MASSIMIZZAZIONE DELLA PRODUTTIVITA’

NELLA LAVORAZIONE DEL TEMPRATO

Dipartimento di Meccanica Politecnico di Milano

Giovedì 7 Luglio 2016

Relatore : Ing. Alberto Cattaneo

HEIDENHAIN ITALIANA S.r.l.

La storia

Wilhem Heidenhain fonda a Berlinouna società per l‘incisione del metallo.

Il Dr. Johannes Heidenhain entra a far parte dell‘azienda paterna.

Invenzione del processo di copiaturaa solfito di acciaio METALLUR.

Il Dr. Johannes Heidenhainsi trasferisce a Traunreut.

Invenzione del processo DIADUR.

Costituzione della foundazione non-profit DR. JOHANNES HEIDENHAIN STIFTUNG GmbH.

19701970

19501950

19481948

19281928

19231923

18891889

1948 Il nuovo inizio

a Traunreut

1889 I primi annia Berlino

DR. JOHANNES HEIDENHAIN GmbH ─ Traunreut

Oltre 50 filiali nel mondo

DR. JOHANNES HEIDENHAIN GmbH

Employees 2015

Traunreut: Approx. 3.200Total: Approx. 11.000

Consolidated: approx. € 1.435 million

HEIDENHAIN group companiesExternal turnover58,1 %

Other companiesin the group41,9 %

Modelli per ricamo ─ 1913

Proiettori ottici, per misurazioni su macchine utens ili

� Visualizzatori� Controlli CNC

� Tastatori 3D� Sistemi di

calibrazione

Programma di produzione

� Encoder rotativi� Encoder angolari

� Encoder lineariincapsulati

� Encoder lineariaperti

� Tastatori di misura

Applicazioni dei prodotti HEIDENHAIN

Macchina utensile: CNC e accessori

Sistemi di misuralineari/angolari/rotativi

Accessori presetting/tastatori

Motori assi/mandrino

Azionamenti e regolazione(motori sincroni/asincroni/diretti/mandrini sincroni)

Controllo numerico

Printingand paper

Textileindustry

Materialshandling Drives

and motionPackagingindustry

Robotics

Altre applicazioni

Applicazioni nel settore dell'elettronica

Wafer/LCD manufacturing

Measuring machines

PCB drilling machine/PCB assembly machine

Settore medicale

TNC facts� More than 30 years of

experience in the development of NC technology

� More than 240 000installed TNCs

Basic design� User friendly

and� Compatible in operation and

programming

History of HEIDENHAIN Controls

TNC Controls – Overview

TNC 128

Straight-cut control� Analog� Up to 5 control loops� Compact hardware� 12.1” screen

TNC 320TNC 620

Contouring control� Digital (HSCI) / analog� Up to 6 control loops

(5 analog)�Compact hardware�15” screen

TNC 640

High-end contouring control�Latest generation�Digital (HSCI)�5-axis simultaneous

machining�Milling/turning�Up to 20 control loops�Modular hardware design�15” and 19” screen

iTNC 530

High-end contouring control�Established technology �Digital (HSCI)�5-axis simultaneous

machining�Milling / tool and mold making�Up to 20 control loops�Modular hardware design�15” and 19” screen

TNC 640 – Highlights – Tornitura e fresatura “user frien dly”

Fresatura e Tornitura nello stesso programma

Con il TNC 640 è possibile passare liberamente dalla fresatura alla tornitura in modo semplice e intuitivo attraverso il programma di lavoro.

Durante la transazione tornio-fresa il TNC 640 assume in automatico tutte le modifiche interne necessarie (cinematica, visualizzazione diametro, origini e orientamento utensili)

� Stessa operatività e programmazione per i modi operativi tornitura e fresatura

� Disponibile un’ampia serie di cicli anche per la tornitura. Ad esempio: sgrossatura, finitura, recessinge svariati cicli di filettatura

� Funzioni specifiche con supporto grafico per programmare sottosquadra, cavità e recessi

� Importazione diretta di file .dxf con visualizzazione grafica anche per tornitura

TNC 640 – Highlights ADP – Advanced Dynamic Prediction

Improved surface quality andfaster machining

NC data with an insufficient resolution and variable point density in neighboring paths can lead to

� feed rate fluctuations and� faults on the workpiece surface

ADP improves the calculation of the optimum speedfor a precise and smooth movement of the TCPAdvantages:

� Higher contour speed and shorter machiningtimes

� Superior surface quality

0.05 mm

Without ADP

With ADP

TNC 640 – Highlights– Visualizzazione grafica

Grafica 3D per fresatura e tornitura

Con la nuova velocissima e dettagliata simulazione grafica 3D del TNC 640, è possibile valutare esattamente il risultato dei processi produttivi anche prima della lavorazione vera e propria.

Il TNC 640 calcola il tempo di lavorazione e lo mostra espresso in ore, minuti e secondi.

� Visualizzazione ad alta risoluzione 3D

� Percorsi utensile come linee grafiche 3D

� Visualizzazione in trasparenza definibile tra utensile o pezzo in lavorazione

� Corrispondenza dei colori tra utensile e parte lavorata sul pezzo

� Accentuazione dei bordi

� Rotazioni veloci e ingrandimenti spinti

� Visualizzazione del blocco di programma

CAD – CAM – CNC

CAD

CAM

CNC

Mecha-tronics

Design

Path generation

Tool compensation

NC program interpreter

Motion control

Tolerance monitoring

Velocity profiles

Feed rate control

Machine & Drives

CC

CL

y

v

t

x

t

y

t

The workpiece contour is modeled with NURBS (Non-Uniform Rational B-Splines).

Surfaces of the CAD contourare reproduced point for point by paths

Convert path into axis movement and velocity profile

Point for point TNC processing

Axis movements are available in a fixed time grid as nominal and actual movements

x

s s

Path generation� Effective monitoring of contour tolerances� High reproducibility between neighboring paths

even with changing directions of milling and uneven point distributions

Motion control� Acceleration and deceleration processes with

smoothed motion profiles� Highly-dynamic motion control for vibration-free

machining

Advantages of the TNC controls� Accurate workpiece geometry� Improved surface definition� Optimized machining time

TNC Key Feature: HSC Machining

Functions for HSC Machining: contour tolerance

� Preference: Rapid machining / roughing� Large Cycle 32 tolerance� Select MP settings with higher jerk/accelerations� NC data with less data density is possible� Poorer surface/precision � oversize

� Preference: Precise machining� Small Cycle 32 tolerance� Select MP settings with lower jerk/accelerations� NC data must be fine enough to precisely approach

transitions/corners.

� Preference: Surface quality—attractive surface � Average Cycle 32 tolerance � Select MP settings with lower jerk/accelerations � NC data with small chord error generated from CAD

model

Smooth

Fast

Accurate

Impostazione tolleranza sul profilo

Ciclo 32 – Tolleranza sul profilo

Deviazione dal profiloT= Valore tolleranza

Selezione 0:Finitura, 1:Sgrossatura

Assi rotativiTA= Valore di tolleranza

• Riduzione tempo• Qualità superficiale• Rispetto delle tolleranze

• Semplicità d’uso• Selezione automatica dei parametri

• Riduzione tempo• Qualità superficiale• Velocità costante

NC path for a spherical cutter(Tool Center Point TCP) with radius compensation with respect to the workpiece, program with toleranceFeed rate: 10 m/min

Enlarged detail showing the contour-monitored nominal path of TCP

Tolerance 0.02 mm

Tolerance 0.01 mm

Contour tolerance is always kept (+ chord error from CAD/CAM)

Requirements Contour Tolerances Paths after Direction Reversal Vibrations

Effective Control of Contour Tolerances

TNC Key Feature: HSC MachiningMonitoring of Defined Path Tolerances

Workpiece contour and associated line blocks with reciprocating traverse. The points represent the data points in the program.Deviations between neighboring paths means poor surface quality

Very high surface definition, Homogeneous surface with reciprocating milling of free-form surfaces, Increased service life of the tools

Deviations from contour between forward and backward paths are negligible

Requirements Contour Tolerances Paths after Direction Reversal Vibrations

TNC Key Feature: HSC MachiningHigh Accuracy during Forward and Backward Movements

A

B

Advanced motion control for 5-axis machining

� Optimum speed control on the contour� Efficient tolerance management for contouring

accuracy and tool contact angle� Different parameter settings (e.g. cycle 332)

Advantages of the TNC controls� Quick progress from the CAD model to the first

good part, without the need for adapting machine parameters

� High accuracy and surface definition, considerably reduced reworking effort

� Stable cutting conditions ensure constant load on the cutting edge and increase the tool life

� Tool orientation also for special tools (toroidal and concave tools)

TNC Key Feature: 5-Axis MachiningFast Milling with High Contour Accuracy

Velocity at the TCP during 5-axis milling

Acceleration of a Machine Slide

A linearly increasing speed would result in an infinitely large jerk.

Optimum motion control withlimited and smoothed jerk .

Measured actual positions, recorded with a gridencoder at a rounded corner

� Contour tolerances are monitored

� Excitation of vibrations is avoided� Velocity profile is smoothened

Requirements Contour Tolerances Paths after Direction Reversal Vibrations

A reduction in contouring speed may cause machine vibrations

The path control by the iTNC 530systematically prevents excitation of vibrations.

Vibrations during Highly Dynamic Motion

Schema parametri taratura assi

Dynamic Precision

Qualità superficiale con elevato grado di accuratezza

Dynamic Precision

High production rates of precisely machined workpieces

� CTC (Cross Talk Compensation) prevents errors caused by acceleration forces

� AVD (Active Vibration Damping) reduces machine vibrations

� PAC (Position Adaptive Control) always offers the optimum controller setting irrespective of the position in the working space

� LAC (Load Adaptive Control) permits adjusting the controller settings depending on the workpiece weight

Dynamic Precision functions� Increase accuracy during dynamic contouring

movements� Reduce scrap and rework� Save time and cost

Adaptive Control Functions –Cross Talk Compensation (CTC)

CTC – Application Example

CTC offPositioning errors at the TCPcause defects on the workpiece

CTC onPrecise movements at the TCP result in better surfaces andhigher accuracies on the workpiece

Accuracy of the Circular Movement

Damage to the stud by milling the square

Deviation from the nominal contour,in 500-fold magnification

Active Vibration Damping (AVD)

Machine vibrations caused by � deformations of the machine base� elasticity in the drive train� Frame vibrations

can impair the surface quality considerably.

The AVD controller function effectively reduces machine vibrations. Advantages:

� Rapid, vibration-free milling, and therefore:� Shorter program run times� Improved quality of surfaces

Active Vibration Damping (AVD) – Advantages

The AVD adaptive controller function effectivelyreduces machine vibrations

� Rapid, vibration-free milling, and therefore:� Shorter program run times� Improved quality of surfaces

AVD off AVD on

Active Vibration Damping (AVD) – KGM Measurements

Vibration of machine base at 17 HzError at TCP AVD off: 15 µm

AVD on: 4 µm

KGM: Grid encoder, path deviations in 2000-fold magnification

AVD off AVD on

x [mm]

y [m

m]

y [m

m]

-80 -40 0 40 80x [mm]

-80 -40 0 40 80

80

40

0

-40

-80

80

40

0

-40

-80

Dynamic Efficiency

Un nuovo insieme di prestazioni tecnologiche checomprende:

� Fresatura trocoidale� Controllo adattativo della velocità � Controllo dell’effetto “chatter”

Consente nelle lavorazioni di fresatura di : � Ottimizzare l’asportazione di materiale� Ridurre il rischio di rotture utensili� Prolungare la vita utensile� Risparmiare tempo di lavoro e costi