Optimisation of NC Programme in the Production of a Belt Guide Component

In mechanical engineering, as in other industries, progress is very important. If we progress successfully, not only does the company benefit from this, but also customers and business partners. With appropriate development, we produce and deliver quality products that are manufactured within the agreed time. It turned out that the milling head works as was stated and as was shown in the test. The head performed much more cutting on the selected product and the cutting edges were still in very good condition.

Problem

In mechanical engineering, as in other industries, progress is very important.

Solution and Method

If we progress successfully, not only does the company benefit from this, but also customers and business partners. With appropriate development, we produce and deliver quality products that are manufactured within the agreed time. I can say that the set objectives were achieved. In some respects, even exceeded. He decided to optimise production by purchasing newer cutting tools, as he wanted to change the method of milling in certain situations.

This was quite a large investment for their small company, so he first tested the tool by obtaining it for use for a short time, naturally in the presence of the representative. He received all the necessary data for using the tool from the manufacturer. Based on the testing, he was satisfied with the tool, but this was still insufficient for making a purchase decision. Therefore, he first created a computer simulation with which he made a comparison between the old and new production.

The simulation gave the author fairly accurate answers to the questions posed. Based on the data obtained from the computer comparison, the path was charted in the right direction. However, I used the data obtained from the initially set parameters, because it would not make sense to use the tool at maximum regimes if we wanted to use it long-term. Just for additional comparison, he conducted a test with maximum cutting. The simulation production time was naturally not equal to the actual production.

This was somewhat longer. However, I could not accurately measure the actual machining time for the first product, as this is almost impossible when manufacturing 'piece by piece'. In serial production, we can calculate the time down to the second, but with individual pieces it is very difficult, because each product must literally be tested and we cannot afford to simply let the entire manufacturing process run freely.

Even in serial production, we test the first piece to see how the operations proceed, and then optimise them. By testing or creating an additional comparison on a different product, he arrived at confirmation that he was on the right track, which was shown later in the production of all the parts that belong to the belt guide. Deadlines in production are very important and you must adhere to them if you want to maintain the business and be competitive. The production times for the product shown by the simulation were very satisfactory. ** However, we must know that they are not entirely realistic.

Between the simulation time and the actual time** that the machine takes to produce a product, differences occur, but not so large that I would doubt the data obtained. If their company were more involved with products where simulation is required, these differences could also be eliminated by entering (into the software) all the data about the machine. One such example is the time between tool changes when we use several different tools, as well as the clamping method, the tool path when it is not machining, etc.

Based on both experiences, namely testing the tool and hypothetical production, he decided to purchase the cutting tool. He used all the data that he collected himself and that he obtained from testing.

Results

It turned out that the milling head works as was stated and as was shown in the test. The head performed much more cutting on the selected product and the cutting edges were still in very good condition. As mentioned, the actual time differed from the simulation time.

This was also because differences arose due to the machine's capabilities, as he mentioned in the introduction to the diploma thesis. The CNC machine that I use is not designed for working with very fast working feeds. When it comes to straight lines, deviations do not yet occur.

Stoppages occur due to more demanding shapes (curves) and when the tool must quickly change the direction of movement between axes. However, the time difference between the work performed with the old tool and the work with the new one was nevertheless very satisfactory. Even in subsequent cutting, when he was milling similar products, it proved to be a very good tool.

The good side of the new tool is that the machine operates almost without load, even when the cutting edges are already worn. Which I cannot claim for the old tool. Another excellence of using this milling head was revealed.

As he claimed, no cooling is required. This also proved to be true, which is another very good characteristic of this. Thus they also saved on emulsion. The more we cut, the more coolant we use, because during heavy rough cutting, heat is generated and the emulsion evaporates.

This information is also important from a health perspective, as during machining at high speeds the liquid disperses into mist and thus travels through the air that we breathe. And the working environment is thus cleaner. The amortisation of the tool was achieved within a foreseeable time, but certainly not as quickly as he assumed.

This was mainly because their work varies greatly and daily we produce several different pieces and accordingly use different cutting tools. Tool A, as he named it, is sometimes not used for several days, whilst sometimes it is in use for several days in succession. I can say that the purpose of the research assignment has been achieved.