The present disclosure relates generally to milling machines and lathes. More specifically, the present disclosure relates to a tooling system and method for converting a milling machine into a machine capable of performing turning operations typically done on a lathe.
The lathe and the milling machine are basic to the art of machining. The lathe is designed to rotate material clamped in a spindle while a non-rotating cutting tool, fixed to a slide, removes some of the material. In the case of a milling machine, the material does not rotate but is fixed to the slide or table while the cutting tool rotates in the spindle to remove some of the material. As a result, the lathe produces basically round shapes while the milling machine can mill, drill, ream, tap, etc.
Currently, it is the common practice to perform turning operations on a lathe and leave the various other machining operations to be performed by milling machines. Accordingly, good machine shops typically have lathes and milling machines in order to be able to handle all types of machining operations. There are many instances when a shop may have an abundance of lathe work and are low on millwork and vice versa. Yet, because automated lathes and milling machines are so expensive, it may not be economically feasible to purchase another lathe, for example, to keep up with demand. Moreover, it is of extreme importance for a manufacturer or machine shop to keep their machine tools running at capacity at all times. Therefore, the applicant has discovered that the ability to quickly convert a milling machine to perform work that the overburdened lathe department cannot handle would be of immense value.
Various machines that perform both milling and turning operations are known. The principal advantage of these machines is that the workpieces can remain on the same table and in one setting for different milling and turning operations. The main disadvantage of these machines is that they require the purchase of complex gear driven or motorized accessories that are attached to a milling machine structure. These attachments tend to be cumbersome and take up much of the working envelope of the machine tool. Furthermore, they only allow small components to be machined and are limited in their use. U.S. Pat. Nos. 5,301,405 and 5,586,382 provide examples of such machines.
In recent years, automatic lathes have been developed for machining of much more complex workpieces from a bar-shaped work material. For example, compound or combination machining has been developed, where a large number of types of tools are provided on a tool rest to enable diverse automatic machining, including the performance of milling functions. Further, to shorten the machining time, various multifunction type automatic lathes carrying a plurality of spindles and a plurality of tool rests close together on a single lathe bed have been proposed. These lathes are capable of performing different types of machining simultaneously on the same bar or simultaneous machining on different bars. These options, however, are expensive and such lathes are typically limited in the size of the area in which any milling functions can be performed. Moreover, there are few options to do three-axis milling on a lathe that is converted to perform milling functions. In addition, reprogramming lathes to perform the functions of a milling machine can be a lengthy, difficult, and expensive process.
Therefore, it would be highly desirable to be able to use a milling machine for turning functions. Moreover, it would be highly desirable to be able to easily, quickly, and cheaply perform both milling and turning operations on a milling machine. It would also be highly desirable to perform turning operation on a milling machine platform.
In accordance with one embodiment, there is provided a milling machine system that includes a tooling platform, a cutting too spindle, an automated control system including code for controlling operation of a milling machine to perform milling operations, and software that converts the code for controlling operation of a milling machine to perform milling operations into code for controlling operation of a milling machine to perform one or more turning operations. The tooling platform includes one or more tools extending horizontally from the tooling platform and one or more tools extending vertically from the tooling platform. The cutting tool spindle rotates about an axis of rotation, wherein the spindle includes a securing means adapted to secure a piece of material to be machined in an orientation along the axis of rotation of the spindle.
In accordance with another embodiment, there is provided a milling machine system that includes a cutting tool spindle that rotates about an axis of rotation, a rotary tooling platform, an automated control system with code for controlling operation of the milling machine to perform milling operations, and software that converts the code for controlling operation of a milling machine to perform milling operations into code for controlling operation of a milling machine to perform one or more turning operations. The rotary tooling platform includes a rotary cylinder that rotates about an axis of rotation that is substantially perpendicular to the axis of rotation of the cutting tool spindle of the milling machine. The rotary cylinder includes a cylindrical base and a first set of tools that extend radially outward from the base and a second set of tools that extend in a direction substantially parallel to the axis of rotation of the rotary tool cylinder. The cutting tool spindle has securing means adapted to secure a piece of material to be machined along the axis of rotation of the spindle. The cutting tool spindle can rotate about a vertical axis, a horizontal axis, or a hybrid axis.
In accordance with another embodiment, a machining tool includes a tombstone mounting fixture and a rotary tooling platform. The tombstone mounting fixture rotates about a first axis of rotation and has a top surface. The rotary tooling platform includes a cylindrical base that rotates about a second axis of rotation. The rotary tooling platform has a first set of tools that extend radially outward from the base and a second set of tools that extend in a direction substantially parallel to the axis of rotation of the base. The rotary tooling platform is mounted on the top surface of the tombstone mounting fixture, and the second axis of rotation is substantially parallel to the first axis of rotation.
In accordance with another embodiment, a milling machine system includes a cutting tool spindle, a tombstone mounting fixture, a rotary tooling platform, an automated control system comprising code for controlling operation of the milling machine system to perform milling operations, and software that converts the code for controlling operation of a milling machine system to perform milling operations into code for controlling operation of a milling machine system to perform one or more turning operations. The spindle rotates about a first axis of rotation and includes a securing means adapted to secure a piece of material to be machined in an orientation along the first axis of rotation of the spindle. The tombstone mounting fixture rotates about a second axis of rotation and has a top surface. The rotary tooling platform includes a cylindrical base that rotates about a third axis of rotation. The rotary tooling platform has a first set of tools that extend radially outward from the base and a second set of tools that extend in a direction substantially parallel to the axis of rotation of the base. The rotary tooling platform is mounted on the top surface of the tombstone mounting fixture, and the third axis of rotation is substantially parallel to the second axis of rotation.
In accordance with another embodiment, there is provided a method for turning an unfinished piece of material. The method includes providing a milling machine with a cutting tool spindle that rotates about an axis of rotation and a work platform that has one or more working tools. The position and orientation of the work platform in relation to the position and orientation of the spindle can be changed using an automated control system. The method also includes securing the piece of material to the cutting tool spindle of the milling machine so that the material is secured in a vertical orientation along the axis of rotation of the spindle. The method further includes rotating the spindle thereby spinning the material about the axis of rotation, and bringing one or more of the working tools into contact with the material, thereby removing a portion of the material.
The tooling block 20 includes a number of horizontally arranged insert holders 23, which are mounted on the tooling block 20. The insert holders 23 can be cutting tool holders that hold, for example, outside diameter (“OD”) tools 31 or inside diameter (“ID”) tools 32. The insert holders 23 depicted in
The tooling block 20 also includes one or more vertically oriented tools such as those shown in
In addition, one or more of the tools shown in
The tooling block 20 is properly located and firmly anchored to a milling machine table 5 prior to use. As an option, the tooling block 20 can also include one or more riser blocks (not shown). Riser blocks are used to offset the height of the tooling block 20 from the milling machine table 5 to allow for a longer part to be machined. As few as one or as many as twenty or more riser blocks can be used to prop up the tooling block 20. The riser blocks can be between one and six inches tall, and as many riser blocks as needed can be stacked atop each other and secured to the bottom of the tooling block 20.
The milling machine conversion system 1 also includes a spindle assembly 10. The spindle assembly 10 is generally assembled to a milling machine. In use, the spindle assembly 10 is positioned above the tooling block 20. The spindle assembly 10 includes a milling machine spindle 13 (part of the milling machine), a chuck 11 with chuck jaws 12 that holds the part 40 or piece that is to be machined. The chuck 11 has a matching interface with the milling machine spindle 13. This configuration allows the chuck 11 to be easily and firmly connected to the milling machine spindle 13. In a typical milling machine, a tool is attached to the spindle and is used to cut, bore, or otherwise machine a part that is secured to the milling machine table. In the present embodiment, chuck 11 is configured to hold a part 40, material, or piece that is rotated (turned) against one or more of the tools secured to the tooling block 20 positioned below the spindle assembly 10. In addition, chuck 11 can be replaced with a collet chuck 15 to hold smaller diameter materials. The chuck 11 can also be replaced with a tooling faceplate to allow for larger diameter or odd shaped work pieces to be held in the milling machine spindle 13.
As explained above, the tooling block 20 has been depicted with four horizontal OD tools 31 and four vertical ID tools 32. The tool block 20 could, however, be larger to accommodate a greater number of tools if space within the milling machine would allow. Likewise, the tooling block 20 could be smaller to accommodate fewer tools and a smaller work area or a different manufacturing need.
As shown in
The system 100 also includes a cylindrical tooling fixture 200 as opposed to the linear block configuration shown in
As shown in
A method of turning an unfinished part or piece of material in accordance with the embodiments shown in
In another embodiment, as shown in
The milling machine includes a table or platform 605 that carries a rotary table 630. A tombstone mounting fixture 650 is mounted on the rotary table 630. The tombstone mounting fixture 650 can be loaded with milling block parts 655, which are held in place with vises 657 in a manner generally known in the art. As shown in
As shown in
The turret 200 can be similar to the turret 200 shown in the previous figures. The rotary tool turret 200 can have a first set of tools that extend radially outward 280 from the cylindrical base 201 and a second set of tools 290 that extend in a direction substantially parallel to the axis of rotation of the rotary tool turret 200 or perpendicular to the cylindrical base 201. In one embodiment, tools 280 extending radially outward are turning tools or OD tools, such as boring and threading tools, while tools 290 are ID tools or drilling tools. In another embodiment, tools 280 are ID tools or drilling tools, while tools 290 are turning tools or OD tools. In addition, one or more of the ID or drilling tools can be live rotary tools, such as an air or electric spindle added to one of the tooling fixtures to allow for milling operations to be performed on the part 640 being rotated or held firmly in chuck 611.
The system 600 also includes a computer aided control system 400 controlling the milling machine, such as in the case of a Computer Numerical Control (“CNC”) milling machine.
In another embodiment, not shown, a tombstone is not included, and the tool turret 200 can be attached directly to the horizontal milling machine table 605 or to a platform attached to the horizontal milling machine table 605.
A method of turning an unfinished part or piece of material in accordance with the embodiments shown in
The tombstone mounting fixture 650 has a rotary tool turret 200 mounted on its top horizontal surface 656. The rotary tool turret 200 includes a cylindrical base 201 and a plurality of tools extending along various vectors from the base 201. The cylindrical base 201 of the rotary tool turret 200 can be rotatably bolted to the top surface of the tombstone mounting fixture 650 with a bolt 241 running through the center of the turret 200. The turret 200 is rotatably mounted atop the tombstone 650 on the top surface 656 of the tombstone 650 so that the turret 200 can be rotated about its axis B. The axis of rotation of the turret 200 is the same as or parallel to the axis of rotation of any rotary table on which the tombstone 650 may sit. The turret 200 is rotatable independent from the tombstone 650, so that the turret 200 can rotate about its axis B while the tombstone 650 can remain radially stationary or can rotate at a different speed or direction from the turret 200.
The rotary tool turret 200 can have a first set of tools that extend radially outward 280 from the cylindrical base 201 and a second set of tools 290 that extend in a direction substantially parallel to the axis of rotation of the rotary tool turret 200 or perpendicular to the cylindrical base 201. In one embodiment, tools 280 extending radially outward are turning tools or OD tools, such as boring and threading tools, while tools 290 are ID tools or drilling tools. In another embodiment, tools 280 are ID tools or drilling tools, while tools 290 are turning tools or OD tools. In addition, one or more of the ID or drilling tools can be live rotary tools, such as an air or electric spindle added to one of the tooling fixtures to allow for milling operations to be performed on the part 640 being rotated or held firmly in chuck 611.
The machining steps described above are performed either manually or by a computer aided control system 400 controlling the milling machine, such as in the case of a Computer Numerical Control (“CNC”) milling machine. For example, the computer aided control system 400 depicted in
There are several ways in which a computer aided control system is typically programmed. A computer aided control system usually includes a keyed control pad, and one way to program the system to operate the milling machine is to hand program using the control pad. Alternatively, the control system can be programmed on a separate computer and imported to the computer aided control system.
Another way to program a milling machine is to use cad/cam software. An accurate image of the part to be machined is created in cad and imported to the cam software. Tool paths along the features of the cad image are then created. Once the tool path is created, the software asks the programmer for the type of machine control to which the code should be converted. This conversion code, or Post, is customized for each type of machine, such as Haas, Fadel, Mazak, and the like. The Post then takes the cad/cam toolpath and converts it to the proper language that the individual machine control needs to run the toolpath.
A third way in which a milling machine control system is programmed is by using conversational programming built in to the control system. A control system with conversation programming prompts the user, such as a machinist, to input the parameters of the shape to be cut. An example would be the length, diameter, location in X and Z of any grooves or threads or inside thread dimensions. The control system then builds the proper code to produce the proper toolpath.
With respect to the computer aided control system 400 presented herein, a custom Post may not exist. Therefore, in one embodiment, changes to the program can be made manually so that the milling machine can operate as a lathe.
In another embodiment, an automatic editor can be used to convert a cad/cam program posted for a lathe control into one that can be used by a mill control. For example, if a program is created in cad/cam and posted for a Haas milling machine control, it will currently post for a lathe control because a custom post does not exist to run lathe parts on a mill. Thus, without the custom post, the cad/cam Haas control posted lathe program can be run through the editor to convert it into one that the mill control can read.
In another embodiment, the milling machine can be built from the beginning to run milling operations but with a conversion feature that includes a machine control that has the functionality of a mill control and a lathe control. For instance, the milling machine includes software that includes custom posts to write code from a cad/cam software that requires no editing. This embodiment eliminates the need for an automatic editor to convert a lathe program into a mill program or a mill program into a lathe program. The computer aided control system 400 can therefore include controls that have the option to have conversation programming ability built in.
While particular embodiments have been disclosed, it is to be understood that various different modifications are possible and are contemplated within the true spirit and scope of the appended claims. There is no intention, therefore, of limitations to the exact abstract or disclosure herein presented.
This application claims priority of U.S. Provisional Patent Application Ser. No. 60/706,802 entitled “Milling Machine Turning System and Manufacturing Method”, filed Aug. 9, 2005 and U.S. Provisional Patent Application Ser. No. 60/775,446 entitled “Milling Machine Turning Systems and Methods”, filed Feb. 21, 2006. Priority of the aforementioned filing dates is hereby claimed, and the disclosures of the Provisional Patent Applications are hereby incorporated by reference.
Number | Date | Country | |
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60706802 | Aug 2005 | US | |
60775446 | Feb 2006 | US |