{"id":17093,"date":"2021-01-18T10:49:30","date_gmt":"2021-01-18T09:49:30","guid":{"rendered":"https:\/\/niles-simmons.de\/center-axis-alignment\/"},"modified":"2021-02-02T08:17:44","modified_gmt":"2021-02-02T07:17:44","slug":"center-axis-alignment","status":"publish","type":"page","link":"https:\/\/niles-simmons.de\/en\/center-axis-alignment\/","title":{"rendered":"Fully automated complete machining of turbine and special shafts"},"content":{"rendered":"
[vc_row][vc_column][vc_video link=\u00bbhttps:\/\/youtu.be\/o65WrrDecpo\u00ab][\/vc_column][\/vc_row][vc_row][vc_column][vc_column_text]\n

Fully automated complete machining of turbine and special shafts \u2013 NILES-SIMMONS develops the new \u00bbCENTER AXIS ALIGNMENT\u00ab process
\n<\/strong><\/h1>\n

Dr.-Ing. Moritz Halle, Dipl.-Ing. Tho\u00admas W\u00e4cht\u00adler, <\/em>NILES-SIMMONS Indus\u00adtrie\u00adan\u00adla\u00adgen GmbH <\/em><\/p>\n

 <\/p>\n

The field of application<\/strong><\/p>\n

In highly tech\u00adni\u00adcal, inno\u00adva\u00adtive, and sen\u00adsi\u00adtive indus\u00adtrial sec\u00adtors such as the aero\u00adspace indus\u00adtry or the defense and energy sec\u00adtors, the demands on the pro\u00adduc\u00adtion of com\u00adplex com\u00adpon\u00adents and the machi\u00adning of high-strength mate\u00adri\u00adals are con\u00adstantly incre\u00adasing. In par\u00adti\u00adcu\u00adlar, the reduc\u00adtion of error within pro\u00adduc\u00adtion pro\u00adces\u00adses for highly com\u00adplex and cost-inten\u00adsive work\u00adpie\u00adces is beco\u00adming more important with regard to the \u00bbcost-per-part\u00ab and the accu\u00adra\u00adcies to be achieved.<\/p>\n

To meet these requi\u00adre\u00adments, NILES-SIMMONS has deve\u00adlo\u00adped the new fully auto\u00adma\u00adted and paten\u00adted machi\u00adning and mea\u00adsu\u00adring pro\u00adcess of \u00bbCENTER AXS ALIGNMENT\u00ab spe\u00adci\u00adfi\u00adcally for the machi\u00adning of tur\u00adbine shafts. This pro\u00adcess enables the com\u00adplete machi\u00adning of com\u00adpli\u00adca\u00adted, deep-hole dril\u00adled shaft-shaped work\u00adpie\u00adces inclu\u00adding all in-pro\u00adcess mea\u00adsu\u00adre\u00adments wit\u00adhout manual ope\u00adra\u00adtor intervention.<\/p>\n

 <\/p>\n

\"Komplettbearbeitung<\/em><\/p>\n

Image 1 \u2013 Com\u00adplete Machi\u00adning of Tur\u00adbine Shafts wit\u00adhout Ope\u00adra\u00adtor Intervention<\/em><\/p>\n

 <\/p>\n

The aim of the machi\u00adning pro\u00adcess is to adapt the outer con\u00adtour of the work\u00adpiece exactly to the inner con\u00adtour in order to achieve a uni\u00adform wall thic\u00adk\u00adness of the work\u00adpiece along its axis. The pro\u00adcess is appli\u00adca\u00adble to all elec\u00adtri\u00adcally con\u00adduc\u00adtive mate\u00adri\u00adals such as simple steels, but also for super alloys or nickel-based alloys such as Inco\u00adnel 718. In addi\u00adtion to the machi\u00adning of tur\u00adbine shafts, it also applies to other deep-hole dril\u00adled work\u00adpie\u00adces up to two meters in length.<\/p>\n

 <\/p>\n

The machine configuration<\/strong><\/p>\n

The new pro\u00adcess is exe\u00adcu\u00adted on a NILES-SIMMONS N30MC machi\u00adning cen\u00adter with a cen\u00adter distance of 4500 mm and a swing dia\u00adme\u00adter of 780 mm; the machine has been pur\u00adpo\u00adsely con\u00adfi\u00adgu\u00adred for this machi\u00adning ope\u00adra\u00adtion. The spe\u00adci\u00adfic equip\u00adment of the machine includes a main spindle, a tur\u00adning-mil\u00adling unit, a lowerable tail\u00adstock, two ste\u00adady rest slides with one ste\u00adady rest and one dam\u00adping unit, and a bor\u00ading bar slide.<\/p>\n

 <\/p>\n

\"Dreh-Fr\u00e4s-Bearbeitungszentrum<\/p>\n

Image 2 \u2013 Pro\u00adcess \u00bbCENTER AXIS ALIGNMENT\u00ab on a NILES-SIMMONS Machi\u00adning Cen\u00adter N30MC<\/em><\/p>\n

 <\/em><\/p>\n

Fur\u00adther\u00admore, inde\u00adpen\u00addent tool maga\u00adzi\u00adnes are available for both the bor\u00ading bar slide and the tur\u00adning-mil\u00adling unit. The maga\u00adzine for the multi-axis tur\u00adning-mil\u00adling unit, pla\u00adced on the main spindle side, can be equip\u00adped with up to 144 tools. For the bor\u00ading bar slide, up to 16 posi\u00adti\u00adons are available in an addi\u00adtio\u00adnal bor\u00ading bar maga\u00adzine on the tail\u00adstock side. Sys\u00adtem bor\u00ading bars up to two meters long, dri\u00adven bor\u00ading bars, sta\u00adtic bor\u00ading bars, sta\u00adtic bor\u00ading bars with con\u00adtroll\u00adable cut\u00adting edge, mea\u00adsu\u00adring lan\u00adces, or a car\u00adtridge with drive and chuck func\u00adtion can be used.<\/p>\n

With this con\u00adfi\u00adgu\u00adra\u00adtion, and par\u00adti\u00adcu\u00adlarly by using the lowerable tail\u00adstock, all types of tur\u00adbine shafts curr\u00adently available on the mar\u00adket can be machi\u00adned in dif\u00adfe\u00adrent lengths on one machine. Even par\u00adti\u00adcu\u00adlarly long com\u00adpon\u00adents can be easily machi\u00adned, espe\u00adci\u00adally due to this option, wit\u00adhout having to choose a machine with a lar\u00adger footprint.<\/p>\n

Fur\u00adther\u00admore, all cut\u00adting tech\u00adno\u00adlo\u00adgies such as tur\u00adning, mil\u00adling, dril\u00adling, gear hob\u00adbing, tap\u00adping, thread mil\u00adling, thread tur\u00adning, rea\u00adming, spind\u00adles, inter\u00adnal machi\u00adning with indexa\u00adble inserts, power ski\u00adving, 5\u2011axis mil\u00adling, and deep-hole dril\u00adling up to 2000 mm depth can be map\u00adped in a pro\u00adcess-relia\u00adble man\u00adner. In addi\u00adtion, the machine inte\u00adgra\u00adtes the auto\u00adma\u00adted touch probe and opti\u00adcal mea\u00adsu\u00adre\u00adment of tools as well as the auto\u00adma\u00adtic touch pro\u00adbing of the work\u00adpiece. With that, it is pos\u00adsi\u00adble to achieve accu\u00adra\u00adcies less than 5\u00b5m for the tur\u00adning and mil\u00adling pro\u00adces\u00adses. Due to the inte\u00adgra\u00adtion of all neces\u00adsary tech\u00adno\u00adlo\u00adgies in one machine, the auto\u00adma\u00adted too\u00adling, and the use of com\u00adplex mea\u00adsu\u00adring tech\u00adno\u00adlo\u00adgies, an unat\u00adten\u00added com\u00adplete machi\u00adning pro\u00adcess is applied in a pro\u00adcess-relia\u00adble manner.<\/p>\n

 <\/p>\n

\"Innenbearbeitung<\/p>\n

Image 3 \u2013 Inter\u00adnal Machi\u00adning with Sys\u00adtem Bor\u00ading Bar with adjus\u00adta\u00adble Cut\u00adting Edge<\/em><\/p>\n

 <\/p>\n

To achieve increased tem\u00adpe\u00adra\u00adture sta\u00adbi\u00adlity and to ensure the accu\u00adracy requi\u00adred by the cus\u00adto\u00admer despite tem\u00adpe\u00adra\u00adture fluc\u00adtua\u00adtions, we use a liquid-coo\u00adled spe\u00adcial con\u00adcrete machine bed. In addi\u00adtion, the machi\u00adning cen\u00adters have dam\u00adpe\u00adning and vibra\u00adtion-redu\u00adcing com\u00adpon\u00adents such as FE-opti\u00admi\u00adzed slide geo\u00adme\u00adtries, hydrau\u00adli\u00adcally clam\u00adped com\u00adpon\u00adents of the work\u00adpiece sup\u00adport com\u00adpon\u00adents such as tail\u00adstock and ste\u00adady rest slide, dam\u00adpe\u00adning sur\u00adfaces in machi\u00adning direc\u00adtion, and rol\u00adler gui\u00addes of the machi\u00adning axes in size 45\/55.<\/p>\n

To ensure clear and simple ope\u00adra\u00adtion of the machine, we use a Sie\u00admens OP19 with an addi\u00adtio\u00adnal touch screen for pro\u00adcess monitoring.<\/p>\n

 <\/strong><\/p>\n

The paten\u00adted mea\u00adsu\u00adring process<\/strong><\/p>\n

The key ele\u00adment of this inno\u00adva\u00adtive pro\u00adcess is the new mea\u00adsu\u00adring pro\u00adcess for deter\u00admi\u00adning the opti\u00admal shaft cen\u00adter axis. This pro\u00adcess was deve\u00adlo\u00adped and paten\u00adted by NILES-SIMMONS and is based on the appli\u00adca\u00adtion of the eddy cur\u00adrent mea\u00adsu\u00adring prin\u00adci\u00adple which mea\u00adsu\u00adres the distance bet\u00adween the eddy cur\u00adrent sen\u00adsor and the workpiece.<\/p>\n

\"Wirbelstromsensor<\/p>\n

Image 4 \u2013 Eddy Cur\u00adrent Sen\u00adsor for Deter\u00admi\u00adning the Opti\u00admal Work\u00adpiece Cen\u00adter Axis<\/em><\/p>\n

 <\/em><\/p>\n

This prin\u00adci\u00adple belongs to the non-cont\u00adact induc\u00adtive mea\u00adsu\u00adring prin\u00adci\u00adples, which can also mea\u00adsure through non-con\u00adduc\u00adtive mate\u00adri\u00adals wit\u00adhout having any influence on the mea\u00adsu\u00adring result. The method is the\u00adr\u00ade\u00adfore ide\u00adally sui\u00adted for use in harsh indus\u00adtrial envi\u00adron\u00adments. Dust, dirt, and oil do not influence the mea\u00adsu\u00adre\u00adment. Tem\u00adpe\u00adra\u00adture fluc\u00adtua\u00adtions are off\u00adset by an effi\u00adci\u00adent tem\u00adpe\u00adra\u00adture compensation.<\/p>\n

Due to the fully auto\u00adma\u00adted mea\u00adsu\u00adre\u00adment value recor\u00adding, the pro\u00adcess can be car\u00adried out wit\u00adhout any ope\u00adra\u00adtor \u2013 from the first clam\u00adping of the work\u00adpiece until it is clam\u00adped in its new center.<\/p>\n

A spe\u00adcial eddy cur\u00adrent sen\u00adsor inclu\u00adding eva\u00adlua\u00adtion unit from \u00b5Ep\u00adsi\u00adlon is used here, which has been cali\u00adbra\u00adted to the work\u00adpiece-spe\u00adci\u00adfic pro\u00adper\u00adties. This sen\u00adsor covers a mea\u00adsu\u00adring range of up to 9 mm with a reso\u00adlu\u00adtion of less than one micrometer.<\/p>\n

The applied sen\u00adsor is moun\u00adted at the tip of a 2000 mm long car\u00adbon lance, which is inte\u00adgra\u00adted in an exch\u00adan\u00adgeable modu\u00adlar mea\u00adsu\u00adring cas\u00adsette. Thus, the sen\u00adsor is posi\u00adtio\u00adned and moved via the machine axes of the bor\u00ading bar unit in the working area of the machine within the deep hole dril\u00adled work\u00adpiece. Once the sen\u00adsor is posi\u00adtio\u00adned, the distances bet\u00adween the sen\u00adsor and the work\u00adpiece can be mea\u00adsu\u00adred with pre\u00adcis\u00adion at any angle by rota\u00adting the workpiece.<\/p>\n

 <\/p>\n

\"Karbonmesslanze<\/em><\/p>\n

Image 5 \u2013 Car\u00adbon Mea\u00adsu\u00adring Lance in the \u00bbCENTER AXIS ALIGNMENT\u00ab Process<\/em><\/p>\n

 <\/p>\n

The cen\u00adter point of the con\u00adside\u00adred dia\u00adme\u00adter is cal\u00adcu\u00adla\u00adted from these mea\u00adsu\u00adred data. Along the lon\u00adgi\u00adtu\u00addi\u00adnal axis of the work\u00adpiece, any num\u00adber of cen\u00adter points can be deter\u00admi\u00adned with this method, which repre\u00adsent the cur\u00adrent course of the bore. Kno\u00adwing the course of the bore, the ideal new course of the cen\u00adter axis is cal\u00adcu\u00adla\u00adted from the cal\u00adcu\u00adla\u00adted cen\u00adter points. This cen\u00adter axis then forms the basis for machi\u00adning the new clam\u00adping seats of the work\u00adpiece to accom\u00admo\u00addate it in the new clam\u00adping operation.<\/p>\n

This auto\u00adma\u00adted pro\u00adcess mini\u00admi\u00adzes the devia\u00adtion of the outer con\u00adtour line from the inner con\u00adtour line, thus ensu\u00adring a uni\u00adform wall thic\u00adk\u00adness of the shaft along its axis.<\/p>\n

 <\/p>\n

The Value\u2003<\/strong><\/p>\n

The main advan\u00adtage of \u00bbCENTER AXIS ALIGNMENT\u00ab is the fully auto\u00adma\u00adted mea\u00adsu\u00adre\u00adment, ali\u00adgnment, and machi\u00adning of deep-hole dril\u00adled work\u00adpie\u00adces wit\u00adhout ope\u00adra\u00adtor intervention.<\/p>\n

All steps neces\u00adsary for the pro\u00adcess run fully auto\u00adma\u00adti\u00adcally within pro\u00adgrammed pro\u00adcess limits. Faulty manual ope\u00adra\u00adti\u00adons or error-prone manual mea\u00adsu\u00adring pro\u00adces\u00adses, which were neces\u00adsary in con\u00adven\u00adtio\u00adnal pro\u00adces\u00adses, are eli\u00admi\u00adna\u00adted. This makes it pos\u00adsi\u00adble to reduce the pro\u00adduc\u00adtion of scrap parts to a mini\u00admum and to improve the qua\u00adlity of the work\u00adpie\u00adces signi\u00adfi\u00adcantly. Unsui\u00adta\u00adble raw parts are iden\u00adti\u00adfied and rejec\u00adted at the begin\u00adning of the process.<\/p>\n

The inte\u00adgra\u00adtion of all tech\u00adno\u00adlo\u00adgies and mea\u00adsu\u00adring pro\u00adces\u00adses in one machine allows cycle times to be shor\u00adtened and logi\u00adstics and hand\u00adling pro\u00adces\u00adses to be reduced.<\/p>\n

The mea\u00adsu\u00adring method is immune to envi\u00adron\u00admen\u00adtal influen\u00adces such as tem\u00adpe\u00adra\u00adture fluc\u00adtua\u00adtions or for\u00adeign sub\u00ads\u00adtances and can be used fle\u00adxi\u00adbly for a wide range of mate\u00adri\u00adals. Due to the modu\u00adlar design of the NILES machi\u00adnes, dif\u00adfe\u00adrent types of work\u00adpie\u00adces can be pro\u00adces\u00adsed and in-pro\u00adcess mea\u00adsu\u00adre\u00adments taken on the same machine. This crea\u00adtes maxi\u00admum fle\u00adxi\u00adbi\u00adlity for the customer.<\/p>\n

The pro\u00adcess has alre\u00adady been suc\u00adcessfully inte\u00adgra\u00adted into tur\u00adbine shaft pro\u00adduc\u00adtion on the market.<\/p>\n

 <\/p>\n

DOWNLOAD<\/h3>\n

<\/i>Download Whitepaper as PDF<\/a><\/h4>\n

<\/h3>\n

CONTACT<\/strong><\/h3>\n
If you have any ques\u00adti\u00adons about the machi\u00adning con\u00adcept or about our machi\u00adnes and tech\u00adno\u00adlo\u00adgies, please do not hesi\u00adtate to cont\u00adact us:<\/strong><\/div>\n

SALES \u2013 TEAM<\/p>\n

NILES-SIMMONS Indus\u00adtrie\u00adan\u00adla\u00adgen GmbH
\nTel.: +49 371 \u2013 802 204
\nMail: sales.nsi@nshgroup.com[\/vc_column_text][\/vc_column][\/vc_row]\n<\/p><\/div>","protected":false},"excerpt":{"rendered":"

[vc_row][vc_column][vc_video link=\u00bbhttps:\/\/youtu.be\/o65WrrDecpo\u00ab][\/vc_column][\/vc_row][vc_row][vc_column][vc_column_text] Fully auto\u00adma\u00adted com\u00adplete machi\u00adning of tur\u00adbine and spe\u00adcial shafts \u2013 NILES-SIMMONS deve\u00adlops the new \u00bbCENTER AXIS ALIGNMENT\u00ab pro\u00adcess Dr.-Ing. Moritz Halle, Dipl.-Ing. Tho\u00admas W\u00e4cht\u00adler, NILES-SIMMONS Indus\u00adtrie\u00adan\u00adla\u00adgen GmbH    The field of appli\u00adca\u00adtion In highly tech\u00adni\u00adcal, inno\u00adva\u00adtive, and sen\u00adsi\u00adtive indus\u00adtrial sec\u00adtors such as the aero\u00adspace indus\u00adtry or the defense and energy sec\u00adtors, the demands on\u2026<\/p>\n","protected":false},"author":3,"featured_media":0,"parent":0,"menu_order":0,"comment_status":"closed","ping_status":"closed","template":"","meta":{"inline_featured_image":false,"wp_typography_post_enhancements_disabled":false,"footnotes":""},"class_list":["post-17093","page","type-page","status-publish","hentry","entry","no-media"],"_links":{"self":[{"href":"https:\/\/niles-simmons.de\/en\/wp-json\/wp\/v2\/pages\/17093","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/niles-simmons.de\/en\/wp-json\/wp\/v2\/pages"}],"about":[{"href":"https:\/\/niles-simmons.de\/en\/wp-json\/wp\/v2\/types\/page"}],"author":[{"embeddable":true,"href":"https:\/\/niles-simmons.de\/en\/wp-json\/wp\/v2\/users\/3"}],"replies":[{"embeddable":true,"href":"https:\/\/niles-simmons.de\/en\/wp-json\/wp\/v2\/comments?post=17093"}],"version-history":[{"count":7,"href":"https:\/\/niles-simmons.de\/en\/wp-json\/wp\/v2\/pages\/17093\/revisions"}],"predecessor-version":[{"id":17229,"href":"https:\/\/niles-simmons.de\/en\/wp-json\/wp\/v2\/pages\/17093\/revisions\/17229"}],"wp:attachment":[{"href":"https:\/\/niles-simmons.de\/en\/wp-json\/wp\/v2\/media?parent=17093"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}