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    Improving the Accuracy of Heavy Lathes
    Viktor Kovalov1; Yana Antonenko2; Marina Saenko1;
    1DONBAS STATE ENGINEERING ACADEMY, Kramatorsk, Ukraine; 2, Kramatorsk, Ukraine;
    PAPER: 418/Manufacturing/Regular (Oral)
    SCHEDULED: 18:05/Tue./Mar Azul (50/1st)



    ABSTRACT:
    Improving the accuracy of heavy lathes is a complex and critical problem in achieving the quality of new products. At present, from the theoretical and experimental studies of numerous scientists, considerable material on technological quality assurance of processing [2] has been accumulated, which allows the creation of mathematical models for controlling the processing on machines [1-3]. Based on the calculation of limit values of distributed loads which act on the base frame support, deformation strength by method of finite elements were modeled with the tool package CosmosWorks. The simulation was performed for the cases that have the most significant effect on the size of the deformation of the carrier system [4]. To determine the optimal construction of a heavy machine lathe with a carrying capacity of 100 tons, a comparative analysis of the results of computer modeling of the welded frame and field studies of the cast frame of heavy lathes were carried out. As a result of production tests, the coincidence of the results of mathematical modeling with full-scale tests is found to be 6-25%. The design of the frame heavy lathe high accuracy load capacity of 100 tons, with the possibility of machining up to 12.5 m and 2.5 m in diameter with maximum cutting powers of 200 kN are developed. Recommendations on designing of carrier systems of CNC heavy machine tools high accuracy are given. Deformations of the frame of support under extreme workloads are presented in a range from 29 microns to 83 microns. The results are introduced at PJSC KZTS range with the release of heavy CNC lathes of new generation. One of the most promising ways to further improve the accuracy of machine tools is to equip their with adaptive systems [5].

    References:
    References:
    [1] Brgozovsky B.M. The accuracy and reliability of automated precision machine tools.Saratov: SGTU 1992; 124. (In Russian)
    [2] Averchenkov V.I., Fedorov V.P., Heyfec M.P. Fundamentals of mathematical modelling of engineering systems. Bryansk: BGTU 2004; 271. (In Russian)
    [3] Jung J.H., Choi J.P., Lee S.J. Machining accuracy enhancement by compensating for volumetric errors of a machine tool and on-machine measurement. Journal of Materials Processing Technology 2006, 174 (1-3); 56-66.
    [4] Kovalev V., Vasilchenko Y., Gakov S., Kurilenko Y. Trends of adaptive control of accuracy of the technological system on the basis of heavy machine-tools, 2. International Conference "ICQME 2007", Budva, Montenegro, 2007, pp. 263-275.
    [5] Kovalev, V.D.; Vasilchenko, Y.V. and DašiA�, P.: Adaptive optimal control of a heavy lathe operation. Journal of Mechanics Engineering and Automation (JMEA), Vol. 4, Issue 4 (April 2014), pp. 269-275.