1. Kalpakjian Schmid Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 24-1 CHAPTER 24 Machining and Turning Centers, Machine-Tool Structures, and Machining Economics

2. Kalpakjian Schmid Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 24-2 Examples of Parts Machined on Machining Centers Figure 24.1 Examples of parts that can be machined on machining centers, using various processes such as turning, facing, milling, drilling, boring, reaming, and threading. Such parts would ordinarily require a variety of machine tools. Source: Toyoda Machinery.

3. Kalpakjian Schmid Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 24-3 Horizontal-Spindle Machining Center Figure 24.2 A horizontal-spindle machining center, equipped with an automatic tool changes. Tool magazines can store 200 cutting tools. Source: Courtesy of Cincinnati Milacron, Inc.

4. Kalpakjian Schmid Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 24-4 Five-Axis Machining Center Figure 24.3 Schematic illustration of a five-axis machining center. Note that in addition to the three linear movements, the pallet can be swiveled (rotated) along two axes, allowing the machining of complex shapes such as those shown in Fig. 24.1. Source: Toyoda Machinery.

5. Kalpakjian Schmid Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 24-5 Pallets Figure 24.4 (a) Schematic illustration of the top view of a horizontal-spindle machining center showing the pallet pool, set-up station for a pallet, pallet carrier, and an active pallet in operation (shown directly below the spindle of the machine). (b) Schematic illustration of two machining centers with a common pallet pool. Various other arrangements are possible in such systems. Source: Hitachi Seiki Co., Ltd.

6. Kalpakjian Schmid Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 24-6 Swing-Around Tool Changer Figure 24.5 Swing-around tool changer on a horizontal-spindle machining center. Source: Cincinnati Milacron, Inc.

7. Kalpakjian Schmid Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 24-7 Touch Probes Figure 24.6 Touch probes used in machining centers for determining workpiece and tool positions and surfaces relative to the machine table or column. (a) Touch probe determining the X-Y (horizontal) position of a workpiece, (b) determining the height of a horizontal surface, (c) determining the planar position of the surface of a cutter (for instance, for cutter-diameter compensation), and (d) determining the length of a tool for tool-length offset. Source: Hitachi Seiki Co., Ltd.

8. Kalpakjian Schmid Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 24-8 Vertical-Spindle Machining Center Figure 24.7 A vertical-spindle machining center. The tool magazine is on the left of the machine. The control panel on the right can be swiveled by the operator. Source: Courtesy of Cincinnati Milacron, Inc.

9. Kalpakjian Schmid Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 24-9 CNC Turning Center Figure 24.8 Schematic illustration of a three-turret, two-spindle computer numerical controlled turning center. Source: Hitachi Seiki Co., Ltd.

10. Kalpakjian Schmid Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 24-10 Chip-Collecting System Figure 24.9 Schematic illustration of a chip-collecting system in a horizontal- spindle machining center. The chips that fall by gravity are collected by the two horizontal conveyors at the bottom of the troughs. Source: Okuma Machinery Works Ltd.

11. Kalpakjian Schmid Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 24-11 Machining Outer Bearing Races on a Turning Center Figure 24.10

12. Kalpakjian Schmid Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 24-12 Machine-Tool Structure and Guideways Figure 24.11 An example of a machine- tool structure. The box- type, one-piece design with internal diagonal ribs significantly improves the stiffness of the machine. Source: Okuma Machinery Works Ltd. Figure 24.12 Steel guideways integrally-cast on top of the cast-iron bed of a machining center. Because of its higher elastic modulus, the steel provides higher stiffness than cast iron. Source: Hitachi Seiki Co., Ltd.

13. Kalpakjian Schmid Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 24-13 Chatter Figure 24.13 Chatter marks (right of center of photograph) on the surface of a turned part. Source: General Electric Company.

14. Kalpakjian Schmid Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 24-14 Internal Damping of Structural Materials Figure 24.14 The relative damping capacity of (a) gray cast iron and (b) epoxy- granite composite material. The vertical scale is the amplitude of vibration and the horizontal scale is time. Source: Cincinnati Milacron, Inc.

15. Kalpakjian Schmid Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 24-15 Joints in Machine-Tool Structures Figure 24.15 The damping of vibrations as a function of the number of components on a lathe. Joints dissipate energy; the greater the number of joints, the higher the damping capacity of the machine. Source: J. Peters.

16. Kalpakjian Schmid Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 24-16 Machining Economics Figure 24.16 Graphs showing (a) cost per piece and (b) time per piece in machining. Note the optimum speeds for both cost and time. The range between the two is known as the high- efficiency machining range.