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Automatisation of machining operations
Lemaitre Benard, Paul Jean Pierre Daniel ; Sliwková, Petra (oponent) ; Píška, Miroslav (vedoucí práce)
Due to an increase of orders for aeronautics parts, ArianeGroup decided to increase its activity to meet the growing. The number of parts produce by year has risen and the production service needs to be optimized. The final objective is to reduce the number of stop machines. Many technical solutions exist to reduce the number of stop machines. The problem is that it is difficult to implement these technical solutions directly on the machine. It is not possible to stop the production and implement some technical solutions. However, it is possible to implement technical solutions during qualification. Qualification is when a part is machining for the first time on a machine. Three parts have been qualified and some technical solutions have been applied during these qualifications. • Safety of the process: The first aspect to work on is the safety of the process. The non-ejection of the part from the jaws must be guarantee. That is why a calculation of the clamping pressure for Disc D has been asked. A second aspect to work on is the non-deformation of the part. Due to a too high clamping pressure, the part has some geometric deformation. That is why a second calculation of the clamping pressure for Disc D & Disc B has been asked. The objective is to know if it is possible to low the clamping pressure and respect the non-ejection condition of the part. A third aspect is to guarantee the safety of the process. It happens that operators forgot to remove flanges. An automatic detection of the external flanges have been implemented to verify if the operators forgot to remove the flanges. This automatic action will avoid collisions. As seen in Figure 1, the probe will detect or not the internal flange. A message will appear and the door will open, to ask the operator to remove the internal flange. • Robustness of the process: A robust process is a process with a low number of breaking tool insert. A technical solution exist. It consists in implementing a breaking and wear tool monitoring. It is possible by the help of a tool probe and a BLUM laser. During the qualification of Disc D, the turning tools are now controlled by the tool probe and the milling tool are controlled with the BLUM laser. • Performance of the process: An innovative approach to enhance the cutting conditions is the integration of the high pressure. The high pressure assistance has been added for some parts. A study to adapt the turning tools to the high pressure assistance has been effected with insert constructors. An estimation has been done. Another solution is to integer tool sisters in the process. The stop machines to change insert are replaced by a tool sister. During the qualification of Disc D, tools sisters have been added. In addition, a work has been effected to manage the tool and block the tool in the tool magazine once it has been used. New technologies of insert has been implemented in order to increase the cutting conditions and save time. • Automation of machining operations: The principle reason of the stop machines are the dimensional control by the operators. Technically, it is possible to replace these actions by automatic controls. The automatic controls are done by automatic probes. The problem is if the conformity of the measurement instrument is not correct, the process can be distorted. A first work have been proceed to choose a unique calibration

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