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M.A.L. Products

HIGH PERFROMANCE MACHINING TECHNOLOGY from MAL Manufacturing Automation Laboratories Inc Vancouver, B.C., CANADA http://www.malinc.com. M.A.L. Products. MAL Inc. has two lines of Products to boost productivity of machining operations

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M.A.L. Products

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  1. HIGH PERFROMANCE MACHINING TECHNOLOGY from MAL Manufacturing Automation Laboratories Inc Vancouver, B.C., CANADA http://www.malinc.com M.A.L. Products

  2. MAL Inc. has two lines of Products to boost productivity of machining operations • ShopPro – Practical, easy to learn and use, integrated tap testing, chatter avoidance and diagnostics software for milling • CUTPRO – Advanced Simulation and Testing Software tool box to design, optimize, measure and diagnose machining operations, cutters and machine tools. Products

  3. ShopPro/CUTPRO Instrumentation Set • Labtop computer • National Instruments NI9233 USB Measurement Box • Impact hammer and accelerometer • Microphone Instrumentation

  4. 3 Simple Steps in Using ShopPro • Enter material type and basic cutter geometry • Tap test the cutter on the machine or define dynamic parameters • Chatter stability lobes (vibration free speeds and depth of cuts), torque, power and material removal rates will be displayed instantly. • The noise from the machine can be recorded, and ShopPro provides automated diagnosis and advice. ShopPro Steps

  5. Step 2 - Tap Test the tool to obtain machine stiffness ShopPro

  6. Step 3- Machine Sweet Spots (depth of cut, spindle speed) are displayed with Torque, Power and MRR ShopPro

  7. CUTPRO Machining Software Modules • MALTF – Advanced Tap Testing System • MALDAQ – Multi Channel Data Collection • MODAL – Modal Analysis with machine data base and tool tuning modules • MILLING – Advanced cutter design, optimization and simulation system for milling • TURNING, DRILLING and BORING Modules • SpindlePro – Finite Element Modeling and Analysis of Spindle Drives • Virtual CNC – A complete 5 axis modular CNC system design with drive design, sensors, amplifiers, friction, trajectory generation, interpolation and control modules CUTPRO Modules

  8. CUTPRO :Parametric Tool Definition in APT

  9. Helical flute is wrapped around the solid end mill.

  10. CUTPRO: Prediction of milling forces from tool geometry and orthogonal cutting material data.

  11. CUTPRO: Tapered Helical Ball End Milling (Jet Engine Machining) Cutter:Taper helical ball end mill, rake angle=10°, relief angle=10°, D=6.0, R=3.0, Rr =0, Rz =3.0, h=38.0, lead=105.0mm, a=0°, b=4.0°, Nf =1 Cutting Mode: Slot cutting Cutting Coefficients: Orthogonal cutting coefficients for Ti6Al4V by using orthogonal to oblique transformation

  12. CUTPRO: Inserted Helical End Mill

  13. CUTPRO: Prediction of Serrated Cutter Forces

  14. Source of Vibrations in Machine Tools FlexSource.ai

  15. CUTPRO : Vibration Model of Milling System

  16. REGENERATION MECHANISM

  17. TF measurement MALTF FRF file Milling Module Modal Analysis Module Stability Lobes CMP files Process simulation and chatter stability lobe prediction in CUTPRO

  18. N=17000 [rpm], DOC=4.5 [mm] n=15400 [rpm], DOC=4.0 [mm] 2884 [Hz] Chatter frequency 567 [Hz] Tooth passing frequency Milling Mode: Slotting Machine tool: Mori Seiki SH403 Tool:Jabro,16.0 [mm], 2-fluted cylindrical endmill Feed rate: 0.1 [mm/tooth] Surface finish Surface finish Increase the material removal rate by 500% and avoid poor surface finish and tool/spindle damage

  19. N=17,000 [rev/min], depth of cut = 4.5 [mm] NO CHATTER N=15,400 [rev/min], depth of cut = 4.0 [mm] CHATTER Slot milling of Al7050 with 2 Fluted, 16mm diameter end mill.

  20. ShopPro: Detection of Chatter with a microphone

  21. Chatter is avoided by selecting proper speed recommended by ShopPro

  22. Material: AL 7050-T7451, 100x100x50 [mm] Tool: Jabro 16 [mm] diameter, 50 [mm] length Number of flutes:2 Roughing 17400 [rpm] Depth of cut: 7mm slotting Chip load: 0.2 mm Finishing:20,000 [rpm] Depth of cut: 1mm, Width of cut:10 mm, Chip load:0.25 mm Thickness of the wall: 0.15 [mm] Height of the wall: 35 [mm] Feed rate: 0.25 [mm/tooth] Machine tool:Mori Seiki SH403 Cycle time:9 min 20 sec. High Speed Milling of Spiral

  23. Cycle Time Reduction: 62% • Cycle Time Reduction: 62% BEFORE AFTER Surface roughness improved by 8.4 fold Impeller Milling UBC + P&WC NSERC Chair

  24. Force in X and Y directions 4.5 [mm] Surface finish 17600 10600 Example - 2

  25. Milling Module Types of cutters in CUTPRO

  26. + Universities and many more… Customers and/or Research Partners

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