metal removal processes such as turning and boring are still one of the most used techniques for fabricating metal products. Although the essential metal removal process is the same, new advances in technology have led to improvements in the monitoring of the process allowing for reduction of power consumption, tool wear, and total cost of production. Replacing used CNC lathes from the 1980’s in a manufacturing facility may prove costly, thus finding a method to modernize the lathes is vital. This research focuses on Phase I and II of a three phase research project where the final goal is to optimize the simultaneous turning and boring operation of a CNC Lathe. From the optimization results it will be possible to build an adaptive controller that will produce parts rapidly while minimizing tool wear and machinist interaction with the lathe. Phase I of the project was geared towards selecting the sensors that were to be used to monitor the operation and designing a program with an architecture that would allow for simultaneous data collection from the selected sensors at high sampling rates. Signals monitored during the operation included force, temperature, vibration, sound, acoustic emissions, power, and metalworking fluid flow rates. Phase II of this research is focused on using the Response Surface Method to build empirical models for various responses and to optimize the simultaneous cutting process. The simultaneous turning and boring process was defined by the four factors of spindle speed, feed rate, outer diameter depth of cut, and inner diameter depth of cut. A total of four sets of experiments were performed. The first set of experiments screened the experimental region to iii determine if the cutting parameters were feasible. The next three set s of designs of experiments used Central Composite Designs to build empirical models of each desired response in terms of the four factors and to optimize the process. Each design of experiments was compared with one another to validate that the results achieved were accurate within the experimental region. By using the Response Surface Method optimal machining parameter settings were achieved. The algorithm used to search for optimal process parameter settings was the desirability function. By applying the results from this research to the manufacturing facility, they will achieve reduction in power consumption, reduction in production time, and decrease in the total cost of each part.

The FP interferometer was found to be feasible for detecting changes in machining forces. The fiber optic sensor was able to detect increases in strain corresponding to force increases detected by a dynamometer. The FP interferometer system must progress in several ways. A better data acquisition and data analysis system must be developed. A robust sensor must be made to withstand the harsh environment of machining. Also a method for eliminating the affects of thermal strain must be created. Finally, the placement of the FP sensor must also be determined. The FP has the potential to effectively monitor machining forces without affecting the rigidity of a turning operation setup. / Master of Science

Machining operations in automated manufacturing centers are under-performing by 20-80%. Optimizing these machining operations requires on-line knowledge about the cutting tool's condition and the process state. Currently, this information is either not reliable or not available in a timely manner. This is due to the lack of suitable sensors, which must measure on-line directly and accurately one or more of the relevant tool and process information sources in the hostile machining environment. A direct, active, ultrasonic method for on-line sensing of the tool condition and process state in turning operations was developed. Sensing is achieved by using an ultrasonic transducer operating at 10 MHz in a pulse-echo mode to send pulses through the tool. The amplitude and propagation time of the reflected pulses are modulated by the tool nose, flank, temperature, and by the material in contact with the tool. The reflected pulses are received and processed by a high speed digital signal processing system. This method has the potential to directly and accurately measure on-line several relevant processes and cutting tool parameters through the use of a single sensor. These parameters are tool-workpiece contact, tool wear, tool chipping, temperature and chatter. / Ph. D.

Baigiamajame magistro darbe ištirta skystųjų kristalų (cholesterolio stearatas) priedų prie tepimo ir aušinimo skysčio (TAS) įtaka kietlydynio peilio nudilimui ir apdirbto paviršiaus šiurkštumui tekinimo operacijoje. Ištirtas sriegiklio pasipriešinimo momento kitimas sriegiant skyles rankiniais sriegikliais, kai sriegikliai tepami skystaisiais kristalais ir konsistentiniu tepalu. Paviršiaus šiurkštumo tyrimai buvo atlikti tekinant 45 plieninį strypą: pastūma – 0,1 mm/aps., pjovimo greitis buvo keičiamas nuo 85 iki 267 m/min, o cholesterolio stearato kristalų koncentracija emulsijoje – nuo 0,1 iki 0,5 %. Eksperimentas buvo atliekamas pagal dviejų veiksnių ortogonalinį eksperimento planą. Rezultatai pateikti kaip tekinto paviršiaus šiurkštumo parametro Ra priklausomybė nuo pjovimo greičio ir cholesterolio stearato koncentracijos TAS. Peilio užpakalinio paviršiaus nudilimas buvo nustatomas esant tokiems režimams: pjovimo greitis 160 m/min, pastūma 0,1 mm/sūk., aušinimas – mineralinė emulsija BLASOCUT ir ta pati emulsija su 0,1% cholesterolio stearato. Rezultatai pateikti kaip dilimo priklausomybės nuo įrankio kelio grafikai. Nustatyta, kad skystųjų kristalų priedai pagerina įrankio patvarumą ir sumažina įrankio dilimą. Taip pat nustatyta, kad sriegiklio pasipriešinimo momentas mažėja iki 1,1 karto, tepant jį skystaisiais kristalais, lyginant su tepimu konsistentiniu tepalu. Darbą sudaro keturios dalys: įvadas, literatūros analizė, eksperimentiniai tyrimai, išvados. Darbo... [toliau žr. visą tekstą] / The influence of the liquid crystals (cholesteryl stearate) additives on technological properties of the cutting fluid is investigated in the master‘s thesis. Influence of the presence of the liquid crystals in cutting fluid on wear of the carbide lathe tool and roughness of the turned surface is established. Also changes in the cutting torque of the hand tap in the tapping operation were obtained when tap were lubricated with grease and liquid crystals. Research of the surface roughness was done at the following conditions: tool feedrate – 0.1 mm/rev., cutting speed was varied from 85 to 267 m/min and concentration of the liquid crystals was varied from 0.1 to 0.5%. Experimental research was performed by means of two factors second order orthogonal design. The results presented as graphs of dependence of average roughness of turned surface on cutting speed and concentration of the liquid crystals in the coolant. The wear of carbide tool relief face was established under following conditions: cutting speed 160 m/min, feedrate – 0.1 mm/rev., cutting fluid – mineral coolant BLASOCUT with 0.1% and without liquid crystals additives. The results are presented as graphs of dependence of tool wear on the length of tool path. It is established that liquid crystals additive reduces tool wear and increase tool life. It is also established, that cutting torque of the hand tap reduces about 1.5 times when it is lubricated with liquid crystals, as compared with lubrication with... [to full text]

The research objectives of this thesis are as follows: (1) Investigate the effects of carbon content, alloying, and heat treatment of steels on white layer formation, (2) Prove/disprove that the temperature for phase transformation in machining is the same as the nominal phase transformation temperature of the steel, (3) Quantify the contributions of thermal and mechanical effects to white layer generation in machining, (4) Develop a semi-empirical procedure for prediction of white layer formation that accounts for both thermal and mechanical effects. These research objectives are realized through experimental and modeling efforts on steels. Depth and hardness measurements of the white layers formed in steels show the importance of heat treatment and carbon content on white layer formation. Measurements of workpiece surface temperature and X-Ray Diffraction characterization of the machined surfaces show that phase transformation occurs below the nominal As temperature suggesting that mechanical effects play an important role in white layer formation. The maximum workpiece surface temperature, the effective stress, and plastic strain on the workpiece surface are measured and/or calculated and shown to affect the white layer depth and amount of retained austenite. A semi-empirical procedure is developed by correlating the maximum workpiece temperature and the unit thrust force increase with white layer formation.

Turning is one of the most widely used processes in machining and is characterized by a cutting tool moving along the axis of a rotating workpiece as it removes material. A detrimental phenomenon to productivity in turning operations is unstable cutting or chatter. This can reduce the life of tooling, dimensional accuracy, and the quality of a part's surface finish because of severe levels of vibration. Ideally, cutting conditions are chosen such that material removal is performed in a stable manner. However, it is sometimes unavoidable because of the geometry of the cutting tool or workpiece. This work seeks to develop a dynamic cutting force model that can be used to predict both the point of chatter instability as well as its amplitude growth over time. Previous chatter models fail to capture the physics of the process from a first-principles point of view because they are oversimplified and rely on various "cutting force coefficients" that must be tuned in order to get a desired correlation with experimental results. The proposed approach models the process in a geometrically rigorous fashion, also giving treatment to the strain, strain rate, and temperature effects encountered in machining. It derives the forces encountered during a turning operation from two sources: forces due to chip formation and forces due to plowing and flank interference. This study consists of a detailed derivation of two new cutting force models. One relies on careful approximations in order to obtain a closed-form solution; the other is more explicit and obtains a solution through numerical methods. The models are validated experimentally by comparing their prediction of the point of instability, the magnitude of vibration in the time and frequency domains, as well as the machined surface topography during chatter.

Pour répondre à la demande croissante de bois et pour préserver les forêts primaires, les méthodes de sylviculture les plus dynamiques ont été privilégiées de manière générale sur la planète.. Les objectifs de la recherche étaient 1) déterminer le point de démarcation/ âge de transition entre le bois juvénile et le bois mature sur sengon (Falcataria moluccana), jabon(Anthocephalus cadamba Miq.), peuplier (Populus sp) et douglas (Psedotsuga menziesii); 2) analyser l'effet de la juvénilité sur un fissuration cyclique, la rugosité et de mouillage; 3) analyser l'effet de la fissuration cyclique et juvénilité sur la résistance à l'adhérence de la colle et les propriétés mécaniques du LVL en flexion; et 4) appliquer un nouveau modèle analytique pour estimer la variation du module d'élasticité du lamibois (sengon et jabon) depuis la moelle vers l'écorce. A partir de la longueur des fibres, le point de démarcation entre le bois juvénile et le bois mature ont été estimés. Pour les essences sengon and jabon, les placages obtenus à partir du cœur des arbres, réputés juvéniles, sont plus fissurés plus rugueux et avec une haute mouillabilité comparativement à ceux obtenus à partir du bois près de l’écorce (plus mature). Une phase d’étuvage préliminaire des bois dans un bain d’eau chaude à 75°C pendant 4 heures a permis d’améliorer sensiblement la qualité des placages en diminuant la fissuration, la rugosité et s’accompagne d’une augmentation de la mouillabilité. La résistance à l'adhérence de la colle, et les modules élastiques et de rupture spécifiques (SMOE et SMOR) du LVL (jabon et sengon) diminuent à mesure que la fréquence de fissure augmente ou en partant de l'écorce vers la moelle. L'avantage de l'utilisation de placages en peuplier de bois mature a été prouvé avec une amélioration de 15 à 20% en moyenne pour les propriétés mécaniques, pour un poids de panneau comparable. Pour le douglas, l'utilisation de placages de bois mature dans la constitution des panneaux de LVL permet également d’améliorer les performances en flexion (de 7 à 22 % sur el MOR). Le modèle analytique a été utilisé afin de prédire les variations du module élastique allant de la moelle à l’écorce. Il permet à partir d’un grand nombre de combinaisons d’estimer le potentiel issu d’une ressource donnée. Pour le contexte de l’étude qui représente bien le potentiel sylvicole de l’Indonésie, la proportion de bois juvénile étant quasi-totale (100%), l’action de trier les placages n’est pas apparue comme pertinente. / The development of plantation and community forest to meet wood demand in society has produced fast growing wood species. The research objectives were 1) to determine demarcation point/transition age between juvenile and mature wood on sengon (Falcataria moluccana), jabon (Anthocephalus cadamba Miq.), poplar (Populus sp) and douglas fir (Psedotsuga menzii); 2) to analyze the effect of juvenility on lathe check, surface roughness and wettability; 3) to analyze the effect of lathe check and juvenility on glue bond strength and laminated veneer lumber (LVL) bending properties; and 4) to apply a new analytical model to determine the variation of specific MOE LVL values of sengon and jabon from pith to bark. Based on fiber length trait, the demarcation point between juvenile and mature wood were approximately at segmented rings 17th (sengon) and at segmented ring 24th (jabon). While, transition age of poplar cultivars and douglas-fir, transition age happened approximately at 12 years old and 18 years old, respectively. The results showed that wood near pith on sengon and jabon resulted veneers with higher lathe check, rougher surface and high wettability, while wood near bark resulted veneers with lower lathe check, smoother surface and low wettability. Glue bond strength, Specific MOE (SMOE) and Specific MOR (Modulus of Rupture) of sengon and jabon LVL were decreased as the frequency of lathe check increased or those strength values increased from pith to bark. The advantage of using poplar veneers from mature wood was proved with an improvement of 15 to 20% on average for mechanical properties, while for douglas-fir, was 7 to 22%. An analytical model was used to predict the variation of the LVL mechanical characteristics using different scenarios. According to the context of this study assumed to be close to the Indonesian resource there is no need to sort veneers since most of the tree is juvenile wood for logs no older than 7.

The first part of the diploma thesis deals with a brief research of turning operations and the characteristic of vertical lathes with description of individual parts. There are described possibilities and a typical vertical lathe assortment and also representatives of Czech manufacturers of vertical lathes. In the second part, the thesis deals with elaboration of the design technology production of the selected component, including the NC program. First, a component and material is selected, a semi-finished product is designed, suitable machines and tools are selected and finally a technological process of production is developed. The conclusion of the thesis contains the technical–economic evaluation, where the total costs of production are solved.