Modernization of the milling metalworking machine will increase the technical potential and significantly expand its productive capabilities. One of options modernization consists in installing a coordinate mini-table on the milling machine. By using a coordinate table for the milling unit, the manufacturer can significantly reduce labor intensity.
Characteristic
The device of the coordinate table is an additional design to the machine, which allows you to move the part fixed on it along the required trajectory. The unit can be used for both milling and drilling units. There are two types of coordinate table - industrial factory or small home-made.
The table can be set in motion by mechanical action manually, by means of electric drives or by means of computer control systems. When using numerical control, production is as automated as possible, and the accuracy of part processing varies in the region of several micrometers.
Variety
In the factory version, the coordinate part installed on a milling or drilling machine includes:
- bearing support;
- control drives;
- part fixing system;
- automated control system.
Fixing parts is divided into three types:
- vacuum;
- using the mass of the part itself;
- mechanical.
Coordinate structures have several different execution schemes, but there are two main ones:
- portal;
- cross.
The cross scheme is used for processing volumetric parts, which is solved by using additional structures with three degrees of freedom. This means that the workpiece being machined has the ability to move in X, Y, and Z coordinates. In this design, the coordinate structure is installed on a milling machine.
The portal scheme is a rotary table that is used to work with flat parts, in particular for drilling, with a rigidly fixed working body when movement along the vertical axis is necessary.
At enterprises for the manufacture of large-sized products, long coordinate aluminum structures are installed. This increases the functionality of the machines used, because it is possible to fix equipment on the workbench, such as:
- special connector for tools;
- cooling drive;
- lubrication drive;
- neutralization of harmful gases and vapors;
- dust and chip removal drive.
Features of the supporting structure
The execution of the coordinate settings for the milling machine and the machine differs in the material from which the supporting structure is made. If these are metal massive parts, then it is necessary to use a more rigid structure, which may consist of cast metal.
More rigid structures are still used to ensure the necessary clarity of movement of the work item on machines with, since the speed of movement of the workpiece in such a production can reach several meters per second.
The material that is used to make the coordinate mounting pads is chosen as follows:
- steel;
- cast iron;
- aluminum alloys.
Structures made up of aluminum alloys, are designed for light loads and are often used to equip drilling machines, where only the vertical movement of the workpiece is implied.
The advantages of such a device are:
- manufacturability;
- budgeting;
- low weight of the structure.
Movement Transmission Mechanisms
Factory and homemade coordinate mini-platforms are set in motion mechanically. If the production is associated with high-precision processes, then in such cases electric motors are used.
Types of gears for converting rotational motion into translational, as well as for moving the part relative to the work item, are divided according to the method of implementation.
They are divided into:
- gear;
- belt;
- screw.
Parameters that affect the selection of the transmission type:
- the speed of movement of the site with the workpiece fixed on its surface;
- electric motor power;
- processing accuracy.
The best option with respect to the coefficient useful action and ensuring the accuracy of moving the part has a ball screw, which still has a number of other features:
- lack of jerks when moving;
- no noise;
- small backlash.
One of the disadvantages of such a transfer implementation is the inability to move the coordinate table at high speed. The second disadvantage is the high cost.
The high cost is one of the disadvantages of this transfer
Additional Options
It will be cheaper to use a belt drive, but in proportion to the decrease in cost, the disadvantages also increase:
- increased wear;
- the need for frequent maintenance;
- high probability of belt breakage;
- low accuracy.
High accuracy and fast movement of the part on a fixed platform can be ensured when using a gear, but in such a mechanism you need to be prepared for the appearance of backlash some time after the start of operation.
One of the best options for transferring motion from a motor to a mini coordinate system is to use a direct drive, which consists of:
- linear motor;
- servo amplifier.
Servo amplifier
The advantage of these drives is that there is no need to use mechanical transmissions. This design allows you to directly transfer the movement from the engine to the elements of the coordinate table.
Another advantage is the increased speed and accuracy of part processing. Due to the fact that there are no auxiliary gears in the table scheme, the number of series-connected elements is reduced, and this, in turn, better side affects the reliability of the coordinate setting.
conclusions
Noticeably, in relation to other types of gears, the error is also reduced, which is at the level of units of micrometers. Direct drive is characterized by high rates of braking and acceleration.
Due to the fact that in a direct drive there are no parts that are subject to friction, the coordinate aluminum installation less subject to wear, which has a positive effect on its durability.
One of the few, but at the same time the most significant drawbacks of direct drive is its price. The high cost of mass high-precision production is justified and paid off.
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Equipment:
Servo drives and motors DELTA (Taiwan)
Axis guides Hiwin (Taiwan)
· Coordinate table with portal
Fiber optic laser source:
IPG (Russia, Fryazino)
Raycus (China) optional
Laser cutting head Raytools (Switzerland)
Industrial cooler chiller
Extractor hood with snail and pipes
Consumable kit
Specifications:
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Laser type: fiber laser
Machine manufacturer: Kuban Radikal LLC
Laser Power: Optional
Laser wavelength: 1070 nm
Guide rails X, Y: Hiwin 25
Z-axis guides: Hiwin 20
X axis transmission; Y: rack/helical gear
X-axis motor; Y; Z: servo
Servo drives along the X axes; Y: DELTA Electronics
Z-axis servo: DELTA Electronics
Z-axis height control system: capacitive non-contact
Control system: CypCut
Software compatibility: AutoCAD, Compass, etc.
Machine operation format: drawing files with *.dxf extension,
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The efficiency and accuracy of machining a part largely depends on the quality of the machine. Properly selected mechanism serves as a guarantee of product compliance with all specified standards and tolerances. Important role in compliance with the drilling technology, the coordinate table plays.
Concept and types
The table is a manipulator for fixing the workpiece to be processed. Outwardly, it looks like a plate with the possibility of fixing the part using:
- mechanical method;
- vacuum method;
- own weight of the workpiece.
Products come with one, two and three degrees of freedom. This means that the feed is carried out along the X, Y, Z coordinates. For drilling flat parts, it is enough horizontal movements. With a bulky product or a fixed drill, a vertical movement of the table is necessary.
For large industrial drilling installations, long coordinate platforms are made. They are equipped with their own installation frame. On such a device, both the part and the processing unit itself are mounted. The table for small machines is made with fastening to the device or on a workbench surface.
By setting the table in motion, the design can be:
- mechanical;
- electric;
The latter type is the most accurate, but the cost of such a device is significant.
Manufacturing of load-bearing elements
The materials for the manufacture of the skeleton of the table are:
- cast iron;
- metal;
- aluminum.
The latter material is used for circuits with light loads and low torsional forces. This option is acceptable when drilling wood or plastic.
drawn aluminum profile frame, mounted on threaded connections. Thus, it turns out solid foundation. Advantages of the material in:
- low weight;
- availability;
- ease of installation.
Many companies produce ready-made kits for assembling tables with their own hands.
Cast base structures are often cast iron. Their weight is significant, but the efforts that they are able to withstand are quite high. Such tables are used for large volumes of production. Installation is carried out on the foundation, permanently.
The welded bed is the best option both for production facilities and for home use. The main thing is to reduce the weld stresses of the metal by releasing when welding with your own hands. Otherwise, when the engine is gaining speed, cracks may appear in the frame.
Drilling machines use two technological schemes table:
- cross;
- portal.
The first is used for bulk workpieces. It makes it possible to carry out other manipulations on the fixed workpiece. Access to the part with this scheme is provided from three sides.
The portal scheme is used when drilling flat products. It is easier to manufacture and is characterized by increased processing accuracy.
Selection of guides
From right choice and fastening of the movement guides of the table surface depends on the accuracy of processing. Rail and cylindrical elements are used. They are produced with carriage superstructure and mounted bearing units.
The choice of the type of table guides depends on the type of drive. The part under consideration works to overcome the friction force. If you need high precision in movement, it is better to choose plain bearings. Rolling bearings reduce friction but create a lot of backlash.
By type of carriage guides are:
- with an enlarged flange, for fastening to the bottom of the table;
- flangeless for conventional mounting to top threaded holes.
When making your own hands, you can order rails with a stainless coating. They have a longer service life and longer abrasion resistance.
Types of gears for table movement
With a small desktop machine the movement of the table is carried out mechanically. But the greater the speed, accuracy and performance required, the more carefully the type of drive is chosen. Mostly electric motors are used.
The essence of the operation of the unit is to convert the rotational operation of the engine into the translational movement of the table plane. There are three types of transfers:
- rack and pinion;
- belt;
- ball screw.
The choice of node type is made based on:
- workpiece movement speed;
- machine engine power;
- required processing accuracy.
Machining accuracy with various transmission units
Ball screw advantages:
- the possibility of high-precision processing;
- small backlash;
- smooth movement of the table;
- noiselessness of work;
- ability to take on heavy loads.
A significant disadvantage is the limited feed rate. The decrease in speed is especially pronounced with a propeller length of more than 1500 mm. Approximate calculation of speed: for a drive with a power of 1 kW, the rotation speed is 3000 rpm. With a screw pitch of 10 mm, the transmission speed is 0.5 m/s. In this case, 3 m will be covered in 6 seconds.
Another disadvantage is the high cost. You can reduce the cost of the project by using a connection with a screw and nut. In this case, it is necessary to ensure constant lubrication of the assembly.
In drilling machines of a new generation, lubrication of the movable mechanisms of the coordinate surface is carried out automatically. Sensors for monitoring the temperature of important parts are mounted in the device.
With rack and pinion transmission, high speed and sufficient accuracy are ensured. The disadvantage is a high degree of backlash when transferring forces from the drive.
Installing a belt is the most budgetary and common way to create a table with your own hands. The low cost of a belt drive and feed speed up to 1 m/s is offset by the following disadvantages:
- rapid wear;
- loss of tension due to stretching;
- the possibility of breaking during acceleration;
- low precision work.
When buying a coordinate table for drilling or do-it-yourself installation, you must take into account the working conditions. The ratio of all mechanisms by parameters: workload, service life, heating and cooling, will give good result at work. This is especially important when self-manufacturing from improvised materials.
The coordinate table helps to make the work of the unit accurate, smoothly move the workpiece to the desired position, avoid jumps, twisting of the part. The efficiency of work on a machine of any type increases significantly when using a coordinate table, especially a do-it-yourself one.
The coordinate table makes drilling faster, easier and more accurate. If a person has a set of tools and materials at hand, such equipment is easy to do on their own.
Types and purpose
Tables for drilling machines come in several different types, can be made of various materials and operate on different principles. This is a simple fixing device, with the help of which the workpiece is fixed in the desired position.
With the help of a table during processing, the part is able to change its position and its angle, manipulation allows you to perform different types processing without removing or moving the part. Methods for fixing equipment are as follows:
- using vacuum and differential pressure;
- mechanical devices;
- the part is held on the table independently due to its large weight.
For lovers about to make a table for drilling machine with your own hands, the second fixation option is most suitable.
Workpiece to be clamped in different installations has an unequal number of degrees of freedom - two or three. In the first case, she is able to move only along the X and Y coordinates, in the second, the ability to move up, down, or along the Z coordinate is added. For home use, two degrees of freedom is enough.
Equipment use
Before starting the operation of the coordinate base, the foreman is obliged to study the safety rules, equipment features, as well as the requirements for lighting in the room where the work takes place.
Bringing the table into action is implemented in the main ways:
- mechanical movement;
- use of electric drive;
- installation .
The first or second option, when implemented with your own hands, will be the most suitable.
Separately, it is worth mentioning such design options as a turntable and a cross.
The first is able to rotate around its own axis and is the maximum convenient option, if you need to machine parts with axial symmetry, round and disc-shaped workpieces.
The cross table for the drilling machine is more common in everyday use and provides the ability to move the workpiece in two directions: X and Y.
base material
Before starting to create a device, you need to think about what materials and spare parts to use. Preliminary preparation necessary so that they can give the future creation the following characteristics:
- Normal working weight, so that one person can work with such a table without tangible difficulty.
- Ease and versatility of installation. A good product must fit different types drilling equipment.
- Maximum cost savings in production. If the development turns out to be too expensive, then isn't it easier to buy a ready-made item.
Most often, these requirements are met by such common and economical options:
- steel;
- metal;
- cast iron;
- aluminum;
- duralumin.
If the table is needed mainly for drilling soft materials(wood, plastic), then aluminum will the best option. It is extremely lightweight and has sufficient strength.
If you have to work with metals, drill serious details to a relatively large depth, then you will need something more durable - steel, cast iron, iron. These are heavy materials, but the loads they can withstand are impressive.
Guides
Of particular importance in the design of the device being developed are the so-called guides - components along which the table moves in the necessary directions.
The better they are made, the more accurately the specialist will work on the machine, set the position of the workpiece being processed and it will be easier to move it to the right place, apply filler materials and perform other necessary actions.
Guides of two types are used: cylindrical type and rail. It is difficult to say which of them is more efficient - with high-quality implementation, both options show themselves worthy in work.
In order for the sliding of the guides to be as smooth and accurate as possible, it is necessary to use special carriages and bearings. If the requirements for the accuracy of the equipment are not too high, then rolling bearings are quite suitable, otherwise plain bearings should be used.
Rolling bearings will create a small amount of play, but in typical applications this is not a big problem.
For smooth sliding of the guides, the use of rolling bearings is possible.
When making a product with your own hands, you need to choose the option that is most suitable for future tasks.
Movement transmission mechanism
The most important part of the future device, whether it is a rotary table for a drilling machine or a cross version, is the mechanism for transmitting movement from the control knobs to the device.
It is best to make a drive with a mechanical type of movement, they are manually controlled. In this way, specialists can achieve greater accuracy of movements, high quality of work performed.
The components of the motion transmission mechanism are:
- racks and gears, gears;
- belt mechanisms;
- ball screws.
Experts advise choosing the latter type of mechanism, especially when it comes to a cross table, it has many significant advantages:
- extremely small backlash of the system;
- the movement of the product is very smooth, without jerks;
- the ball screw operates quietly;
- under significant workloads, it shows high stability.
The minus of the mechanism, experts call the inability to achieve high speed, but if a cross table for a drilling machine is considered, then here high speed usually not required.
To save money, the master needs to try to implement belt drives. They are simple and affordable, but have disadvantages:
- low accuracy;
- rapid wear;
As a conclusion, we note that if a person decides to make a table for a drilling machine with his own hands, then there is nothing fundamentally unrealistic in this. An elementary set of material and tools will help to quickly implement the task. The task for the specialist is to choose right kind design and qualitatively manufacture all the critical components of the future device.
