Beruflich Dokumente
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WARANGAL, TELANGANA-506004
A report
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Contents
Page.No.
1. Introduction
... 3
2. Classification beds
3. Manufacturing of beds
..
4.References
Introduction
The main unit of a machine tool is the bed, base or column which joins all
the units (mechanisms) and components together, and with respect to which all the
movable units (mechanism) travel and are located.
The accuracy of mutual coordination and travel of these units is ensured by
the locating datum surfaces i.e the bed ways. In accordance with their purpose,
ways, or slide-ways, as they are frequently called, can be divided into ways for
travel, along which units are (such as lathe carriages) of the machine tool travel in
the course of operation, and ways for adjustment, along which units are adjusted in
setting up the machine too (for example the tailstock of a lathe). Requirements
made to machine tool slide-ways concern their surface finish and wear resistance.
2. The same type of bed but cast integral part with headstock.
headstock is casted along with bed. As shown in fig.2.
Fig.4
5. The same type of columns but with no spindle bores Ex. Upright drill press
6. Cylindrical columns with a flat base square to the column. Ex. Radial
drilling machine
The rough castings for beds, bases and columns are delivered for machining with
allowance provided on all surfaces that are to be machined. The weldments for bed
of welded design have smaller machining allowance and more accurate geometric
features.
2.1 Difficulties in casting
In cooling the metal of the casting solidifies non-uniformly because the
thinner parts will solidify first and then the more massive parts i.e slideways, lugs,
etc. This prevents normal shrinking of the casting and leads to the development of
internal stresses. If a bed is machined in the stressed state, stresses will be
redistributed, as a rule, and the casting will be distorted.
To preserve the accuracy of a machine tool over a long period of operation,
measures are taken to eliminate the internal stresses in castings. This includes
design measures (more uniform distribution of the metal among the elements of the
bed, elimination of abrupt changes in cross section etc.), addition of nickel and
chromium to the cast iron to reduce internal stresses, as well as processing
measures, in particular, ageing.
Distinction is made between natural and artificial ageing. In the former, after
machining off the foundry skin, the casting is held for 10 to 20 days in the open air.
The ageing time depends upon the shape of the casting and accuracy requirements.
Artificial ageing is accomplished by heat treatment carried out in the following
order: heating during 3 to 4 hours to a temperature of 500oC, holding at this
temperature from 4 to 6 hours, and cooling in the furnace to a temperature of
200oC.
Before being machined, bed casting undergo fettling in which the gating
system is cut off and the surface are cleaned of adhering sand and burn-on.
Beside the addition of nickel and chromium to the cast iron, the wear resistance of
bed slide-way is increased in many cases by chilling the slide-way surface to
Another widely used measure in machine tool engineering is the use of hardened
steel attached ways. After machining such ways undergo carburization and
hardening. Then they are attached to the semi-finished surfaces of the cast bed in
the form of strips. Finally, the working surfaces of the ways are ground. The use of
attached ways increases the service from 5 to 10 times. Plastic ways are also used.
They are attached to the travelling units or mechanisms in section in the form of
pads.
Welded steel beds have the advantages over cast iron beds in that, for same
rigidity, they have a higher wear resistance and require less metal. The ways of
welded steel beds may be made of special rolled stock and the feet, reinforcing
ribs, pan and other components, of flat and press worked sheet and plate steel.
These components are assembled and welded in special rotary welding jigs.
3. Machining of Beds:
The ways are taken as the processing datum features in machining beds,
bases and columns since the accuracy of the machine tool depends, in the final
analysis, on the ways (The geometrical accuracy of a work piece frequently
depends upon the straightness of the machine tool ways). An end face of the bed is
one of the locating datum features. The initial operations are used for rough
machining surfaces parallel to the ways. These surfaces are subsequently used for
location in machining the ways. The base surfaces of the legs are machined by face
milling cutters in milling machines fig. 5 or by segmented grinding wheels in
special grinders. The point of application of the clamping forces in fixates is
arranged opposite to the corresponding locating point of the bed to exclude
possible deformation of the bed due to clamping.
Bed ways may machined by milling with face milling cutters or a gang milling
cutters, or by planning with single point tools. See the fig.7
Planning or milling with faces milling cutters are general purpose methods. Milling
with a gang of cutters is a more productive method but is used, as rule, only in lot
production because of the relatively higher cost of the special cutting tools.
Heavy duty planning machine is generally employed in machining the beds, using
special attachments task is performed.
After rough machining all the principal and auxiliary surfaces as well all cord hoes
for the bearing of the spindle, lead screw and other components, the casting
undergo ageing. Then the surfaces are finished in the same order, in the same
machine tools and fixtures as in the rough machining operation.
Lapping may be used for micro-finishing the bed ways of high precision machine
tools. It is done after scraping and hand honing.
Following scraping the bed ways are sometimes honed with silicon carbide sticks.
This operation is performed in the same way as scraping, except that an abrasive
stick is used in place of a steel scraper. During hand honing, the sticks are washed
from time to time in kerosene to prevent loading. The lapping operation is begun
after washing the ways with kerosene. In the lapping operation the table or saddle
is mounted on the ways and is loaded to 200 or 220 kg with weights, the amount of
the load depending upon the size of the bed and table. The table travers hand wheel
is replaced by a pulley which is driven by periodically reversed electric motor. The
table reciprocates at a speed to 7m per min. lapping takes from 2 to 4hrs during the
ways are amply lubricated with kerosene.
References