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I. INTRODUCTION
Since people have began using metals, they have been
concerned with advancing metalworking to shape metals.
Machining, a process by which a power-driven tool uses a
subtractive cutting process is an effective way to shape a
material. Milling, a type of machining, involves a rapidly
rotating cutting tool with multiple cutting edges which come
into contact with a work piece. The appeal of milling is
that it is an effective way to machine flat or curved shapes
on both the inside and outside surfaces of a work piece. A
common milling machine is the Bridgeport machine found in
many machine shops. Milling machines allow repeatability and
Figure 1. Roland MDX-15 is a desktop CNC milling machine produced by
precision, which make them effective in an industrial setting. Roland DGA. While it does meet most of the requirements for the device
Since modern electronics started taking off in the middle of being designed, it is unable to machine anything beyond aluminum and has a
the 20th century, more automation has been integrated into prohibitive cost of around $4000[5]. Furthermore, it can only machine work
pieces that are 152.4 mm x 101.6 mm x 60.5 mm in size, which is smaller
milling machines, resulting in Computer Numerical Controlled than desirable.
(CNC) milling machines. These machines use a combination
of sensors, motors and control systems in order to perform the
precise milling operations[1], [2]. structures to use for various parts of the mill, as well as what
However, a CNC mill will cost from around $3000 to components to purchase. As a first order estimate, one can only
upwards of $10000, even for those meant for small scale use. look at static loading scenarios, and ignore dynamic loads.
In addition, operating a CNC mill is challenging as it requires This may prove to be an erroneous path as vibrational modes
knowledge of G-code, a language which guides the positioning of mills are important. However, if the structure stiff enough
of the cutting tool during a machining operation. G-code is a such that static displacements are minimal, this estimate could
difficult programming language to learn, and errors made in be valid.
G-code could cause damage to both the machine and the work In any design project, there are different sets of require-
material[3]. ments, usually set by different stakeholders to the project. In
This summer, I am attempting to design and fabricate a the next section, the more specific technical requirements will
CNC mill. The idea is to create a low cost mill that could be detailed. The list below is a subset of the requirements for
fit compactly on a tabletop in order to bring the CNC mill to the device set by the customers, the eventual end users of the
more people. I hope that this mill would be utilized instead of machine.
using more expensive additive rapid prototyping technologies 1) The machine must be compact. This is too allow it to
for custom parts and class projects. Current additive rapid pro- fit on a table top or workbench easily.
totyping technologies do not result in parts that are necessarily 2) As a safety measure, the machine should be easily
structural as they print the parts in layers that are weak against encloseable to prevent chips of metal from spraying
shear stresses. Furthermore, current technologies are only able around. This is again to make it easier to use the machine
to utilize polymers like ABS, which is not ideal if parts that in a classroom or tabletop setting.
need to withstand significant loads are to be fabricated[4]. 3) Materials that can be machined can be as weak as
To design the mill, is is necessary to establish some idea polystyrene and as strong as mild steel
about the typical loads experienced by a machine during a 4) Cutting speeds and feed rates (rates at which the cutting
milling operation. This will allow one to determine what tool is moving) are not too important, as long as most
Mechanics of Solids and Structures Spring 2009
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Mechanics of Solids and Structures Spring 2009
Figure 4. Forces on the main support beam from the cutter. Fx ,Fy and
Figure 3. Some milling operations. Important details to note is the rotation
Fz are 2500N, 625N and 1250N respectively. L(25cm) is the length of the
of the cutter, direction of feed and depth of cut[2]. It is expected for the
beam and LBC (25cm) is the length from the centroid of the contact area of
machine being designed to carry out the first five operations(all other than
the cutter to the centroid of the beam cross section. Both L and LBC are
form milling).
estimates based on the required dimensions for the work area.
Firstly, the actual load experienced by the cutter depends on be good enough for an estimate. The support columns for
the contact area between the cutter and the work piece. The the beam can made much more rigid than the beam without
greater the contact area, the more actual cutting of material changing the design, thus this assumption should be valid.
occurs, therefore more load. The next factor is the feed rate, Figure 4 shows the forces experienced by the cutting tool
the speed of which a workpiece is being moved towards and the resulting forces and moments on the beam. These will
a cutter. The feed rate proportionally increases the forces cause five effects which will cause a deflection of the cutting
experienced, especially tangential to the cutter. At the same tool[9]. They are:
time, the spindle rate of the cutter matters, as the greater the
1) Torsion of the beam will cause a deflection in both y and
spindle rate, the greater the force. Finally, the type of material
z and is one of the biggest effects. Multiplying by LBC is
being worked on matters. Machining guides provide tables
required to translate the angle of twist of the beam to a
with the machinability factors of different materials, which
deflection at the tip.
could be used as a linear quantity to scale feed rates and cutting
speeds[2], [7]. Mx (L/2)
δz1 = · LBC
A survey of published papers rarely revealed exact numer- E·I
ical data. One tabulated the forces in the radial, tangential
Mx (L/2)
and axial directions for a few different operations[8]. The δy1 = · LBC
maximum forces were in the tangential direction, followed E·I
by the radial and finally the axial, in a consistent 4 : 2 : 1 2) The moment from Fx will cause a deflection in y.
pattern. In all the operations, the maximum forces in those My · (L/2)3
three directions was about 2500N, 1250N and 625N. These δy2 =
3 · E · Izz
will be used as the load for all subsequent calculations. It is
important to understand the condition for this loading. The 3) The force Fz will cause a deflection in z.
workpiece was ASSAB760 plain carbon steel and the cutter Fz · (L/2)3
was a high speed steel end mill running at a feed rate of δz2 =
3 · E · Iyy
4mm/min and a spindle speed of 600rpm. These settings are
on the high side, and the machine being designed does not 4) Similarly, the force Fy will cause a deflection in y.
need to meet these standards. However, using this as a baseline
Fz · (L/2)3
comparison will aid in defining what is needed. δy3 =
3 · E · Izz
IV. MAIN SUPPORT BEAM 5) Finally, the force Fx will cause a stretching in x
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Mechanics of Solids and Structures Spring 2009
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Mechanics of Solids and Structures Spring 2009
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Mechanics of Solids and Structures Spring 2009
Figure 9. Tapered roller bearings. The greater the angle of the taper, the
greater the axial load that the bearing can withstand. The taper also allows a
greater contact area between the rollers and the rings, enabling greater loads
to be experienced by the bearings.
Figure 8. Loads on the bearings. The bearings (in red) will only have to
support Fz as the linear shafts should help support the forces and moments
in the other directions.
high speed due to their momentum[10].
Since it is possible to find appropriate bearings, the basic
inherent wear to the system due to friction. Different bearings design of this subsection is valid. Once the columns and the
have different service lives, and choosing one with the right cutting tool and carriage are designed, a more accurate value
service life for the expected loads and usage is important. for the load on the bearings will available. The same bearings
Going forward with the design using a leadscrew to propel could be used for the leadscrew for actuating the carriage.
the the cutting head, we know that the shafts running parallel to Although this would be overkill, this will minimize the number
the leadscrew will bear most of the load from the cutting head of unique parts in machine, which will help reduce costs.
(Figure 8). However, these shafts will not be able to sustain any
load along their axis as they are designed to allow free moment
VII. D IAGNOSIS AND R EFLECTION
along them. Therefore, the forces in the z direction(Figure 8)
will have to be borne primarily by the bearings on the lead This project was my first experience in carrying out any
screws. This is assuming the shafts are perfectly smooth and analysis before designing a system completely. It required
that all shafts and column are as depicted in Figure 8 and not me to take a different approach. First, define and prioritize
deformed significantly due to loading. Significant deformation the functional requirements of the system. Based on those
or misalignment of the shafts or column would cause the requirements, come up with a basic design that would meet the
bearings to have to bear a significant radial load in addition requirements. Then, use the basic design and knowledge about
to their axial load. the loading of the device to identify key design constraints.
Taking the maximum force again, the bearing will have to Perform the necessary analysis on those key constraints in
withstand an axial force of about 250N . This is well within order to quantify them. In performing the analysis, it may
the loads that normal bearings have to bear. To mitigate the be desirable to simplify the system somewhat. With the
assumptions made previously, that the bearings only have to quantified design constraints, it is possible to proceed to a
bear axial loads, we also have to consider how the bearing more fleshed out design. Once that design is made, the design
bears moment or radial loads. The basis for the previous should be verified to ascertain if the design constraints were
assumptions is that the leadscrew in the bearing is perfectly not exceeded. This should be an iterative process that will
lined up, which is not necessarily true. Slight misalignment probably take a few cycles before a design that suitably
would cause some of the axial load to be applied in a radial achieves its requirements is achieved. At each iteration, the
direction. This means that using a pure thrust bearing would models could be made more complex, to account for not just
not be ideal. the statics, but also the dynamics of the system and concerns
Consequently, it is recommended to use tapered roller about manufacturing.
bearings(Figure 9). These bearings have a taper where the The main problems that I faced in this project were in
greater the angle, the greater the axial force that the bearing identifying the key design decisions to make. This is where I
can withstand. Furthermore, the taper distributes the load to feel knowledge learned in my statics came to bear the most.
a bigger surface area, which allows the bearing to support To paraphrase the professor, the point of the class is not just to
greater loads compared to spherical (ball) bearings. The ge- be able to crunch some numbers, but to develop an ability to
ometry also means that the tangential speed of the surface judge systems qualitatively as well. In executing the analysis
of each of the rollers are the same throughout the contact on this system, I felt that if I had to perform a very thorough
area, preventing differential friction which helps reduce rolling analysis, I would have to spend a lot more time and not yield
friction and wear. In addition, the rollers are guided by a flange too much. It would be more effective for me to simplify the
on the inner ring which stops the rollers from sliding out at model, and get values that were not as precise. Making the
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Mechanics of Solids and Structures Spring 2009
decision about the complexities of the models was where a [5] Roland DGA ”Desktop 3D Scanning and milling MDX-15/20”
lot of my qualitative understanding came through. <http://www.rolanddga.com/asd/resources/pdf/brochure_MDX20.pdf>
April 25 2009.
This paper does not sufficiently or completely describe or [6] Nook Industries ”Linear Motion Slides”
show the difficulties I faced in carrying out the project. When <http://www.nookindustries.com/slidesystem/SlideHome.cfm> April 25
I started working on the problem, I was not too certain about 2009
[7] Cormier, Denis and Ronald Walsh. Mcgraw-Hill Machining and Metal-
where the crucial design decisions needed to be made. It working Handbook. New York: McGraw-Hill, 2006.
seemed that a lot of the system would need to be analyzed then [8] H. Z. Li, W. B. Zhang, X. P. Li, ”Modelling of cutting forces in helical
designed appropriately. Only after consultation with others end milling using a predictive machining theory” International Journal
of Mechanical Sciences Volume 43, Issue 8, August 2001
was I able to scope the design decisions I needed to make [9] Riley, William. Mechanics of Materials. City: John Wiley & Sons Inc,
sufficiently. I was persistently caught in the conflict between 2006.
doing too little and too much analysis, and found it difficult [10] Mott, Robert. Machine Elements in Mechanical Design. Upper Saddle
River: Merrill, 1992.
keeping a middle ground. My belief throughout this time was
that even if I performed too much analysis, all models would
have limitations, the results would not be that much more
useful. Therefore, I made the analysis easier by using simple
models but making my assumptions clear. This would allow
me to follow my logic in the future, and improve upon the
models.
R EFERENCES
[1] Waters, F. Fundamentals of Manufacturing for Engineers. Washington:
Taylor & Francis, 1996
[2] Doyle, Lawrence and Carl Keyser. Manufacturing Processes and Mate-
rials for Engineers. Englewood Cliffs: Prentice-Hall, 1985.
[3] Geng, Hwaiyu. Manufacturing Engineering Handbook. New York:
McGraw-Hill, 2004.
[4] El-Hofy, Hassan. Advanced Machining Processes. New York: McGraw-
Hill, 2005.