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  1. #109
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    Default Re: 6-axis Horizontal Machining Center for Education

    Ishi, I was thinking that you could use the 2 axis spindle directly to grab tools, if it can rotate to look straight up.

    You could avoid the tool length issue if the conveyor is orientated the other way - why have the tools point in towards the conveyor? They could move around the edge (similar to a carousel tool changer, but implemented upside down).

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    *Registered User* ishi's Avatar
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    Default Re: 6-axis Horizontal Machining Center for Education

    Quote Originally Posted by pippin88 View Post
    Ishi, I was thinking that you could use the 2 axis spindle directly to grab tools, if it can rotate to look straight up.

    You could avoid the tool length issue if the conveyor is orientated the other way - why have the tools point in towards the conveyor? They could move around the edge (similar to a carousel tool changer, but implemented upside down).
    pippin88,

    The spindle *will* grab the tools directly, because it can rotate to look straight up. This is exactly what I am doing in the latest design:

    https://drive.google.com/drive/u/3/f...3dQrx?ogsrc=32

    And yes, if we put the carousel horizontal instead of vertical, we solve the tool length issue. This will also make the tool holders much more rigid. Brilliant! Thank you pippin88. I'll update the design accordingly.



  3. #111
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    Default Re: 6-axis Horizontal Machining Center for Education

    Quote Originally Posted by ishi View Post
    pippin88,

    The spindle *will* grab the tools directly, because it can rotate to look straight up. This is exactly what I am doing in the latest design:

    https://drive.google.com/drive/u/3/f...3dQrx?ogsrc=32

    And yes, if we put the carousel horizontal instead of vertical, we solve the tool length issue. This will also make the tool holders much more rigid. Brilliant! Thank you pippin88. I'll update the design accordingly.
    Here is what the tool magazine will look like. So much better...

    Attached Thumbnails Attached Thumbnails 6-axis Horizontal Machining Center for Education-screen-shot-2018-07-19-7-53-a  


  4. #112
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    Default Re: 6-axis Horizontal Machining Center for Education

    Hi....would I be right in saying that without the ATC this is a 5 axis and with an ATC it's a 6 axis?
    Ian.



  5. #113
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    Default Re: 6-axis Horizontal Machining Center for Education

    Quote Originally Posted by handlewanker View Post
    Hi....would I be right in saying that without the ATC this is a 5 axis and with an ATC it's a 6 axis?
    Ian.
    I don't think so. I think you're confusing the axes of the machine and the axes of the ATC. If you look carefully at the pictures shown there, you will see that a typical double arm ATC requires 5 motors/actuators (5 axes), irrespectively of the machine it is attached to (3, 4, 5, 6, n axes machine).

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    But with our design, we removed 4 out of 5 actuators in the ATC. So, we still have a 6-axis machine (no matter which ATC we use), but our ATC only requires one motor. Of course, that means that our controller requires 7 motor drivers (in fact, many more, because our 3 linear axes on the machine require two drivers each).

    This configuration should save $10k to $20k on the ATC alone/



  6. #114
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    Default Re: 6-axis Horizontal Machining Center for Education

    Thanks...…..this configuration is quite involved and, just my opinion, very complicated for what is reqd to machine in one hit 5 sides of a work piece....4 sides and the end face etc.....but as that configuration is the way the industry you're aiming at is probably going you're a front runner no doubt with this design.

    BTW, I think the conventional design of a vertical mill with a rotary table in a trunnion is simpler and only requires 5 axes to machine a block on all 4 sides and the end face which is what your design is about.....I can't see any other advantages although no doubt there are some.

    BTW2....what is the anticipated maximum end mill size for your design?....also what tool shank is in the spindle end?
    Ian.



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    Default Re: 6-axis Horizontal Machining Center for Education

    Quote Originally Posted by handlewanker View Post
    Thanks...…..this configuration is quite involved and, just my opinion, very complicated for what is reqd to machine in one hit 5 sides of a work piece....4 sides and the end face etc.....but as that configuration is the way the industry you're aiming at is probably going you're a front runner no doubt with this design.

    BTW, I think the conventional design of a vertical mill with a rotary table in a trunnion is simpler and only requires 5 axes to machine a block on all 4 sides and the end face which is what your design is about.....I can't see any other advantages although no doubt there are some.

    BTW2....what is the anticipated maximum end mill size for your design?....also what tool shank is in the spindle end?
    Ian.
    handlewanker,

    This post explains the design of our 6-axis machine:

    https://www.cnczone.com/forums/uncat...ml#post2198222

    I actually tend to think that it's a simpler configuration than many 5-axis machines using a trunnion table, especially because of the fully-balanced 3+3 design.

    The benefits of 6-axis over 5-axis have been demonstrated for quite a while:

    6-axis can offer better accuracy than 5-axis alternatives.
    6-axis can offer faster feeds and speeks than 5-axis alternatives.
    6-axis can improve ergonomics (HMC + VMC in one machine).

    There are many different reasons for these benefits, but going through them would require quite a bit of work on the kinematics side of things. A detailed comparison of our configuration against alternative configurations would make for a great masters thesis.

    As far as tooling is concerned, we will offer two options: HSK F63 and HSK E40, as can be seen there:

    HST310

    You'll be able to use pretty much any tool supporting these standards, especially with the new ATC design that won't impose any limit on tool length or diameter (some tools with very large diameter might require that you put them next to small tools on the ATC though, because there is only 105mm between two consecutive links on the conveyor).

    Last edited by ishi; Today at 04:21 PM.


  8. #116
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    Default Shorter Y-Axis Carriage

    The height of the Y-Axis Carriage has been reduced in order to bring it closer to the ATC. This is required in order to mount the conveyor horizontally right on top of the vertical column and have tools picked up with a rotation on the front of the machine instead of the back. A back rotation through the vertical column's hollow spine would have been possible because our A axis supports ±120° rotation, but this felt funky, and if this design has taught me anything, it is that if it does not feel right (or look right), it's probably wrong... Marcel Dassault (the guy who founded the company that makes the Falcon, Mirage, and Rafale aircraft) famously proclaimed that for an airplane to fly well it must be beautiful. I think he was right, and what he said also applies to CNC machines, even though it takes a special kind of person to appreciate the beauty of a CNC machine...

    This reduced height will reduce rigidity on the Y-axis a little bit, but I think it's totally manageable, especially with our two motors driving the axis (like the other two linear axes). Deflection should remain minimal.

    Attached Thumbnails Attached Thumbnails 6-axis Horizontal Machining Center for Education-screen-shot-2018-07-19-1-23-a  


  9. #117
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    Default Conveyor Mount

    This one was hard: we had to find a way to mount our ATC conveyor on top of the vertical column while ensuring that our spindle head could properly reach our tools. Well, that's one scenario where using a CAD tool is really handy, because the set of constraints that one has to deal with is quite large. Anyway, here is a first attempt at it. By the look of it, it's going to be a transition step in the design, in the sense that I fully expect things to be streamlined once we figure out ways to improve a few design elements, but this is a good-enough proof of concept for now. As far as I can tell, and assuming that we can prove that rotary tool insertion/extraction won't break our forks or wear them out too fast, we've gotten ourselves an ATC, and it should not require more than a single motor and driver...

    As you can see on the picture called "Magazine", the tools ride on the back of a flange on the column's top. This flange is there to extend the length of our Y-axis rail as high up as we can, thereby ensuring that our spindle head can reach the tools in the first place. The picture called "Column" shows how we're taking advantage of our switch to a mineral casting, implementing geometries that would be virtually impossible with regular granite.

    Attached Thumbnails Attached Thumbnails 6-axis Horizontal Machining Center for Education-magazine-jpg   6-axis Horizontal Machining Center for Education-machine-profile-jpg   6-axis Horizontal Machining Center for Education-column-jpg  


  10. #118
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    Default Streamlined Y-Axis Carriage

    I am designing a streamlined Y-Axis carriage in order to extend the reach of the spindle head and increase the thickness of our thinnest mineral casting profiles. Later on in the design process, FEM will tell us whether I've gone too far with this.

    Attached Thumbnails Attached Thumbnails 6-axis Horizontal Machining Center for Education-screen-shot-2018-07-19-4-23-a  


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    Default Reinforced Y-Axis Carriage

    I decided to reinforce the back of the Y-Axis Carriage, just in case...

    Attached Thumbnails Attached Thumbnails 6-axis Horizontal Machining Center for Education-screen-shot-2018-07-19-4-53-a  


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